Bra cup production system and bra cup production method

Abstract

A bra cup production system (999) and method (600). The bra cup production system (999) comprises: a shaping station (100) for shaping cut pieces into shaped cut pieces; a trimming station (200) for trimming the received shaped cut pieces to form bra cups with predefined sizes and contours, the trimming station (200) comprising at least one positioning bracket (20) and a trimming assembly, wherein the trimming assembly comprises a cutter (25) and a robotic arm (23) operably connected to each other; and at least one controller comprising a memory and a processor, wherein the memory prestores at least predefined motion trajectory parameters of the trimming assembly and parameters of predefined cutting force and cutting angle, and the processor is configured to output robotic arm control instructions to the robotic arm (23) to control the robotic arm (23) to move on the basis of the predefined motion trajectory parameters, and to output the parameters of the predefined cutting force and cutting angle to the cutter (25), thereby trimming the shaped cut pieces into bra cups with the predefined sizes and contours. The bra cup production system and method achieve automated production of bra cups.

Description

Bra cup production system and bra cup production method Technical Field

[0001] This invention relates to a breast cup production system and production method. Background Technology

[0002] Bra cups primarily serve to protect, shape, augment, and beautify the breasts. However, the manufacturing process involves cutting fabric into cups, followed by inspection and packaging. The production process for bra cups is complex, and existing production lines for cutting, inspecting, and packaging have numerous steps that cannot be fully automated, resulting in low production efficiency and poor product consistency. Summary of the Invention

[0003] To address the problems existing in the prior art, in one aspect, the present invention provides a bra cup production system, comprising: a shaping station configured to shape cut pieces into shaped cut pieces; wherein the shaping station includes at least one bra cup shaping mold configured to heat-shape at least a portion of the cut piece placed in the mold into a shaped cut piece having a predefined bra cup shape; a trimming station configured to trim the received shaped cut pieces into bra cups of predefined size and profile, wherein the trimming station includes: at least one positioning bracket configured to hold the bra cup shape and relative position of the shaped cut piece thereon; and a trimming assembly including a cutter and a robotic arm operably connected to each other, the trimming assembly being configured to trim the shaped cut piece held on the positioning bracket. The piece is trimmed to a predefined size and profile; and at least one controller, including a memory and a processor, wherein the memory at least pre-stores predefined motion trajectory parameters of the trimming component and predefined cutting force and cutting angle parameters, wherein the processor is configured to output robotic arm control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and to output predefined cutting force and cutting angle parameters to the cutter, such that the robotic arm moves according to the predefined motion trajectory under the control of at least one controller, while the cutter applies a predefined cutting force and cutting angle to the pre-shaped piece under the control of at least one controller, thereby trimming the pre-shaped piece into a bra cup of a predefined size and profile.

[0004] Another aspect of this application proposes a method for manufacturing a breast cup, comprising the following steps:

[0005] (1) The shaping station shapes the cut pieces into shaped cut pieces, wherein at least one of the bra cup shaping molds heat-shapes at least a portion of the cut pieces placed in the mold into shaped cut pieces having a predefined bra cup shape.

[0006] (2) The trimming station trims the pre-shaped pattern piece fed therein into a breast cup of a predefined size and profile, wherein: at least one positioning bracket holds the breast cup shape and relative position of the pre-shaped pattern piece thereon; and the trimming assembly trims the pre-shaped pattern piece held on the bracket into a predefined size and profile.

[0007] (3) The processor outputs control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle to the cutter, so that the robotic arm moves according to the predefined motion trajectory parameters under the control of at least one controller, and the cutter applies a predefined cutting force and cutting angle to the pre-shaped cut piece under the control of at least one controller, thereby trimming the pre-shaped cut piece into a breast cup of predefined size and contour.

[0008] Therefore, at least one embodiment of the present invention has at least one of the following technical effects:

[0009] 1. Automatic feeding of cut pieces has been achieved;

[0010] 2. Automatic shaping of cut pieces has been achieved.

[0011] 3. It enables the automatic cutting of pre-cut pieces into bra cups of the required shape and size.

[0012] 4. Automatic detection, classification, management, and storage of color differences in bra cups have been achieved.

[0013] 5. Automatic transportation of pre-cut pieces from the shaping station to the trimming station has been achieved.

[0014] 6. Fully automated production from cut pieces to qualified bra cups has been achieved. Attached Figure Description

[0015] The performance and advantages of the invention can be further understood by referring to the remainder of this specification and the accompanying drawings, in which the same reference numerals are used for the same component. In some cases, a sub-label is placed after a label followed by a hyphen to indicate one of many similar components. When a label is mentioned without specifically naming an existing sub-label, it refers to all of these similar components.

[0016] Figure 1 is a schematic diagram of the production line of the present invention;

[0017] Figure 2 is a schematic diagram of the feeding station of the present invention.

[0018] Figure 3 is a schematic diagram of the structure of the feeding station of the present invention;

[0019] Figure 4 is a schematic diagram of the feeding station of the present invention.

[0020] Figure 5 is a side view of the feeding station of the present invention;

[0021] Figure 6 is a schematic diagram of the rotary stenter of the present invention;

[0022] Figure 7 is a schematic diagram of the structure of the shaping die assembly of the present invention;

[0023] Figure 8 is a schematic diagram of the structure of part A of the present invention;

[0024] Figure 9 is a schematic diagram of the structure of the flipping station of the present invention;

[0025] Figure 10 is a second structural schematic diagram of the flipping station of the present invention;

[0026] Figure 11 is a schematic diagram of the cup-retrieving robotic arm according to Embodiment 1 of the present invention;

[0027] Figure 12 is a schematic diagram of the structure of part B in Embodiment 1 of the present invention;

[0028] Figure 13 is a schematic diagram of the structure of the robot trimming machine according to Embodiment 1 of the present invention;

[0029] Figure 14 is a schematic diagram of the structure of the robot trimming machine according to Embodiment 1 of the present invention;

[0030] Figure 15 is a side view of the robot trimming machine according to Embodiment 1 of the present invention;

[0031] Figure 16 is a second side view of the robot trimming machine according to Embodiment 1 of the present invention;

[0032] Figure 17 is a schematic diagram of the structure of the glue-laying mechanism according to Embodiment 1 of the present invention;

[0033] Figure 18 is a schematic diagram of the waste receiving mechanism according to Embodiment 1 of the present invention;

[0034] Figure 19 is a schematic diagram of the color difference sorting machine according to Embodiment 1 of the present invention;

[0035] Figure 20 is a side view of a color difference sorting machine according to an embodiment of the present invention;

[0036] Figure 21 is a schematic diagram of the color difference sorting machine according to Embodiment 1 of the present invention.

