Sewing cell adjustable feature

Abstract

To provide a robotic sewing assembly.SOLUTION: A robotic sewing assembly includes: a fixture to support an article being sewn; and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitching to the article. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the article. The fixture includes a servo unit to which the article is connected and which is configured to manipulate the article in multiple directions relative to the sewing head. The robotic arm, the sewing head and the servo unit are operable in concert.SELECTED DRAWING: Figure 3

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 571,770, filed March 29, 2024, the disclosure of which is incorporated herein by reference in its entirety. [Background technology]

[0002]

[0002] Exemplary embodiments of the present disclosure relate to the art of robotic sewing assemblies for use in sewing processes.

[0003]

[0003] Robotic sewing techniques often include a sewing head. The sewing head may include an upper arm and a lower arm and may be attached to a robotic arm. The robotic arm positions the sewing head near an article to be sewn. The article may be, but is not necessarily, an automobile instrument panel (IP), for example, and is typically held in place by a fixture. The robotic arm orients the sewing head so that a given stitching operation can be performed on the article. Summary of the Invention

[0004] According to one aspect of the present disclosure, a robotic sewing assembly is provided. The robotic sewing assembly includes a fixture for supporting an article to be sewn and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitches to the article. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the article. The fixture includes a servo unit, the article is connected to the servo unit, and the servo unit is configured to manipulate the article in multiple directions relative to the sewing head. The robotic arm, the sewing head, and the servo unit are cooperatively operable.

[0005]

[0005] According to additional and / or alternative embodiments, the robotic arm includes a first arm rotatable in at least one direction, a second arm rotatably attached to the first arm so as to be rotatable in at least one direction, and a coupling, and the sewing head is rotatably attached to the second arm by the coupling so as to be rotatable in at least two directions.

[0006] According to additional and / or alternative embodiments, the sewing head includes a sewing needle and a stitch plate.

[0007]

[0007] According to additional and / or alternative embodiments, the fixture further includes a chassis on which the servo unit is mounted and a vertically oriented screen plate supported on the chassis adjacent to the servo unit.

[0008] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the article relative to the sewing head in multiple directions during sewing.

[0009] According to additional and / or alternative embodiments, the servo unit is configured to rotate and translate the article about and along multiple axes.

[0010]

[0010] According to additional and / or alternative embodiments, the servo unit is configured to rotate the article about the article's longitudinal axis, raise and lower the article, and drive the article laterally in first and second transverse directions.

[0011] According to additional and / or alternative embodiments, the robotic sewing assembly further includes a programmable controller that controls the robotic arm, sewing head, and servo unit to operate in coordination with one another without operator intervention.

[0012] According to one aspect of the present disclosure, a robotic sewing assembly is provided for sewing an instrument panel (IP) including an elongated flat section and an elongated curved section defining an opening. The robotic sewing assembly includes a fixture for supporting the IP and a robotic arm. The robotic arm includes a sewing head. The sewing head is configured to apply stitches to the IP. The robotic arm is configured to manipulate the sewing head in multiple directions relative to the IP. The fixture includes a servo unit, and the IP is connected to the servo unit, and the servo unit is configured to manipulate the IP in multiple directions relative to the sewing head. The robotic arm, the sewing head, and the servo unit are cooperatively operable to perform stitching on the elongated flat section and the elongated curved section defining the opening of the IP.

[0013]

[0013] According to additional and / or alternative embodiments, the robotic arm includes a first arm rotatable in at least one direction, a second arm rotatably attached to the first arm so as to be rotatable in at least one direction, and a coupling, and the sewing head is rotatably attached to the second arm by the coupling so as to be rotatable in at least two directions.

[0014] According to additional and / or alternative embodiments, the sewing head includes a sewing needle and a stitch plate.

[0015]

[0015] According to additional and / or alternative embodiments, the fixture further includes a chassis on which the servo unit is mounted and a vertically oriented screen plate supported on the chassis adjacent to the servo unit.

[0016] According to additional and / or alternative embodiments, the servo unit is configured to manipulate the IP relative to the sewing head in multiple directions during sewing.

[0017] According to additional and / or alternative embodiments, the servo unit is configured to rotate about and translate along multiple axes of the IP during sewing.

[0018]

[0018] According to additional and / or alternative embodiments, the servo unit is configured to rotate the IP about its longitudinal axis, raise and lower the IP, and drive the IP laterally in first and second transverse directions during sewing.

