Method and apparatus for automatic change of thread color

Abstract

A needle bar holder for a sewing machine head including a revolver configured to hold a plurality of separate needle bars, a motor operatively coupled to the revolver for rotating the revolver, and means for ensuring alignment and stability of the revolver when one of the plurality of separate needle bars is selected for a sewing process.

Description

【Technical Field】 【0001】 [Cross - reference to Related Applications] 【0001】This application claims priority to U.S. Provisional Patent Application No. 63 / 234,154, filed on August 17, 2021, and U.S. Provisional Patent Application No. 63 / 351,229, filed on June 10, 2022, the entire contents of each of which are incorporated herein by reference thereto. 【0002】 【0002】Exemplary embodiments of the present disclosure relate to the technology of three - dimensional robotic sewing processes. 【Background Art】 【0003】 【0003】A 3D robotic sewing process typically consists of a six - axis robot with a sewing machine attached as an end - effector. The robot operates the sewing machine as needed to place decorative live stitches on a stationary part. The process may be further configured such that the robot moves the part in front of a stationary sewing machine to facilitate the stitch. 【0004】 【0004】Current customer demands include the requirement to frequently change the thread color for each part to comply with the styling sequencing requirements of vehicles. In the current prior art, when it is necessary to change the thread color from one part to the next, the robot must move the sewing head to the service inspection port of the cell so that the thread spool can be manually removed and replaced with the correct color. For this change, the new thread had to be pulled through the entire guiding and tensioning system so that the new color thread was placed spanning from the thread spool to the needle hole. The time required for manual color change is typically about 5 minutes. 【0005】

[0005] In alternative prior art, a separate sewing head is required in the sewing cell for each desired thread color, and each time a color change is needed, the robot must move to the tool cart station to uncouple one head and recouple the others, resulting in extra investment and a considerable additional time to the production cycle for each part. Another alternative, which has minimal additional cycle time but a substantial additional investment, can include multiple robots in a single cell, each having a sewing head that can handle different colored threads. [Overview of the Initiative] 【0006】 [Brief explanation]

[0006] This disclosure addresses the requirement to automatically change thread color within an automated 3D robot sewing process. 【0007】

[0007] The disclosure described herein eliminates the need for an operator to manually change the spool of a robot-mounted sewing head when a change of thread color is required. The disclosure also eliminates the need for multiple sewing heads in a single cell. In one embodiment, a single sewing head is provided with a plurality of needle bars, which may be arranged in a linear or circular configuration, each bar containing a different color of thread. The needle bars may be configured with either a single or double needle holder, depending on the desired application. 【0008】

[0008] After the robotic sewing of one section is completed, the sewing head returns to its home position and receives a signal from the Human-Machine Interface (HMI) computer (PC) indicating the color required for the next section. The sewing head then moves the needle bar rack or revolver to a position where the needle bars of the appropriate color are aligned with the lower arm hook or looper. After the appropriate needle bars are in place, the sewing head moves to the position of the section where sewing will begin. 【0009】

[0009] In addition, if multiple colors are required for the same part, the color change(s) may occur within a single machine cycle and be executed based on instructions from a robot program on the computer. 【0010】

[0010] A needle bar holder for a sewing machine head is disclosed, comprising a revolver configured to hold a plurality of separate needle bars, a motor operably coupled to the revolver to rotate the revolver, and means for ensuring the alignment and stability of the revolver when one of the plurality of separate needle bars is selected for the sewing process. 【0011】

[0011] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the plurality of separate needle bars are six. 【0012】

[0012] In addition to one or more of the above-described features, or as an alternative to any of the above-described embodiments, means for ensuring the arrangement and stability of the revolvers are pneumatic cylinders or electric solenoids. 【0013】

[0013] In addition to one or more of the above-described features, or as an alternative to any of the above-described embodiments, the pneumatic cylinder or electric solenoid extends a piston that engages with one of a plurality of recesses located in the revolver. 【0014】

[0014] In addition to one or more of the above-described features, or as an alternative to any of the above-described embodiments, a pneumatically operated lifting plate is provided which is configured to engage with a plurality of separate needle bars, each of the plurality of separate needle bars having a needle bar clamp connected thereto, the pneumatically operated lifting plate is connected to a pneumatic lifting cylinder via a connecting rod, one needle bar clamp is capable of aligning with an opening in the upper shaft connecting rod clevis through the rotation of the revolver, and the pneumatically operated lifting plate remains stationary while the revolver is rotating. 【0015】