[0037] Figure 22 is a schematic diagram of the breast cup production system according to Embodiment 2 of the present invention;

[0038] Figure 23 is a partial structural schematic diagram of a type-setting station according to an embodiment of the present invention;

[0039] Figure 24 is a side view of the shaping station of the embodiment shown in Figure 23;

[0040] Figure 25 is a schematic diagram of the other side of the shaping station in the embodiment shown in Figure 23;

[0041] Figure 26 is a schematic diagram of the type-fixing station structure according to another embodiment of the present invention;

[0042] Figure 27 is a schematic diagram of the shaping station structure according to another embodiment of the present invention;

[0043] Figure 28 is a side view of a pruning station structure according to an embodiment of the present invention;

[0044] Figure 29 is a schematic diagram of another side view of the pruning station shown in Figure 28 of the present invention;

[0045] Figure 30 is a schematic diagram of the partial structure of the pruning station shown in Figure 28 of the present invention;

[0046] Figure 31 is a schematic diagram of the structure shown in Figure 30 in another state;

[0047] Figure 32 is a schematic diagram of the structure of a transfer station according to an embodiment of the present invention;

[0048] Figure 33 is a structural schematic diagram of a quality inspection station according to an embodiment of the present invention;

[0049] Figure 34 is a structural schematic diagram of a quality inspection station according to another embodiment of the present invention;

[0050] Figure 35 is a schematic diagram of a method for producing a breast cup according to an embodiment of the present invention. Detailed Implementation

[0051] As used herein and in the claims, “comprising” means including the following elements, but does not exclude other elements. The terms “comprising” and “including” mean including the following elements, but do not exclude other elements. It should be understood that for each embodiment using the terms “comprising” and “including”, this disclosure / application also includes alternative embodiments in which the terms “comprising,” “including,” “containing,” or “having” are replaced with “consistently composed of” or “consistent with.” These alternative embodiments using “consistent with” or “consistently composed of” are to be understood as narrower embodiments of the “comprising,” “including,” “containing,” or “having” embodiments.

[0052] For clarity, "containing" allows for additional elements or features beyond the specified basic elements, while "consisting of" is a closed term that is limited to the elements listed in the claims and excludes any elements, steps, or ingredients not specified in the claims.

[0053] The phrase "consisting substantially of..." limits the scope of the claim to specific materials, components, or steps ("basic elements") that do not materially affect the essential features of the claimed invention. In some embodiments, the essential features are the essential and novel features of the claimed invention.

[0054] As used herein and in the claims, unless the context clearly indicates otherwise, the singular form "an / a" also includes the corresponding plural indicator. When a numerical range is mentioned in the specification, the numerical range is understood to include every discrete point within that range. For example, 1-7 represents 1, 2, 3, 4, 5, 6, and 7.

[0055] As used herein, the terms “about,” “substantially,” and “approximately” are understood to mean within the normal tolerance range of the field and not exceeding ±10% of the specified value. By way of example only, approximately 50 refers to all values ​​from 45 to 55, inclusive. As used herein, the phrase “about” also includes specific values; for example, approximately 50 includes 50.

[0056] As used herein and in the claims, the terms "general" or "substantially" mean that it is not necessary to precisely achieve the listed features, angles, shapes, states, structures, or values, but deviations or variations, including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art, may occur in an amount that does not preclude the effect that the feature is intended to provide. For example, an object having a "general" cylindrical shape means that the object has a precisely cylindrical shape or a nearly precisely cylindrical shape. In another example, an object "substantially" perpendicular to a surface means that the object is either completely perpendicular to the surface or nearly completely perpendicular to the surface, for example, with a deviation of 5%.

[0057] For clarity, "characterized in" (along with their related forms as described above) does not limit or change the nature of whether the following list of terms is open or closed. For example, in a claim for "an apparatus comprising A, B, C and characterized in D, E, and F", elements D, E, and F remain open-ended terms, and the claim is intended to include other elements due to the use of the word "comprising" preceding the claim.

[0058] In this application, the term "cut piece" refers to a flat piece of fabric pre-cut to a certain size, which is suitable for heat setting and serves as a qualified raw material for making bra cups.

[0059] In this application, the term "pre-formed fabric piece" refers to a flat fabric piece that has undergone a heat-setting process, after which a local area of ​​the fabric piece forms an arched or non-planar shape. It can be a pre-formed product with a composite structure formed by multiple fabrics.

[0060] In this application, the term "breast cup" refers to the portion retained after a pre-cut fabric piece has been cut, which includes at least a portion of the fabric piece having an arched or non-planar shape after a heat-setting process.

[0061] In this application, the term "X direction" refers to a direction parallel to the ground plane.

[0062] In this application, the term "Y direction" refers to the direction perpendicular to the ground plane.

[0063] In this application, the term "Z-direction" refers to the direction perpendicular to the X-direction in the horizontal direction.

[0064] In this application, the term "vertical motion" refers to up-and-down movement in a direction perpendicular to the ground plane.

[0065] In this application, terms indicating direction, such as up, down, left, right, inside, outside, top, and bottom, are used with reference to the position of the breast cup production system during normal installation and use.

[0066] In this application, the term "mechanical arm" refers to a mechanical connecting arm that controls the swing angle and travel direction of a cutting tool, including at least two movable joints.

[0067] In this application, the term "tool" refers to a component used for cutting, and its shape is not limited.

[0068] In this application, the terms "power unit", "driver", and "drive unit" include, but are not limited to, various types of electric motors and cylinders.

[0069] To address the current limitations of automated bra production, which requires significant manual labor and cannot fully guarantee product consistency (e.g., bra cup shaping and color difference detection still rely heavily on manual operation, resulting in large errors, low production efficiency, and increasing labor costs due to an aging population, leading to a shortage of skilled workers and hindering production), the following solutions are needed.