[0019] According to additional and / or alternative embodiments, stitching is performed along multiple outer and lower surfaces of the IP at one or more of the elongated flat section, the elongated curved section, and the vent.

[0020]

[0020] According to additional and / or alternative embodiments, the robotic sewing assembly further includes a programmable controller that controls the robotic arm, sewing head, and servo unit to operate in cooperation with each other to perform sewing on the elongated flat section and the elongated curved section defining the IP outlet without operator intervention.

[0021] According to one aspect of the present disclosure, a method of operating a robotic sewing assembly to sew an article is provided. The method includes providing a robotic arm including a sewing head and providing a fixture, connecting a servo unit of the fixture to the article, and sewing along a plurality of exterior and underside surfaces of the article. The sewing includes controlling the robotic arm to manipulate the sewing head relative to the article, controlling the sewing head to apply stitches to the article, and controlling the servo unit to simultaneously rotate the article about a longitudinal axis of the article, elevate and lower the article, and laterally drive the article in first and second transverse directions.

[0022] According to additional and / or alternative embodiments, the operating method may be performed by a programmable controller without operator intervention.

[0023]

[0023] According to additional and / or alternative embodiments, the article is an automobile instrument panel (IP) and includes an elongated flat section, an elongated curved section, and one or more vents, and sewing is performed along multiple outer and underside surfaces of the IP at the elongated flat section, the elongated curved section, and the one or more vents.

[0024]

[0024] Additional features and advantages are realized by the techniques of the present disclosure. Other embodiments and aspects of the present disclosure are described in detail herein and are considered part of the claimed technical concept. For a better understanding of the present disclosure, including its advantages and features, please refer to the description and drawings.

[0025] For a more complete understanding of this disclosure, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, in which like reference numerals represent like parts. [Brief explanation of the drawings]

[0026] [Figure 1] FIG. 1 is a perspective view of an article to be sewn, such as an automobile instrument panel (IP), according to an embodiment.

[0027] [Figure 2A] FIG. 2A is a perspective view of a robotic sewing assembly for performing sewing of the article of FIG. 1 according to an embodiment. [Figure 2B] FIG. 2B is a side schematic view of a robotic sewing assembly for performing sewing of the article of FIG. 1 according to an embodiment.

[0028] [Figure 3]FIG. 3 is a schematic diagram of a programmable controller for the robotic sewing assembly of FIGS. 2A and 2B, according to an embodiment.

[0029] [Figure 4] FIG. 4 is a graphical illustration of a sequence of operations of the robotic sewing assembly of FIGS. 2A and 2B, according to an embodiment.

[0030] [Figure 5] FIG. 5 is a flow diagram illustrating a method of operating a robotic sewing assembly for sewing an article, such as an automotive instrument panel (IP), according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0031] A detailed description of one or more embodiments of the disclosed apparatus and method is presented herein by way of example and not limitation with reference to the figures.

[0032] In most cases, fixtures allow the robotic sewing assembly to access the locations on the part or article being sewn where stitches are to be applied. However, certain part configurations prevent access to all stitch locations on the part without reaching the limits of the robotic sewing assembly. For example, accessing locations near the top of an instrument panel (IP) and the bottom of an instrument panel (IP) can be difficult in designs where such access is limited to the top or bottom.

[0033]

[0033] Thus, as described below, a fixture is provided that can adjust the position and / or orientation of a part or article to be sewn relative to a robotic sewing assembly, thereby enabling complete manufacturing of the part or article to be achieved more quickly and efficiently. The part or article is secured to the fixture, which can control the position and / or orientation of the part or article in real time so that the sewing head of the robotic sewing assembly can access all sewing locations on the part or article during the sewing process. This allows the sewing head to access hard-to-reach locations, especially those found on certain parts or articles having complex geometries. The fixture can move the part or article in a variety of ways, including, but not limited to, rotating the part or article about a given axis and moving the part or article upward, downward, or laterally.

[0034] 1 and 2A-2B, a robotic sewing assembly 201 is provided for sewing an article, such as an IP 101 for an automobile (for clarity and brevity, the following description will generally refer to the IP 101, but it should be understood that this term is "article" and can be interchangeable with "article"). The IP includes an elongated flat section 110 and an elongated curved section 120 formed to define one or more vent openings 121. Sewing the IP 101 adds stitches to multiple exterior and underside surfaces of the IP 101 at one or more edges of the elongated flat section 110, the elongated curved section 120, and the vent openings 121.