[0015] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the pneumatically operated lifting plate is provided with a clearance slot to allow one of a plurality of separate needle bars to slide relative to the pneumatically operated lifting plate. 【0016】

[0016] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the multiple separate needle bars are single or double needle bars. 【0017】

[0017] Also disclosed is a sewing machine head for a robot, comprising: a needle bar holder comprising a revolver configured to hold a plurality of separate needle bars; a motor operably coupled to the revolver to rotate the revolver; and means for ensuring the alignment and stability of the revolver when one of the plurality of separate needle bars is selected for a sewing process; and a plurality of separate spools, each providing an upper thread for one of the plurality of separate needle bars, the upper thread being fed from one of the plurality of separate spools through a series of guides and tensioners before entering the upper end of the needle bar holder. 【0018】

[0018] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, each of the multiple separate needle bars is hollow. 【0019】

[0019] In addition to one or more of the above-described features, or as an alternative to any of the above-described embodiments, each of the needle bars functions as an upper thread take-up arm, creating slack in the thread to be caught by a looper or hook during stitching. 【0020】

[0020] In addition to one or more of the above features, or as an alternative to any of the above embodiments, upper threads fed from a plurality of individual spools are delivered through tubes that run from a spool mount guide bracket to the upper plate of the needle bar holder, and the upper threads are then delivered to one of a plurality of individual thread tensioners located below the upper plate of the needle bar holder, and the upper threads pass through one of the plurality of individual thread tensioners and then through a guide manifold, and the upper plate, the plurality of individual thread tensioners, and the guide manifold are configured to rotate together with the revolver assembly to prevent thread tangling. 【0021】

[0021] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the plurality of separate needle bars are six. 【0022】

[0022] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, means for ensuring the arrangement and stability of the revolvers are pneumatic cylinders or electric solenoids. 【0023】

[0023] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the pneumatic cylinder or electric solenoid extends a piston that engages with one of a plurality of recesses located in the revolver. 【0024】

[0024] In addition to one or more of the above-described features, or as an alternative to any of the above-described embodiments, a pneumatically operated lifting plate is provided which is configured to engage with a plurality of separate needle bars, each of the plurality of separate needle bars having a needle bar clamp connected thereto, the pneumatically operated lifting plate is connected to a pneumatic lifting cylinder via a connecting rod, one needle bar clamp is capable of aligning with an opening in the upper shaft connecting rod clevis through the rotation of the revolver, and the pneumatically operated lifting plate remains stationary while the revolver is rotating. 【0025】

[0025] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the pneumatically operated lifting plate is provided with a gap slot to allow one of a plurality of separate needle bars to slide relative to the pneumatically operated lifting plate. 【0026】