[0070] To address the problems existing in the prior art, in one aspect, the present invention provides a bra cup production system, comprising: a shaping station configured to shape cut pieces into shaped cut pieces; wherein the shaping station includes at least one bra cup shaping mold configured to heat-shape at least a portion of the cut piece placed in the mold into a shaped cut piece having a predefined bra cup shape; a trimming station configured to trim the received shaped cut pieces into bra cups of predefined size and profile, wherein the trimming station includes: at least one positioning bracket configured to hold the bra cup shape and relative position of the shaped cut piece thereon; and a trimming assembly including a cutter and a robotic arm operably connected to each other, the trimming assembly being configured to trim the shaped cut piece held on the positioning bracket. The piece is trimmed to a predefined size and profile; and at least one controller, including a memory and a processor, wherein the memory at least pre-stores predefined motion trajectory parameters of the trimming component and predefined cutting force and cutting angle parameters, wherein the processor is configured to output robotic arm control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and to output predefined cutting force and cutting angle parameters to the cutter, such that the robotic arm moves according to the predefined motion trajectory under the control of at least one controller, while the cutter applies a predefined cutting force and cutting angle to the pre-shaped piece under the control of at least one controller, thereby trimming the pre-shaped piece into a bra cup of a predefined size and profile.

[0071] In at least one embodiment, the shaping station further includes a rotary work platform and a driver; wherein: the rotary work platform is driven by the driver to rotate at a predefined angle; at least two bra cup shaping molds are disposed on the rotary work platform; the memory also stores parameters including a predefined angular velocity of the rotary work platform, start-up and pause-up times, heat-setting duration and heat-setting temperature of each bra cup shaping mold; wherein the processor is further configured to output control commands to cause the rotary work platform to rotate at a predefined angular velocity and to start and pause rotation according to the start-up and pause-up times; and wherein the processor is further configured to control each bra cup shaping mold to perform heat-setting on the fabric pieces placed in the molds respectively according to the predefined heat-setting duration and heat-setting temperature parameters, such that while the rotary work platform is operably rotating, at least two bra cup shaping molds perform heat-setting on the fabric pieces placed therein respectively. In one embodiment, one bra cup shaping mold can perform shaping on one pair of bra cups. In another embodiment, one bra cup shaping mold can perform shaping on two pairs of bra cups.

[0072] In at least one embodiment, the heat setting time of each breast cup molding mold corresponds to the time required for the rotating work platform to rotate 180 degrees.

[0073] In at least one embodiment, the shaping station further includes a mold opening and closing control assembly corresponding to the bra cup shaping mold; wherein the bra cup shaping mold further includes an upper mold head and a lower mold head, the size and shape of which are configured to define a space therebetween in a predefined bra cup shape; the lower mold head is disposed on a rotary work platform, and the upper mold head is disposed on the mold opening and closing control assembly; and wherein the mold opening and closing control assembly is configured to be opened by a cylinder at a predefined time to allow insertion or removal of a shaped piece between the upper and lower mold heads, and to close at a predefined time to allow heat shaping of the inserted piece.

[0074] In at least one embodiment, a feeding station is also included, configured to distribute cut pieces to the shaping station at a predefined frequency.

[0075] In at least one embodiment, the loading station further includes a storage device, a first transport component, a material preparation platform, and a first translation module. The storage device is configured to stack multiple cut pieces. The storage device also includes a support platform and a platform height adjustment device. The support platform is mounted on the platform height adjustment device and configured to store stacked cut pieces. The platform height adjustment device is configured to be driven by a motor to move the platform and cut pieces at a predefined speed, so that the first transport component picks up the top cut piece from the support platform at a preset vertical height. The first transport component is positioned above the loading station and includes a first XY-axis motion component and a cut piece gripper. The first XY-axis motion component is configured to move vertically in the Y-axis so that the cut piece gripper picks up a cut piece from the support platform or releases the cut piece. The material is placed on a preparation platform; and configured to drive the piece gripper to move horizontally in the X direction to transport the gripped piece from the support platform to the preparation platform; wherein the preparation platform is configured to move vertically so that the piece gripper releases the piece onto the preparation platform at a predefined vertical height, and causes the first translation module to clamp the edge of the piece at a predefined vertical height; and wherein the first translation module further includes a first X-direction translation track assembly and multiple clamps, the multiple clamps being disposed on the first X-direction translation track assembly, the multiple clamps being configured to clamp the edge of the piece from the preparation platform and release the clamped piece at the bra cup shaping mold, the first X-direction translation track assembly being configured to drive the clamps to move repeatedly in the X direction to repeatedly transport the piece from the preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

[0076] In at least one embodiment, a transfer station is also included, configured to extract the shaped fabric pieces from the shaping station and transport them to a designated location at the trimming station.

[0077] In at least one embodiment, the transfer station further includes a second translation module, a lifting transport platform, and a second transport component. The second translation module further includes a second X-axis translation track assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation track assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly. The clamping part is configured to clamp the edge of the shaped piece from the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward. The second X-axis translation track assembly is configured to drive the clamping part to move repeatedly in the X-axis direction, repeatedly transporting the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency. The lifting transport platform further includes a third XY-axis movement. The system includes a component and a transfer platform, the transfer platform being mounted on and moving with the third XY-direction motion component; a lifting transport platform is configured to move vertically along the Y-direction to allow a second translation module to place the shaped piece onto the transfer platform, and then move along the X-direction to transport the shaped piece from one end near the shaping station to one end near the trimming station; and wherein the second transport component is configured to be mounted above the transfer station, including a second XY-direction motion component and a shaped piece gripper; the second XY-direction motion component is configured to move vertically in the Y-direction to allow the shaped piece gripper to grip the shaped piece from the transfer platform; and is configured to drive the shaped piece gripper to move horizontally in the X-direction to transport the gripped shaped piece to the trimming station.

[0078] In at least one embodiment, the transfer station further includes: a first automatic color difference detection component disposed on the second translation module, including a first camera and a first data transmission unit; the first automatic color difference detection component is configured such that: after the clamping part of the second translation module clamps the shaped piece out of the bra cup shaping mold and before flipping it, the first camera takes a picture of at least the inner side of the arched part of the shaped piece to obtain a first photo, and the data transmission unit transmits the obtained first photo to at least one controller, and the at least one controller detects the color difference of the bra cup according to a preset algorithm.