[0035] The robotic sewing assembly 201 includes a fixture 210 for rotatably and movably supporting the IP 101 and a robot arm 220. The robot arm 220 includes a sewing head 230. The sewing head 230 is configured to stitch multiple exterior and underside surfaces of the IP 101 at the elongated flat section 110, the elongated curved section 120, and one or more edges of the opening 121. The robot arm 220 is configured to manipulate the sewing head 230 in multiple directions relative to the IP 101. The fixture 210 includes an optional base portion 211 onto which the robot arm 220 can be tethered (however, it should be understood that tethering is not required or provided, for example, in a robotic gantry system or other similar case), and a servo unit 212 to which the IP 101 is connected. The servo unit 212 is configured to manipulate the IP 101 in multiple directions relative to the sewing head 230. The robotic arm 220 , the sewing head 230 , and the servo unit 212 are operable in cooperation with one another to perform stitching on the IP 101 .

[0036] The servo unit 212 may include a gripping portion 2121 configured to grip the IP 101 without interfering with the sewing operation, and multiple servo arms 2122 that are movable and rotatable relative to the IP 101 and each other. The gripping portion 2121 includes a gripper 2123 that can grip any portion of the IP 101 and can be rotatable relative to a proximal one of the multiple servo arms 2122. Thus, the servo unit 212 can move and / or rotate the IP 101 in multiple directions and about multiple axes. That is, the servo unit 212 can move the IP 101 up and down, back and forth, left and right, and / or about any vertical or horizontal axis.

[0037]

[0037] The sewing head 230 includes a sewing needle 231 and a stitch plate 232. The robot arm 220 includes the sewing head 230, an optional base 221 that can be anchored to the base portion 211 of the fixture 210 (as mentioned above, for example, in the case of a robotic gantry system or other similar cases, the optional base 221 is not present and no anchoring is needed or provided), a first arm 222 that is rotatable in at least one direction, a second arm 223 rotatably attached to the first arm 222 so as to be rotatable in at least one direction, and a coupling 224, and the sewing head 230 is rotatably attached to the second arm 223 by the coupling 224 so as to be rotatable in at least two directions. Fixture 210 includes an optional base portion 211, a servo unit 212, and further includes a chassis 213 on which optional base portion 211 and servo unit 212 are mounted at a distance from each other, and a vertically oriented screen 214 supported on chassis 213 adjacent to servo unit 212.

[0038] The servo unit 212 is configured to manipulate the IP 101 relative to the sewing head 230 in multiple directions during sewing. More specifically, the servo unit 212 is configured to rotate the IP 101 about multiple axes and translate the IP 101 along multiple axes during sewing. That is, the servo unit 212 is configured to rotate the IP 101 about its longitudinal axis A1, raise and lower the IP 101 along the vertical axis A2, and laterally drive the IP in first and second transverse directions along the lateral directions A3 and A4 during sewing. Thus, as described further below, sewing can be performed along multiple outer and lower surfaces of the IP 101 in one or more of the elongated flat section 110, the elongated curved section 120, and the outlet 121.

[0039] 1 and 2A and 2B, and further with reference to FIG. 3, robotic sewing assembly 201 may further include a programmable controller 301. Programmable controller 301 may include a processor 310, a memory unit 320, and a servo control unit 330 disposed in signal communication with robotic arm 220, sewing head 230, and servo unit 212. Memory unit 320 has executable instructions stored thereon that are readable and executable by processor 310. When the executable instructions are read and executed by processor 310, processor 310, via servo control unit 330, effectively controls robotic arm 220, sewing head 230, and servo unit 212 to operate in coordination with one another to perform sewing on IP 101 without operator intervention.