[0026] In addition to one or more of the above-described features, or as an alternative to any of the embodiments described above, the multiple separate needle bars are single or double needle bars. 【0027】 In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, a lower column assembly is provided that is configured to handle one or two threads by automatically disabling / enabling one of two loops of a loop arm assembly of the lower column assembly. The loop arm assembly includes a fixed arm and a movable arm that each support one of the two loops. The movable arm is lowered relative to the fixed arm when a selected one of a plurality of separate needle bars is a single needle bar. Lowering the movable arm is achieved by a pneumatic cylinder located near the base of the lower column assembly. The movable arm is supported by a pair of guides that allow vertical movement of the movable arm relative to the fixed arm. 【0028】 In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, a swiper arm is provided that is configured to engage a thread connected to one of a plurality of separate needle bars. Due to the rotational movement of the swiper arm, the thread is engaged by a spring clip fixed to a spring clip arm separately fixed to the revolver. 【0029】 A method of changing the color of the thread of a sewing head without manually changing the thread winding, the method comprising the steps of providing a single sewing head having a plurality of needle bars, each needle bar of the plurality of needle bars being mounted on a revolver, each needle bar of the plurality of needle bars including one or more threads of different colors provided by one or more separate and independent thread windings, and moving the revolver until a desired one of the plurality of needle bars is oriented for sewing operations by the sewing head. 【0030】 The following description should not be construed as limiting in any way. Referring to the accompanying drawings, like elements are numbered alike. 【Brief Description of the Drawings】 【0031】 [Figure 1]This is a perspective view of a revolving needle bar holder capable of holding up to six separate needle bars according to the present disclosure. [Figure 2] This is a perspective view of a revolving needle bar holder capable of holding up to six separate needle bars according to the present disclosure. [Figure 3] This figure shows the upper thread being fed from an individual spool through a series of guides and tensioners before entering the upper end of the hollow needle bar according to this disclosure. [Figure 4] This figure illustrates the lower end of the needle bar revolver according to the present disclosure. [Figure 5A] This figure illustrates the position of the plate while the needle bar is rotating according to the present disclosure. [Figure 5B] This diagram illustrates the position of the board during sewing according to the present disclosure. [Figure 6A] This figure illustrates an alternative means for fixing and repositioning an untied thread end using a thread brake as disclosed herein. [Figure 6B] This figure illustrates an alternative means for fixing and repositioning an untied thread end using a thread brake as disclosed herein. [Figure 6C] This figure illustrates an alternative means for fixing and repositioning an untied thread end using a thread brake as disclosed herein. [Figure 7] This figure illustrates the upper thread feeding mechanism according to the present disclosure. [Figure 8] This figure illustrates the swipe arm according to the present disclosure. [Figure 9] This figure illustrates the scissors assembly according to the present disclosure. [Figure 10] This diagram illustrates how additional gaps can be created in a needle bar revolver. [Figure 11] This diagram illustrates a lower column assembly modified to handle one or both threads by automatically disabling / enabling one of the two loopers. [Figure 12] This diagram illustrates a lower column assembly modified to handle one or both threads by automatically disabling / enabling one of the two loopers. [Figure 13]This figure illustrates how the thread end of a sewing head is retained according to an embodiment of the present disclosure. [Figure 13A] This diagram follows the line 13A-13A in Figure 13. [Figure 14] This figure illustrates how the thread end of a sewing head is retained according to an embodiment of the present disclosure. [Figure 15] This figure illustrates how the thread end of a sewing head is retained according to an embodiment of the present disclosure. [Figure 16] This figure illustrates how the thread end of a sewing head is retained according to an embodiment of the present disclosure. [Figure 17] This figure illustrates how the thread end of a sewing head is retained according to an embodiment of the present disclosure. [Figure 18] This figure illustrates the operation of the needle bar lifting plate according to an embodiment of the present disclosure. [Figure 18A] Figures 18 and 19 are perspective views of the lifting plate. [Figure 19] This figure illustrates the operation of the needle bar lifting plate according to an embodiment of the present disclosure. [Figure 20] This is a perspective view of a sewing head according to an embodiment of the disclosure. [Figure 21] This is a perspective view of a sewing head according to an embodiment of the disclosure. [Figure 22] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 23] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 24] This is an exploded view of a part of the sewing head according to the disclosed embodiment. [Figure 25] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 26] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 27] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 28] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 29] This is a perspective view of a part of a sewing head according to the embodiment disclosed herein. [Figure 30] This is a top view of a portion of the sewing head according to the disclosed embodiment. [Figure 31] This is a schematic diagram of a robot having a sewing head according to an embodiment of the present disclosure. [Figure 32] This is a process flowchart of the sewing operation as disclosed herein. [Modes for carrying out the invention] 【0032】 [Detailed explanation] 【0059】 A detailed description of one or more embodiments of the disclosed apparatus and methods is presented herein with reference to the drawings, not as an limitation but as an example. 