[0079] In at least one embodiment, the positioning bracket is configured to hold the arched portion of the shaped cut piece upward and to create a certain suction force on the arched portion.

[0080] In at least one embodiment, the positioning bracket further includes a left bracket and a right bracket, the shapes of which correspond to the shapes of the arched portions on the pre-shaped cut pieces; the left bracket and the right bracket are respectively fixed on different supports and maintain a certain spatial distance.

[0081] In at least one embodiment, the cutter cuts the shaped piece into left and right halves along the midline of the spatial distance between the left and right brackets.

[0082] In at least one embodiment, the cutter cuts the left and right halves respectively, the cutter moving along a predefined motion trajectory and cutting at a predefined cutting angle and cutting force, thereby trimming the bra cup to the desired contour.

[0083] In at least one embodiment, the contours of the left and / or right bracket edges are configured to conform to a predefined motion trajectory.

[0084] In at least one embodiment, the system further includes a quality inspection station configured to perform color difference detection on the bra cups and classify and place them according to the color difference detection results.

[0085] In at least one embodiment, the quality inspection station also inspects the shape and contour of the bra cup.

[0086] In at least one embodiment, the second cameras at the quality inspection station are respectively set at multiple different positions and angles at the quality inspection station, aiming at different positions of the bra cup from different directions to perform multiple different shots; the second photos obtained by each second camera are transmitted to at least one controller through a second data transmission unit, and the at least one controller detects the color difference of the bra cup according to a preset algorithm; wherein, the XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed on the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of at least one controller; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the bra cup with the corresponding color difference grade under the drive of the power unit; and wherein, the at least one controller issues instructions to the XYZ motion component according to the determined color difference grade of the bra cup to control it to classify and place the bra cups with different color difference grades into the designated positions.

[0087] In at least one embodiment, the quality inspection station further includes a labeling unit configured to affix a corresponding label to the bra cup after at least one controller has detected the color difference grade of a bra cup.

[0088] In at least one embodiment, the cutting tool is a circular cutting tool.

[0089] In at least one embodiment, the trimming station further includes: a waste recycling device including a waste receiving tray disposed at the bottom of the trimming station; a conveyor belt; and a recycling station for storing waste, wherein the conveyor belt is operatively connected to the waste receiving tray and the recycling station; wherein the waste recycling device is configured such that the waste receiving tray receives waste generated from trimming at the trimming station, and the conveyor belt transfers the waste from the waste receiving tray to the recycling station.

[0090] In at least one embodiment, the bra cup shaping mold further includes a presser foot assembly configured to apply pressure for a predefined duration to the shaped piece located within the bra cup shaping mold when the mold is opened, so that the shaped piece does not change position as the mold is opened.

[0091] Another aspect of this application proposes a method for manufacturing a breast cup, comprising the following steps:

[0092] (1) The shaping station shapes the cut pieces into shaped cut pieces, wherein at least one of the bra cup shaping molds heat-shapes at least a portion of the cut pieces placed in the mold into shaped cut pieces having a predefined bra cup shape;

[0093] (2) The trimming station trims the pre-shaped pattern piece fed therein into a breast cup of a predefined size and profile, wherein: at least one positioning bracket holds the breast cup shape and relative position of the pre-shaped pattern piece thereon; and the trimming assembly trims the pre-shaped pattern piece held on the bracket into a predefined size and profile.

[0094] (3) The processor outputs control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle to the cutter, so that the robotic arm moves according to the predefined motion trajectory parameters under the control of at least one controller, and the cutter applies a predefined cutting force and cutting angle to the pre-shaped cut piece under the control of at least one controller, thereby trimming the pre-shaped cut piece into a breast cup of predefined size and contour.

[0095] In at least one embodiment, the bra cup production method further includes the step of distributing cut pieces from the feeding station to the shaping station at a predefined frequency.

[0096] In at least one embodiment, the bra cup production method further includes the step of: extracting the pre-shaped cut pieces from the shaping station by a transfer station and transporting them to a designated location at the trimming station.

[0097] In at least one embodiment, the bra cup production method further includes the step of: having a quality inspection station perform color difference detection on the bra cups and classify and place them according to the color difference detection results.

[0098] In at least one embodiment, the loading station further includes a storage device, a first transport component, a material preparation platform, and a first translation module. The storage device is configured to stack multiple cut pieces. The storage device also includes a support platform and a platform height adjustment device. The support platform is mounted on the platform height adjustment device and configured to store stacked cut pieces. The platform height adjustment device is configured to be driven by a motor to move the platform and cut pieces at a predefined speed, so that the first transport component picks up the top cut piece from the support platform at a preset vertical height. The first transport component is positioned above the loading station and includes a first XY-axis motion component and a cut piece gripper. The first XY-axis motion component is configured to move vertically in the Y-axis so that the cut piece gripper picks up a cut piece from the support platform or moves the cut piece... Released to a preparation platform; and configured to drive a piece gripper to move horizontally in the X direction to transport the gripped piece from the support platform to the preparation platform; wherein the preparation platform is configured to move vertically so that the piece gripper releases the piece onto the preparation platform at a predefined vertical height, and causes a first translation module to clamp the edge of the piece at a predefined vertical height; and wherein the first translation module further includes a first X-direction translation track assembly and a plurality of clamps, the plurality of clamps being disposed on the first X-direction translation track assembly, the plurality of clamps being configured to clamp the edge of the piece from the preparation platform and release the clamped piece at the bra cup shaping mold, the first X-direction translation track assembly being configured to drive the clamps to move repeatedly in the X direction to repeatedly transport the piece from the preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

[0099] In at least one embodiment, the transfer station includes a second translation module, a lifting transport platform, and a second transport component. The second translation module further includes a second X-axis translation track assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation track assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly. The clamping part is configured to clamp the edge of the shaped piece from within the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward. The second X-axis translation track assembly is configured to drive the clamping part to move repeatedly in the X-axis direction, repeatedly transporting the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency. The lifting transport platform further includes a third XY-axis movement. The system includes a component and a transfer platform, which is mounted on and moves with the third XY-direction motion component; a lifting transport platform is configured to move vertically along the Y-direction to place the pre-shaped cut piece onto the transfer platform by a second translation module, and then move along the X-direction to transport the pre-shaped cut piece from one end near the shaping station to one end near the trimming station; and wherein the second transport component is configured to be mounted above the transfer station, including a second XY-direction motion component and a pre-shaped cut piece gripper; the second XY-direction motion component is configured to move vertically in the Y-direction to cause the pre-shaped cut piece gripper to grip the pre-shaped cut piece from the transfer platform; and is configured to drive the pre-shaped cut piece gripper to move horizontally in the X-direction to transport the gripped pre-shaped cut piece to the trimming station.