[0040] Continuing to refer to Figures 1 through 3, and further to Figure 4, a sequence 400 of operation of the robot arm 220, sewing head 230, and servo unit 212 is shown. As shown in images (1) and (2) of Figure 4, the robot arm 220 first extends the sewing head 230 toward and over the IP 101 while slightly rotating the sewing head 230. As shown in images (3), (4), and (5) of Figure 4, the rotation of the sewing head 230 continues, and the servo unit 212 begins to rotate the IP 101 counterclockwise so that the underside of the IP 101 faces the sewing head 230. Next, as shown in images (4) and (5) of Figure 4, the robot arm 220 rotates the sewing head 230 curvilinearly downward toward the IP 101 so that the edge of the IP 101 at the exit opening 121 is brought between the sewing needle 231 and the stitch plate 232, while the servo unit 212 rotates the IP 101 clockwise. At this point, as shown in images (6), (7), (8), and (9) of Figure 4, the robot arm 220 drives the sewing head 230 laterally, while the servo unit rotates the IP 101 counterclockwise, so that the sewing head can stitch the edge of the IP 101 at the exit opening 121. As shown in images (10) and (11) of Figure 4, the robot arm 220 then rotates the sewing head around the IP 101 so that the sewing head can continue to stitch the IP 101. As shown in image (12) of FIG. 4, this process continues until sewing is complete, after which the robotic arm 220 begins to pull the sewing head 230 away from the IP 101.

[0041] 5, a method 500 of operating a robotic sewing assembly for sewing an article, such as an instrument panel (IP), is provided, generally as described above with reference to FIGS. 1-4. Method 500 is executable by a programmable controller without operator intervention. As shown in FIG. 5, method 500 optionally includes connecting a robotic arm including a sewing head to a base portion of a fixture and / or providing a robotic arm including a sewing head and providing a fixture (block 501), connecting a servo unit of the fixture to the IP (block 502), and sewing along a plurality of exterior and underside surfaces of the IP (block 503). The sewing of block 503 includes simultaneously controlling the robotic arm to manipulate the sewing head relative to the IP (block 5031), controlling the sewing head to apply stitches to the IP (block 5032), and controlling the servo unit to rotate the IP about its longitudinal axis, raise and lower the IP, and laterally drive the IP in first and second transverse directions (block 5033). Thus, if the IP includes an elongated flat section, an elongated curved section, and one or more voids, the sewing of block 503 may be performed along multiple outer and underside surfaces of the IP at least in the elongated flat section, the elongated curved section, and the one or more voids.

[0042] A technical effect and advantage of the present disclosure is to provide a fixture for a robotic sewing assembly that can adjust the position and / or orientation of a part or article to be sewn relative to the sewing head of the robotic sewing assembly, thereby making complete manufacturing of the part or article achievable more quickly and efficiently.

[0043] The term "about" is intended to include the degree of error associated with measurement of a particular quantity based on equipment available at the time of filing. For example, "about" can include a range of ±8%, or 5%, or 2% of a given value.

[0044]

[0044] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that the terms "comprise" and / or "comprising," as used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0045]

[0045] While the present disclosure has been described with reference to one exemplary embodiment or exemplary embodiments, those skilled in the art will recognize that various changes may be made and equivalents may be substituted for those elements without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope of the present disclosure. Therefore, the present disclosure is not limited to the particular embodiment disclosed as the best mode contemplated for carrying out the disclosure, but the present disclosure is intended to include all embodiments falling within the scope of the appended claims. [Explanation of symbols]

[0046] 101...IP, 110...elongated flat section, 120...elongated curved section, 121...outlet, 201...robot sewing assembly, 210...fixture, 211...base portion, 212...servo unit, 213...chassis, 214...screen, 220...robot arm, 221...base, 222...first arm, 223...second arm, 224...coupling, 230...sewing head, 231...sewing needle, 232...stitch plate , 301...programmable controller, 310...processor, 320...memory unit, 330...servo control unit, 400...sequence, 500...method, 501...block, 502...block, 503...block, 2121...gripping portion, 2122...servo arm, 2123...gripping part, 5031...block, 5032...block, 5033...block, A1...longitudinal axis, A2...vertical axis, A3...lateral direction, A4...lateral direction

Claims

1. 1. A robotic sewing assembly comprising: a fixture for supporting the article to be sewn; a robot arm equipped with a sewing head; Equipped with the sewing head is configured to apply stitches to the article, and the robotic arm is configured to manipulate the sewing head relative to the article in multiple directions; the fixture includes a servo unit, the article is connected to the servo unit, and the servo unit is configured to manipulate the article relative to the sewing head in multiple directions; A robotic sewing assembly, wherein the robotic arm, the sewing head, and the servo unit are cooperatively operable.