【0033】 【0060】 In one concept, a revolver-type needle bar holder, revolver needle bar holder, or revolver 1 is used, capable of holding up to six separate needle bars 7 (see at least Figure 1). The revolver 1 is rotated via a belt 102 by a motor 2 mounted on the side of a head, sewing head, or robot sewing head 100. The revolver is supported by a series of four bearing spools 3 located on an upper support bracket 104. After the desired needle bar 7 has been rotated and positioned, a pneumatic cylinder or electric solenoid 4 is engaged to lock the revolver 1 in place. This locking maintains the alignment and stability of the revolver during sewing. This engagement is also illustrated in Figures 23 and 24, in which the pneumatic cylinder or electric solenoid 4 extends a piston 106 that engages with one of several recesses 108 located on the revolver 1. 【0034】 【0061】As shown in Figure 2, the needle bar clamp 5 engages with the lifting bracket 6 via a mechanical interlock to ensure that the correct needle bar stroke and position are maintained from top dead center (TDC) to bottom dead center (BDC) of the stitch cycle at all sewing speeds. Note that the needle bar 7 not in use is positioned above the TDC of the working needle bar, identified by reference numeral 8, to provide an additional gap between the non-moving needle bar and the partial surface. This is achieved by a swash plate 9 through which all needle bars pass during needle bar changes. The swash plate 9 may be further contoured so that the needle bar 7 closest to the end of the sewing head is positioned higher above the partial surface, further minimizing the possibility of interference with the part being sewn or the part that is fixed during sewing. The outline is illustrated by the dashed line 110 in Figure 10, and the area 112 is removed to create additional space for the part being sewn, so that the needle bar 7 closest to the end of the sewing head 100 is positioned higher above the partial surface, further minimizing the possibility of interference with the aforementioned part or the part that will be fixed during sewing. The needle closest to the end of the sewing head 100 rises as the height increases from right to left (relative to the viewpoint in Figure 10), at least as illustrated in Figure 10. The swash plate 9 also functions as a lower guide for the revolver assembly 1. 【0035】 【0062】Alternatively, and hereby with reference to at least Figures 18 and 19, the repositioning of the needle bar can be achieved by using a pneumatically operated lifting plate 36 instead of a swash plate. The lifting plate 36 is configured to engage with a series of needle bar clamps 37 connected to each needle bar 7. To change the needle bar, a pneumatic lifting cylinder 38 extends in the direction of arrow 114 and pushes the lifting plate 36 downward via a connecting rod 40. The connecting rod 40 is fixed to the lifting plate 36 at one end and to the pneumatic lifting cylinder 38 at the other end. In its full stroke, all needle bar clamps 37 are aligned with an upper shaft connecting rod clevis 41 having an opening 116 configured to align with one of the needle bar clamps 37 of one of the needle bar 7. The motor 2 then rotates the needle bar revolver 1 to align the desired needle bar with the connecting rod clevis 41. The lifting plate 36 remains stationary while the revolver 1 is rotating. During alignment, the revolver locking cylinder 4 extends, locking the needle bar revolver 1 in place. Then, the pneumatic lifting cylinder 38 retracts in the direction of arrow 118, lifting all needle bars 7 that engage with the lifting plate, except for the desired needle bar 7 that is aligned with the opening 116 of the connecting rod clevis 41. A gap slot 43 is provided in the lifting plate 36, which keeps the selected needle bar 7 engaged with the connecting rod clevis 41 in place, or in other words, the selected needle bar can slide into the gap slot 43 and therefore cannot move in the direction of arrow 118. The needle bar 7 engaged with the connecting rod clevis 41 is then used for the next sewing. 【0036】 【0063】As shown in Figure 20, the needle bar revolver assembly 44 includes a revolver 1 and can rotate to allow for the transport of the needle bar as needed. The needle bar revolver assembly 44 pivots around an upper shaft 43. The rotation is driven by a transport arm 45 that rotates together with the lower shaft 46. The rotation of the lower shaft is generated by an eccentric assembly 47 mounted on the main upper drive shaft 48 of the head 100. As the main upper drive shaft 48 rotates, the eccentric assembly 47 generates an oscillating motion that is sent to the lower shaft 46, subsequently causing the transport arm 45 to rotate back and forth in a series of stitch cycles. The eccentric assembly 47 may be adjusted to vary the degree of rotation of the needle bar revolver assembly 44 as desired. 