[0100] In at least one embodiment, multiple second cameras are respectively set at multiple different positions and angles in the quality inspection station, aiming at different positions of the bra cup from different directions to perform multiple different shots; the second photos obtained by each second camera are transmitted to at least one controller through a second data transmission unit, and the at least one controller detects the color difference of the bra cup according to a preset algorithm; wherein, the XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed on the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of at least one controller; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the bra cup with the corresponding color difference grade under the drive of the power unit; and wherein, the at least one controller issues instructions to the XYZ motion component according to the determined color difference grade of the bra cup to control it to classify and place the bra cups with different color difference grades into the designated positions; the label unit is configured to affix a corresponding label to the bra cup after the at least one controller detects the color difference grade of a bra cup.

[0101] In another aspect of this application, a breast cup manufacturing system is provided, comprising:

[0102] The shaping station is configured to shape the cut pieces into shaped cut pieces.

[0103] The shaping station includes at least one bra cup shaping mold, configured to heat-shape at least a portion of the cut piece placed in the mold into a shaped cut piece having a predefined bra cup shape;

[0104] Rotary work platform;

[0105] drive;

[0106] And at least one controller, configured to include memory and processor;

[0107] in:

[0108] The rotary work platform is driven by a driver to rotate at a predefined angle;

[0109] At least two breast cup shaping molds are installed on the rotating work platform;

[0110] The memory also stores parameters including the angular velocity of the predefined rotating work platform, the start and stop times of rotation, the heat setting time and heat setting temperature of each breast cup shaping mold;

[0111] The processor is also configured to output control instructions to cause the rotary work platform to rotate at a predefined angular velocity and to start and stop rotation according to parameters for the start and stop times of rotation; and

[0112] The processor is also configured to control each bra cup shaping mold to perform heat shaping on the cut pieces placed in the mold according to the predefined parameters of heat shaping time and heat shaping temperature, so that at least two bra cup shaping molds perform heat shaping on the cut pieces placed in them while the rotating work platform is operably rotating.

[0113] In at least one embodiment, a trimming station is also included, configured to trim the received pre-shaped fabric pieces into a bra cup of a predefined size and profile.

[0114] The pruning stations include:

[0115] At least one positioning bracket is configured to hold the cup shape and relative position of the shaped pattern piece thereon;

[0116] A trimming assembly, comprising a cutter and a robotic arm operably connected to each other, is configured to trim a pre-shaped cut piece held on a positioning bracket to a predefined size and profile; and

[0117] The memory contains at least pre-defined motion trajectory parameters of the trimming component, as well as pre-defined cutting force and cutting angle parameters.

[0118] The processor is configured to output robotic arm control commands to the robotic arm to control the robotic arm to move according to predefined motion trajectory parameters, and to output predefined cutting force and cutting angle parameters to the cutter, so that the robotic arm moves according to the predefined motion trajectory under the control of at least one controller, while the cutter applies a predefined cutting force and cutting angle to the pre-shaped pattern piece under the control of at least one controller, thereby trimming the pre-shaped pattern piece into a bra cup of predefined size and contour.

[0119] To achieve the above objectives, the present invention provides the following technical solution: a bra cup cutting, inspection and packaging production line, comprising a production line, wherein the production line includes a feeding station, a rotary shaping machine, a turning station, a robotic trimming machine and a color difference sorting machine, wherein the feeding station, the rotary shaping machine, the turning station, the robotic trimming machine and the color difference sorting machine are arranged sequentially.

[0120] Preferably, the feeding station includes a rectangular frame, with a base plate fixedly installed at the bottom of the rectangular frame. Two piece feeding boxes are fixedly installed at the top of the base plate, and feeding platforms are fixedly connected to the bottom of each of the two piece feeding boxes. Double-rail connecting plates are slidably connected to the bottom of each of the two feeding platforms. A first servo motor is fixedly installed on the back of each of the two piece feeding boxes, and upper and lower lifting plates are fixedly connected to the output ends of each of the two first servo motors. The two upper and lower lifting plates are located inside the two piece feeding boxes respectively. A worktable is fixedly installed at one end of the middle of the rectangular frame, and a preparation lifting platform is fixedly installed on the top of the worktable. Conveyors are fixedly installed on both sides of the middle of the rectangular frame, and a double-rail connecting plate is fixedly installed at one end of the bottom of each of the two conveyors. There is a first stepper motor, and the output ends of the two first stepper motors are respectively connected to the surfaces of the two conveyors. A fourth transfer module is fixedly installed at the top inside the rectangular frame. A piece-grabbing suction cup is engaged with the bottom of the fourth transfer module. Side doors are fixedly installed on both sides of the rectangular frame. Position adjustment handwheels are engaged between the two pairs of loading base platforms and the double-rail connecting base plates. A piece-loading robotic arm is engaged with the surfaces of the two conveyors. A second servo motor is fixedly installed on one side of the fourth transfer module. The output end of the second servo motor is connected to the surface of the fourth transfer module. A control box is fixedly installed on one side of the top of the base plate. The first servo motor, the first stepper motor and the second servo motor are all electrically connected to an external power supply through the control box.

[0121] The machine is equipped with a pre-installed feeding station, and the cutting piece feeding box is detachable. The position can be adjusted using the position adjustment handwheel. The upper and lower lifting plates are raised or lowered by the first servo motor, which is more efficient and convenient than the traditional feeding method. The cutting pieces are neatly loaded into the cutting piece feeding box in advance. When the machine is started, the cutting piece suction cup grabs a cutting piece, the transfer module moves the cutting piece to the preparation lifting platform, and then the cutting piece loading robotic arm grabs the cutting piece and sends it to the shaping machine for shaping. The upper and lower lifting plates in the cutting piece feeding box are driven by the first servo motor, which is conducive to precise and efficient feeding.