2. The robot arm a first arm rotatable in at least one direction; a second arm rotatably attached to the first arm so as to be rotatable in at least one direction; Coupling and Equipped with The robotic sewing assembly of claim 1 , wherein the sewing head is rotatably mounted to the second arm by the coupling so as to be rotatable in at least two directions.

3. The robotic sewing assembly of claim 1 , wherein the sewing head comprises a sewing needle and a stitch plate.

4. The fixture is a chassis on which the servo unit is mounted; a vertically oriented screen plate supported on the chassis adjacent to the servo unit; The robotic sewing assembly of claim 1 further comprising:

5. The robotic sewing assembly of claim 1 , wherein the servo unit is configured to manipulate the article relative to the sewing head in multiple directions during sewing.

6. The robotic sewing assembly of claim 1 , wherein the servo unit is configured to rotate and translate the article about and along multiple axes.

7. 2. The robotic sewing assembly of claim 1, wherein the servo unit is configured to rotate the article about a longitudinal axis of the article, lift and lower the article, and laterally drive the article in first and second transverse directions.

8. The robotic sewing assembly of claim 1 , further comprising a programmable controller that controls the robotic arm, the sewing head, and the servo unit to operate in coordination with one another without operator intervention.

9. 1. A robotic sewing assembly for sewing an instrument panel (IP) comprising an elongated flat section and an elongated curved section defining an opening, the robotic sewing assembly comprising: A fixture for supporting the IP; a robot arm equipped with a sewing head; Equipped with the sewing head is configured to apply stitches to the IP, and the robotic arm is configured to manipulate the sewing head in multiple directions relative to the IP; the fixture includes a servo unit, the IP is connected to the servo unit, and the servo unit is configured to operate the IP in a plurality of directions relative to the sewing head; A robotic sewing assembly, wherein the robot arm, the sewing head, and the servo unit are cooperatively operable to perform sewing on the elongated flat section and the elongated curved section that defines the outlet of the IP.

10. The robot arm a first arm rotatable in at least one direction; a second arm rotatably attached to the first arm so as to be rotatable in at least one direction; Coupling and Equipped with The robotic sewing assembly of claim 9 , wherein the sewing head is rotatably mounted to the second arm by the coupling so as to be rotatable in at least two directions.

11. The robotic sewing assembly of claim 9 , wherein the sewing head comprises a sewing needle and a stitch plate.

12. The fixture is a chassis on which the servo unit is mounted; a vertically oriented screen plate supported on the chassis adjacent to the servo unit; The robotic sewing assembly of claim 9 further comprising:

13. The robotic sewing assembly of claim 9 , wherein the servo unit is configured to manipulate the IP relative to the sewing head in multiple directions during the sewing.

14. 10. The robotic sewing assembly of claim 9, wherein the servo unit is configured to rotate and translate the IP about and along multiple axes during the sewing.

15. 10. The robotic sewing assembly of claim 9, wherein the servo unit is configured to rotate the IP about its longitudinal axis, raise and lower the IP, and laterally drive the IP in first and second transverse directions during the sewing.

16. The sewing the elongated flat section; the elongated curved section; one or more of said outlets; 10. The robotic sewing assembly of claim 9, wherein the sewing machine is configured to:

17. 10. The robotic sewing assembly of claim 9, further comprising a programmable controller that controls the robotic arm, the sewing head, and the servo unit to operate in cooperation with one another to perform the sewing on the elongated flat section and the elongated curved section that defines the outlet of the IP without operator intervention.

18. 1. A method of operating a robotic sewing assembly for sewing an article, the method comprising: providing a robotic arm with a sewing head and providing a fixture; connecting a servo unit of the fixture to the article; stitching along a plurality of outer and lower surfaces of the article; Including, The sewing step controlling the robotic arm to manipulate the sewing head relative to the article; controlling the sewing head to apply stitches to the article; controlling the servo unit to rotate the article about its longitudinal axis, to raise and lower the article, and to drive the article laterally in first and second transverse directions; A method comprising:

19. 20. The method of claim 18, wherein the method is executable by a programmable controller without operator intervention.

20. the article is an automobile instrument panel (IP); and a long, narrow flat section; an elongated curved section defining one or more outlets; Equipped with 20. The method of claim 18, wherein the sewing step is performed along a plurality of outer and lower surfaces of the IP at the elongated flat section, the elongated curved section, and the one or more vents.

Images