【0037】 【0064】 As shown in Figure 3, the upper thread or top thread 120 is fed from an individual spool 10 through a series of guides 122 and tensioners 14 before entering the upper end of the hollow needle bar. In other words, each needle bar is hollow. See also Figures 22–26, 28, and 30. Each needle bar itself functions as a lifting arm, creating slack in the thread for capture by a looper or hook during stitching. The thread fed from the spool is delivered through tubes 11 that run from the spool-mounted guide bracket 12 to the upper plate 13 of the revolver assembly 44. The thread is then delivered to an individual thread tensioner 14 located below the upper plate of the revolver assembly. After the thread has passed through the tensioner 14, it is delivered through an additional guide manifold 15 having a thread exit point located below the top dead center (TDC) of the needle bar 7. The guide manifold 15 is adjustable to provide the ability to control the amount of top thread 120 available to the needle for stitching. The top plate, thread tensioner, and guide assembly are mounted on the revolver 1 of the revolver assembly 44 and rotate together to eliminate thread tangling and ensure consistent tension for each color. These components are illustrated by brackets 124 in Figure 3. Lift adjustments, indicated by arrows 126, are also shown. 【0038】 【0065】Figure 4 illustrates the thread emerging from the needle bar exit 16 directly above the needle holder 17. The thread is fed through one or more guides 18 before passing through the eye of the needle 19. The guides 18 may be designed to introduce adjustable tension to the thread as needed to minimize thread movement and thereby improve the formation of the stitch between the needle 19 and the looper or hook 20. Figure 4 illustrates a single-needle configuration. In a double-needle configuration, two threads are fed from the top to the bottom through the center of the needle bar and pass through the same guides before passing through the eye of the needle located in a double-needle holder inserted into the bottom of the needle bar. 【0039】 【0066】 Figures 5A and 5B illustrate one method for fixing and repositioning untied thread ends 21 to prevent interference with partial feature scanning that occurs during sewing. A plate 22, driven by a pneumatic or electric actuator 23, surrounds the needle and moves axially along the length of the needle from a specific distance below the needle tip to a specific distance above the needle tip. When the plate 22 is in its lowest position, the needle bar revolver 1 can rotate freely and change color. After the desired needle bar 7 is in position, the plate 22 is raised to its upper position, capturing all unused untied thread ends of the needle bars by carrying them upward and holding them in place during sewing. 【0040】 【0067】 Figures 6A to 6C illustrate an alternative means of securing and repositioning an untied thread end by using a thread brake 24, which may be employed both to pull in and lock the thread present in a spare needle bar, and to prevent the thread end from interfering with the sewing or partial scanning process. The thread brake has a notch to prevent the needle bar in use from engaging with the thread brake. Figure 6A shows the engaged and disengaged thread brake 24, Figure 6B shows the engaged thread brake, and Figure 6C shows the engaged thread brake and the pulled-in thread. 【0041】 【0068】Figures 13–17 illustrate further alternative means for securing the untied thread end protruding from the idle needle bar 7. After the last stitch, the head 100 stops sewing, and before the revolver is activated or rotated, the swiper arm 34 rotates clockwise from its original position (relative to Figures 13–17 or in the direction of arrow 127) to engage with or capture the top thread connected between the needle and the last stitch of the sewn portion 128. After engagement, the swiper arm 34 continues to rotate clockwise in the direction of arrow 127 until the thread engages with the spring clip 35 that holds the thread. After the thread is captured, the swiper arm rotates counterclockwise (relative to Figures 13–17 or in the direction of arrow 129) until it is possible for the thread to be cut by the scissors 130. After cutting, the top thread from the needle remains constrained by the spring clip 35 while the swiper arm 34 returns to its original position. Here, the needle bar revolver 1 can be rotated to allow for subsequent changes in thread color or needle quantity. 【0042】 【0069】 The rotation of the swipe arm 34 is achieved through a swipe arm cylinder 131 that rotates a shaft 133 fixed to the swipe arm 34. 【0043】 【0070】 Figure 13A is a diagram along line 13A-13A of Figure 13 illustrating a spring clip arm 132 having a spring retaining clip 35 on either side. Each needle bar 7 of the needle bar assembly has an associated spring clip arm 132, which is separately fixed to the revolver 1 of the needle bar revolver assembly 44 via a shaft 134 such that the rotation of the revolver causes each spring clip arm 132 to rotate. The associated spring clip arms 132 are also illustrated in at least Figure 29. 【0044】 【0071】 The concepts described herein take into account the existing implementation requirements for the components necessary for real-time automated thread repositioning, cutting, and scanning of tracking feature locations. The concepts also take into account the typical spatial requirements above and below the partial surface being approached during automated 3D partial sewing. 【0045】 【0072】 The above concept may be used in either double stitching or chain stitching. 【0046】 【0073】 According to various non-limiting embodiments of the present disclosure, the revolver-type needle bar holder 1 may be used in conjunction with a robotic sewing head 100. Furthermore, according to various non-limiting embodiments of the present disclosure, the revolver-type needle bar holder may be used to apply stitches to a part, and in one non-limiting embodiment, the part may be an interior part of a vehicle or automobile. 