[0122] Preferably, the rotary shaping machine includes a shaping frame, a shaping table is fixedly installed inside the shaping frame, a rotary table body is rotatably connected to one side of the top of the shaping table, a third length plate is fixedly installed on the other side of the top of the shaping table, shaping mold head assemblies are installed on both sides of the top of the rotary table body, and a shaping component is fixedly installed in the middle of the top of the shaping frame. The shaping component includes two first lifting cylinders and a first height platform. The movable ends of the two first lifting cylinders are respectively fixedly connected to both sides of the top of the first height platform, and a pressure plate is provided at the bottom of the first height platform. Both ends of the first height platform are threaded with screws. The bottom ends of the four screws are rotatably connected to the four corners of the top of the pressure plate. The middle parts of the two first lifting cylinders are fixedly connected to the shaping frame. A height rail located between the two first lifting cylinders is fixedly installed on the shaping frame. A lifting block is slidably connected to the middle of the height rail. One side of the lifting block is fixedly connected to the side of the first height platform directly opposite it. The four corners of the top of the shaping platform are fixedly installed with first height rods. The four corners of the top of the first height platform are fixedly installed with sliding rods. The connected sliding blocks, both of the aforementioned shaping die head assemblies include a shaping base and a die head body. The top end of the shaping base is connected to the bottom end of the die head body. The bottom end of the shaping base is provided with several fixing feet, and the top end of each of the fixing feet is fixedly mounted with an ejector pin. The top end of each of the ejector pins is connected to the side of the die head body facing away from it. The surface of the shaping base is provided with several drainage grooves. The bottom ends of each of the fixing feet are fixedly connected to the turntable body. A first cylinder base is fixedly mounted on one side of the top end of the third length plate, and a second cylinder base is fixedly mounted on the other side of the top end of the third length plate. A straight track is provided, with a first displacement block slidably connected to the middle of the first straight track. A first positioning block is fixedly installed at the top of the first displacement block. A shaping auxiliary positioning cylinder is fixedly installed on one side of the first cylinder base. The movable end of the shaping auxiliary positioning cylinder is fixedly connected to the side of the first displacement block facing the first displacement block. One side of the first positioning block is in contact with the side of the turntable body facing the first positioning block. A first operation panel is fixedly installed at the top of one side of the shaping frame. Exhaust fans are fixedly connected to both sides of the top of the shaping frame. Inspection doors are hinged to the bottom of the four sides of the shaping frame.

[0123] After the cut pieces are placed on the shaping die head, the shaping process begins. Then, the turntable rotates, and one of the shaping die head components rotates to the cut piece feeding station. The shaping die head component begins to feed and shape the cut pieces. When the other shaping die head component has finished shaping, it is sent to the next station, which is the flipping station. After the flipping station has picked up the cup, the shaping machine turntable rotates back, and the other shaping die head component rotates to the feeding position again. At the same time, the other shaping die head component rotates to the cup picking position. Once one of the shaping die head components has finished shaping, this cycle repeats.

[0124] Preferably, the flipping station includes a flipping frame, a first transfer module is fixedly installed at the bottom of the inner wall of the flipping frame, a bottom color difference detection platform is slidably connected to the top of the first transfer module, a cooling platform is fixedly installed on one side of the top of the bottom color difference detection platform, a second transfer module is fixedly installed in the middle of the inner wall of the flipping frame, cup-picking robotic arms are provided on both sides of the top of the second transfer module, two cup-picking grippers are installed at one end of each opposite side of the two cup-picking robotic arms, and a color difference detector is fixedly installed at the other end of each opposite side of the two cup-picking robotic arms, a first cup-picking lifting mechanism is installed in the middle of the top of the second transfer module, and a third transfer module is fixedly installed at the top of the inner wall of the flipping frame, the third transfer module... The first transfer module is equipped with a second cup-retrieving lifting mechanism. The bottom of the third transfer module is equipped with a construction station loading gripper. The first transfer module includes a fixed base and two second linear tracks. The top two sides of the fixed base are fixedly connected to the bottom ends of the two second linear tracks. Two first limiting plates are fixedly installed in the middle of the top of the fixed base. A first lead screw is rotatably connected between the two first limiting plates. A movable seat that is slidably connected to the fixed base is threaded into the middle of the first lead screw. A second lifting cylinder is fixedly installed at the top of the movable seat. The movable end of the second lifting cylinder is fixedly connected to the bottom color difference detection platform. The bottom end of the fixed base is fixedly connected to the tilting frame. The second transfer module includes two first length plates and four first length... The system consists of a series of tracks, with the top sides of two first length plates fixedly connected to the bottom sides of four first length tracks. A first length block is slidably connected to the middle of each of the four first length tracks. A first movable plate is fixedly installed between the four first length blocks. A second length plate is fixedly installed at the top of the first movable plate. Second length tracks are fixedly installed on both sides of the top of the second length plate. Two second length blocks are slidably connected to the middle of each of the two second length tracks. A second movable plate is fixedly installed between every two pairs of opposing second length blocks. The top of the second length plate is connected to a first cup-retrieving lifting mechanism. The tops of the two second movable plates are respectively connected to two cup-retrieving robotic arms. The bottom ends of the two first length plates are connected to a tilting frame. The third transfer module is fixedly connected to a moving platform and two moving tracks. Both sides of the moving platform are fixedly connected to one side of each of the two moving tracks. Moving blocks are slidably connected to the middle of each of the two moving tracks. A connecting platform is fixedly installed between the two moving blocks. A second stepper motor that drives the moving blocks to slide is fixedly installed on the surface of the moving platform. The top of the moving platform is fixedly connected to a flipping frame. Each of the four cup-flipping grippers includes a clamping shell and two clamping plates. Two ends of one side of the clamping shell are connected to the two ends of the two clamping plates. A first displacement rod is slidably connected inside the clamping shell. The two ends of the first displacement rod are rotatably connected to the opposite sides of the two clamping plates. One end of each of the four clamping shells is connected to the side facing the cup-retrieving robotic arm.Both the first and second cup-retrieving lifting mechanisms include a positioning plate and four first sliding rods. The four corners of the bottom of the positioning plate are fixedly connected to the tops of the four first sliding rods. A cup-retrieving platform is installed between the bottom ends of the four first sliding rods. A first sliding platform is slidably connected to the middle of the four first sliding rods. Sliding sleeves are fitted at the connection points between the four first sliding rods and the first sliding platforms. The positioning plate on the first cup-retrieving lifting mechanism is fixedly connected to a second transfer module, and the positioning plate on the second cup-retrieving lifting mechanism is connected to a third transfer module. Symmetrically arranged sealing doors are hinged to the bottom of the side of the flipping frame.