【0047】 【0074】 The revolver needle bar holder 1 may be further configured to handle single needle clamps 25 at the end of each bar, double needle clamps at the end of each bar, or a combination of one or more needle bars configured for single needle clamps with the remaining needle bars configured for double needle clamps. 【0048】 【0075】 When a revolver needle bar holder is configured to handle both single and double needle bar clamp combinations, it becomes possible to sew both single and double needle decorative stitch patterns onto the same section within the same processing cycle without changing the sewing head or moving the section between multiple sewing cells or stations. 【0049】 【0076】Figures 11 and 12 illustrate a lower column assembly 26 modified to handle one or two threads by automatically disabling / enabling one of the two loopers. The looper arm assembly includes a fixed arm 27 and a movable arm 28, each supporting one looper, with the movable arm lowered when only one needle is in use. Lowering the movable arm is achieved by a pneumatic cylinder 29 located near the base of the column assembly 26. The movable arm 28 is supported by a pair of guides 30 that allow vertical movement of the movable arm relative to the fixed arm 27 in the direction of arrow 132 along the length of the fixed arm 27. Reducing the height of the movable arm 28 prevents an untied thread end 31 protruding from a non-operational looper 32 from being sewn into a stitch created by the operational looper 33. A looper nesting pocket 32a serves to assist in accommodating the untied thread end. 【0050】 【0077】 When switching from a double needle to a single needle, the revolver needle bar holder 1 rotates until the needle bar 7 with the single needle is in the correct position. At the same time, one looper arm is lowered to deactivate the second looper. Similarly, when switching from a single needle to a double needle, the revolver rotates the needle bar with the two needles to its fixed position, and at the same time, the deactivated looper is pushed back to the sewing position. The operation of both the needle bar revolver and the looper arm is automatically controlled through a machine control device. 【0051】 【0078】 In addition, the needle bars within the needle bar holder may be configured to handle multiple thread sizes within a single revolver. For decorative automotive stitching, 135 tex and 210 tex thread sizes are common. 【0052】 【0079】 The ability to automatically change size, thread color, and thread quantity within a single sewing head during a single processing cycle is practically achievable here. 【0053】 【0080】Figure 30 is a top view of a portion of the sewing head 100 according to an embodiment of the present disclosure. As described above, the upper thread or top thread 120 is fed from the individual spools 10 through tubes 11 that pass from the spools 10 to the guides 122 of the revolver assembly 44. 【0054】 【0081】 Figure 31 is a schematic diagram of a robot 136 operably coupled to a sewing head 100 having an arm or other equivalent structure 138 of a robot 135, according to an embodiment of the present disclosure. The robot 136 and sewing head 100 are located within a cage 140. A portion 128 being sewn by the sewing head 100 is also shown. In addition, a second unsewn portion 128' waiting to be sewn by the sewing head 100 is shown. The sewn portion 128 and the unsewn portion 128' are located on a fixture 142 that can be rotated in at least one direction in the direction illustrated by arrow 144. 【0055】 【0082】 A computer human-machine interface 146 is also shown, on which a user 148 can provide input regarding the desired thread color. A part barcode scanner 150 is also provided for scanning a barcode label on the unsewn portion 128'. While portion 128 is being sewn, the unsewn portion 128' is placed on a fixture 142 located outside the cell cage 140. Once the portion is sewn, a signal indicating the required thread color for the unsewn portion is sent from the computer (PC) 146 human-machine interface (HMI) to the sewing head 100. 【0056】 【0083】 After the unstitched portion 128' is placed inside the robot cage 140 before being rotated, the barcode label of the unstitched portion 128' is scanned by the part barcode scanner 150 to verify that the exterior color of the portion 128 matches the desired recipe (for example, the thread color and needle type (double or single) selected in the human-machine interface (HMI) of the computer (PC) 146). 【0057】 【0084】 Figure 32 is a process flowchart 170 of the sewing operation according to the present disclosure. In step or box 172, the operator removes the part to be sewn 128 from the attachment 142 and places a new part 128' on top. Then, it is determined whether the current needle thread color is correct for the new part. This determination is illustrated by boxes or steps 174 and 176. If the current needle thread color is correct, the robot 136 leaves its home position and starts the first processing cycle or stitch trajectory. This start is represented by box or step 178. If the current needle thread color is incorrect, the sewing head 100 switches to the correct needle thread by the rotation of the revolver. This switch is represented by box or step 180. 【0058】 【0085】 In box or step 182, the robot 136 enters the portion 128 of the first stitch path with the sewing head 100. In box or step 184, the sewing head 100 completes the first partial stitch of the current path. If necessary, and depending on the contour of the part being sewn, in box or step 186, the robot 136 raises and lowers its lower arm using a lifting mechanism. Then, in box or step 188, the robot 136 sews the remainder of the current path.

[0059] 【0086】 If necessary, and depending on the contour of the part being sewn, at box or step 190, the robot 136 raises or lowers its lower arm again by the lifting mechanism. If the current stitch path is the last path (box or step 192), the sewing head 100 leaves part 128 and the robot returns to home. This return is represented by boxes or steps 192 and 194.

[0060] 【0087】 However, if the current stitch path is not the last path (box or step 196), the robot 136 moves the sewing head 100 to the next path (box or step 198).

[0061] 【0088】If the current needle thread color is correct, robot 136 starts the first processing cycle on the current stitch path. This start is represented by boxes or steps 200 and 184. If the current needle thread color is incorrect (box or step 202), the sewing head 100 switches to the correct needle thread by the rotation of the revolver. This switch is represented by boxes or step 204. Subsequently, robot 136 starts the first processing cycle on the current stitch path. This start is represented by boxes or step 184.

[0062] 【0089】 The term "about" is intended to include the degree of error associated with a measurement of a particular quantity based on the equipment available at the time of filing this application. For example, "about" may include a range of ±8%, 5%, or 2% of a given value.

[0063] 【0090】 The terms used herein are intended solely to describe specific embodiments and are not intended to limit the disclosure. The singular forms “a,” “an,” and “the” used herein are intended to include the plural form unless otherwise specified in the context. It should be further understood that the terms “comprises” and / or “comprising,” as used herein, indicate the presence of the described features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0064] 【0091】While this disclosure is described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various modifications may be made without departing from the scope of this disclosure, and that equivalents may be substituted for elements of this disclosure. In addition, many modifications may be made to adapt the teachings of this disclosure to specific circumstances or materials without departing from the essential scope of this disclosure. Thus, this disclosure is not limited to any particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but it is intended to include all embodiments that fall within the claims.