[0125] The lifting cylinder extends and retracts, pushing the bottom color difference detection platform from the bottom to adjust its height. The lead screw rotates, and the thread on the lead screw surface matches the thread on the inner wall of the movable seat. The movable seat is limited by the fixed base, so it rotates along the lead screw to adjust the position of the bottom color difference detection platform. The first length block slides along the first length track to adjust the lateral position of the cup-picking robot arm. The second length block slides along the second length track to adjust the longitudinal position of the cup-picking robot arm. The displacement rod slides along the clamping shell, pulling the clamping plates from both sides during its sliding motion, causing the clamping plates to deflect relative to the clamping shell.

[0126] Preferably, the robotic trimming machine includes a trimming machine frame. A mold frame is fixedly installed on one side of the bottom of the inner wall of the trimming machine frame. First movable blocks are slidably connected to both sides of the top of the mold frame. A first cup mold and a second cup mold are respectively fixedly installed on the top of the two first movable blocks. A slitting circular knife is installed in the middle of the inner wall of the trimming machine frame. A knife holder is fixedly installed on one side of the trimming machine frame. A trimming circular knife is fixedly installed on one side of the knife holder. Glue shell placing mechanisms are installed on both sides of the top of the trimming machine frame. Two trimming robots are installed on the trimming machine frame, each located on one side of a glue shell placing mechanism. Two waste receiving mechanisms are fixedly installed on one side of the middle of the trimming machine frame. Several... A cup-shaped vacuum mold is located on one side of the mold frame. An upper auxiliary positioning cylinder is fixedly installed on one side of the top of the inner wall of the trimming machine frame. A third servo motor is fixedly installed on the trimming machine frame below the upper auxiliary positioning cylinder. A cutting servo rotating shaft is fixedly installed at the output end of the third servo motor. A lower auxiliary positioning cylinder is installed in the middle of the cutting servo rotating shaft. The glue shell placement mechanism includes an assembly table and a connecting frame. One side of the bottom of the assembly table is fixedly connected to the top of the connecting frame. Two second displacement rods are fixedly installed at both ends of one side of the connecting frame. A second displacement block is slidably connected between the two second displacement rods. A lifting motor is provided at the top of the assembly table. The output end of the lifting motor passes through the assembly table and the second displacement block in sequence. A second lead screw is fixedly installed. Two second height rods are fixedly installed on both sides of the bottom end of the second displacement block. A second height platform is threadedly connected to the surface of the second lead screw. The top two sides of the second height platform are slidably connected to the middle of the two second height rods, respectively. A rubber suction cup is fixedly installed at the bottom end of the second height platform. A second positioning block is fixedly installed on one side of the connecting frame. A sliding plate is provided at the bottom end of the connecting frame. A rubber recycling and storage shell is fixedly installed on the surface of the sliding plate. Two length rods are slidably connected inside the second positioning block. The bottom ends of the two length rods are fixedly connected to the top two sides of the sliding plate, respectively. The bottom end of the assembly table is fixedly connected to the trimming machine frame. Both waste receiving mechanisms include a receiving frame and a waste platform. A third lifting cylinder is fixedly installed at the top of the receiving frame. The movable end of the third lifting cylinder is connected to the bottom of the waste platform. Waste baffles are connected to both sides of the top of the waste platform. An opening and closing cylinder is installed between the two waste baffles. A tilting cylinder is installed between the waste platform and the two waste baffles. The bottom of the receiving frame is fixedly connected to the trimming machine frame. A third stepper motor that drives the two first movable blocks to slide is fixedly installed on the trimming machine frame. A waste conveying frame is located on the bottom of the inner wall of the trimming machine frame away from the mold frame. An active conveying roller is rotatably connected to one side of the inner wall of the waste conveying frame, and a driven conveying roller is rotatably connected to the other side of the inner wall of the waste conveying frame. A motor is fixedly installed on the surface of the waste conveying frame.The motor's output end is connected to a waste conveyor belt between itself and the driving conveyor roller, and between the driving conveyor roller and the driven conveyor roller. A second operation panel is fixedly mounted on the surface of the trimming machine frame, and an emergency stop button is fixedly mounted inside the trimming machine frame.

[0127] The front station flipping station places the cotton cup onto the cup-shaped vacuum suction mold. After the upper and lower auxiliary positioning cylinders position the cotton cup, the vacuum pump is turned on to suction the cotton cup onto the mold. The servo rotating shaft runs under the drive of the servo motor. After passing through the circular knife, the cotton cup is cut into two halves, namely the left cup and the right cup. The servo rotating shaft, the left cup module, and the right cup module each reach the trimming position. Before the cotton cup begins trimming, the glue shell placement mechanism takes a glue shell and puts it on the cotton cup to increase the vacuum suction force. The waste generated by trimming is collected by the waste baffle and dumped to the rear, and then transported away by the waste conveyor belt.