Claims

[Claim 1] A revolver configured to hold multiple separate needle bars, A motor is operably coupled to the revolver in order to rotate the revolver, A needle bar holder for a sewing machine head, comprising means for ensuring the arrangement and stability of the revolver when one of the plurality of separate needle bars is selected for the sewing process, The means for ensuring the arrangement and stability of the revolver is a pneumatic cylinder or an electric solenoid. The needle bar holder for the sewing machine head further comprises a pneumatically operated lifting plate configured to engage with a plurality of separate needle bars, each of the plurality of separate needle bars having a connected needle bar clamp, the pneumatically operated lifting plate being connected to a pneumatic lifting cylinder via a connecting rod, one needle bar clamp being able to align with an opening in an upper shaft connecting rod clevis through the rotation of the revolver, and the pneumatically operated lifting plate remaining stationary while the revolver is rotating. [Claim 2] The sewing machine head needle bar holder according to claim 1, wherein the plurality of separate needle bars are six. [Claim 3] The needle bar holder for a sewing machine head according to claim 1, wherein the pneumatic cylinder or electric solenoid extends a piston that engages with one of a plurality of recesses located in the revolver. [Claim 4] The needle bar holder for a sewing machine head according to claim 1, wherein the pneumatically operated lifting plate is provided with a gap slot to allow one of the plurality of separate needle bars to slide relative to the pneumatically operated lifting plate. [Claim 5] The needle bar holder for a sewing machine head according to claim 1, wherein the plurality of separate needle bars are single or double needle bars. [Claim 6] A needle bar holder comprising a revolver configured to hold a plurality of separate needle bars, a motor operably coupled to the revolver to rotate the revolver, and means for ensuring the alignment and stability of the revolver when one of the plurality of separate needle bars is selected for the sewing process, A robotic sewing head comprising a plurality of individual spools, each providing an upper thread for one of a plurality of separate needle bars, wherein the upper thread is fed from one of the plurality of individual spools through a series of guides and tensioners before entering the upper end of the needle bar holder, The means for ensuring the arrangement and stability of the revolver is a pneumatic cylinder or an electric solenoid. The robot sewing head further comprises a pneumatically operated lifting plate configured to engage with a plurality of separate needle bars, each of the plurality of separate needle bars having a connected needle bar clamp, the pneumatically operated lifting plate being connected to a pneumatic lifting cylinder via a connecting rod, one needle bar clamp being able to align with an opening in an upper shaft connecting rod clevis through the rotation of the revolver, and the pneumatically operated lifting plate remaining stationary while the revolver is rotating. [Claim 7] The robot sewing head according to claim 6, wherein each of the plurality of separate needle bars is hollow. [Claim 8] The robotic sewing head according to claim 6, wherein each of the plurality of separate needle bars functions as an upper thread lifting arm, creating slack in the thread for capture by a looper or hook during stitch creation. [Claim 9] The upper threads fed from the plurality of individual spools are delivered through tubes that pass from a spool-mounted guide bracket to the upper plate of the needle bar holder, and thereafter the upper threads are delivered to one of a plurality of individual thread tensioners located below the upper plate of the needle bar holder, and after the upper threads have passed through one of the plurality of individual thread tensioners, they are delivered through a guide manifold, and the upper plate, the plurality of individual thread tensioners, and the guide manifold are configured to rotate together with the revolver to prevent thread tangling. [Claim 10] The robot sewing head according to claim 6, wherein the plurality of separate needle bars are six. [Claim 11] The robot sewing head according to claim 6, wherein the pneumatic cylinder or electric solenoid extends a piston that engages with one of a plurality of recesses located in the revolver. [Claim 12] The robotic sewing head according to claim 6, wherein the pneumatically operated lifting plate is provided with a gap slot for allowing one of the plurality of separate needle bars to slide relative to the pneumatically operated lifting plate. [Claim 13] The robot sewing head according to claim 6, wherein the plurality of separate needle bars are single or double needle bars and sewing. [Claim 14] A needle bar holder comprising: a revolver configured to hold a plurality of separate needle bars; a motor operably coupled to the revolver to rotate the revolver; and means for ensuring the alignment and stability of the revolver when one of the plurality of separate needle bars is selected for a sewing process, A robotic sewing head comprising a plurality of individual spools, each providing an upper thread for one of a plurality of separate needle bars, wherein the upper thread is fed from one of the plurality of individual spools through a series of guides and tensioners before entering the upper end of the needle bar holder, The means for ensuring the arrangement and stability of the revolver is a pneumatic cylinder or an electric solenoid. The aforementioned multiple separate needle bars are single or double needle bars and sewing, The robotic sewing head further comprises a lower column assembly configured to handle one or two threads by automatically deactivating / enabling one of two loopers of a looper arm assembly of the lower column assembly, wherein the looper arm assembly includes a fixed arm and a movable arm, each supporting one of the two loopers, and the movable arm is lowered relative to the fixed arm when one of the plurality of separate needle bars is a single needle bar, and the lowering of the movable arm is achieved by a pneumatic cylinder located near the base of the lower column assembly, and the movable arm is supported by a pair of guides that enable the vertical movement of the movable arm relative to the fixed arm. [Claim 15] A needle bar holder comprising: a revolver configured to hold a plurality of separate needle bars; a motor operably coupled to the revolver to rotate the revolver; and means for ensuring the alignment and stability of the revolver when one of the plurality of separate needle bars is selected for a sewing process, A plurality of individual spools, each providing an upper thread for one of the plurality of separate needle bars, wherein the upper thread is fed from one of the plurality of individual spools through a series of guides and tensioners before entering the upper end of the needle bar holder, A robotic sewing head comprising: a swiper arm configured to engage with a thread connected to one of the plurality of separate needle bars, wherein the rotational movement of the swiper arm causes the thread to be engaged by a spring clip fixed to a spring clip arm separately fixed to the revolver.

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