[0128] Preferably, the color difference sorting machine includes a sorting frame, a cup-grabbing mechanism is fixedly installed on one side of the bottom of the inner wall of the sorting frame, a clip-type bubble wrap machine located on one side of the cup-grabbing mechanism is fixedly installed on the sorting frame, a marking machine is fixedly installed in the middle of the bottom of the inner wall of the sorting frame, a rotating platform located on one side of the marking machine is rotatably connected to the sorting frame, an arch detection camera is fixedly installed at the top of one side of the inner wall of the sorting frame, a top appearance detection camera is fixedly installed at the top of the inner wall of the sorting frame, and color difference A placement area, color difference B placement area, and color difference C placement area are fixedly installed from left to right on the other side of the bottom of the inner wall of the sorting frame, and a plurality of color difference A placement area, color difference B placement area, and color difference C placement area are fixedly installed on the sorting frame. The sorting machine has a defective product placement area on one side of the color difference A placement area and on the other side of the color difference C placement area. A bottom appearance contour detection column is installed inside the sorting frame. A color difference detection mechanism is installed at the top of one side of the sorting frame. The cup-picking mechanism includes a picking platform and two connecting seats. The top two sides of the picking platform are fixedly connected to the bottom ends of the two connecting seats. Two linear conveyors are fixedly installed on the picking platform, each located on one side of a connecting seat. A third displacement block is provided at the top of each of the two linear conveyors, and a suction cup body is provided on one side of each of the two third displacement blocks. Pushing cylinders are fixedly installed on one side of the inner wall of the color difference A placement area, one side of the inner wall of the color difference B placement area, and one side of the inner wall of the color difference C placement area. Pushing plates are fixedly installed on the movable ends of the three pushing cylinders. Each of the three pusher plates is rotatably connected to a second limiting plate on both sides. A fourth stepper motor is fixedly installed on the surface of the picking platform. A drive roller is rotatably connected to one side of the inner wall of each of the two linear conveyors, and a driven roller is rotatably connected to the other side of the inner wall of each of the two linear conveyors. A transmission belt drives between each of the two drive rollers and the two driven rollers. A Y-axis passing through a connecting seat is fixedly installed between the two drive rollers. A drive wheel is fixedly installed at the output end of the fourth stepper motor, and a connecting belt drives between the drive wheel and the Y-axis. The bottom end of the picking platform is fixedly connected to the sorting machine frame. The two transmission belts are slidably connected to two third displacement blocks, and a second cylinder base is fixedly installed at the top of each of the two third displacement blocks. Each of the two second cylinder bases has a fourth lifting cylinder fixedly mounted on one side. Each of the two fourth lifting cylinders has a third height platform fixedly mounted on its movable end. Each of the two third height platforms has a second sliding platform fixedly mounted on its top. Each of the two second sliding platforms has a second sliding rod slidably connected to its middle section. Each of the two second sliding rods has a suction cup body fixedly mounted on its bottom end. The color difference detection mechanism includes a detection frame, an X-axis with a color difference detector, and a positioning platform. The top of the detection frame is fixedly connected to the bottom of the X-axis with the color difference detector. A second movable block is slidably connected to the middle of the X-axis with the color difference detector. A Z-axis cylinder is fixedly mounted on the top of one side of the second movable block. The movable end of the Z-axis cylinder is fixedly connected to one side of the top of the positioning platform.A positioning frame is fixedly installed at the center of the top of the positioning platform. A rotary cylinder is fixedly installed at the top of the positioning frame. A sorting suction cup is fixedly installed through the movable end of the rotary cylinder, passing through the positioning platform. A labeling cylinder is fixedly installed on the surface of the positioning platform. The bottom end of the detection frame is fixedly connected to the sorting frame.

[0129] After trimming, the cotton cups are removed by a robotic arm for bottom and contour inspection, as well as arch, color difference, and top appearance checks. Defective products are labeled for traceability. Good products are sorted by color (A, B, C) and placed accordingly. Before placement, an air bubble is placed under each product to prevent stacking and deformation. The stepper motor starts upon power-up, driving the drive wheel. The drive wheel, via a connecting belt, drives the Y-axis, which in turn drives the connected drive roller. The drive roller, via a transmission belt, drives the driven roller, and the transmission belt synchronously moves the displacement block, thus controlling the suction cup body. The cup position is adjusted, the movable block slides along the X-axis of the color difference detector, and the position of the sorting suction cup and the labeling cylinder are adjusted during the sliding process. The Z-axis cylinder moves in extension and retraction, and pushes the positioning table from the top to adjust the height of the sorting suction cup. The rotary cylinder drives the sorting suction cup to rotate and adjusts the adsorption direction of the sorting suction cup. The pushing cylinder moves in extension and retraction, and pushes the pushing plate from one side. The pushing plate and the limiting plate work together to push the cups in the color difference A placement area, color difference B placement area and color difference C placement area.

[0130] Compared with the prior art, the beneficial effects of the present invention are: the production line includes a feeding station, a rotary shaping machine, a flipping station, a robotic trimming machine and a color difference sorting machine, which sequentially perform feeding, shaping and cooling while flipping, robotic trimming and color difference sorting, followed by manual packaging. This makes the overall operation process of the bra cup cutting, inspection and packaging production line convenient and simple, and improves work efficiency.

[0131] Other benefits and advantages offered by the various embodiments of the present invention will be readily apparent from the following description.

[0132] Example 1

[0133] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0134] Please refer to Figures 1-21. The present invention provides a production line for cutting, inspecting and packaging bra cups, including a production line 6. The production line 6 includes a feeding station 1, a rotary shaping machine 2, a turning station 3, a robotic trimming machine 4 and a color difference sorting machine 5, which are arranged in sequence.

[0135] The loading station 1 includes a rectangular frame 1001. A base plate 1005 is fixedly installed at the bottom inside the rectangular frame 1001. Two piece loading boxes 1006 are fixedly installed at the top of the base plate 1005. A loading platform 1007 is fixedly connected to the bottom of each of the two piece loading boxes 1006. A double-rail connecting base plate 1008 is slidably connected to the bottom of each of the two loading platforms 1007. A first servo motor 1018 is fixedly installed on the back of each of the two piece loading boxes 1006. An upper and lower lifting plate 1017 is fixedly connected to the output end of each of the two first servo motors 1018. The two upper and lower lifting plates 1017 are located at the two piece loading boxes 1006 respectively. Inside the rectangular frame 1001, a workbench 1013 is fixedly installed at one end of the middle section. A preparation position lifting platform 1014 is fixedly installed on the top of the workbench 1013. Conveyors 1015 are fixedly installed on both sides of the middle section of the rectangular frame 1001. A first stepper motor 1003 is fixedly installed at one end of the bottom of each of the two conveyors 1015. The output ends of the two first stepper motors 1003 are respectively connected to the surfaces of the two conveyors 1015. A fourth transfer module 1011 is fixedly installed at the top of the rectangular frame 1001. A cutting piece suction cup 1012 is engaged at the bottom of the fourth transfer module 1011.

[0136] Side doors 1010 are fixedly installed on both sides of the rectangular outer frame 1001. Position adjustment handwheels 1009 are engaged between the two pairs of loading base platforms 1007 and the double-rail connecting base plate 1008. Loading cutting piece robotic arms 1016 are engaged on the surfaces of the two conveyors 1015. A second servo motor 1004 is fixedly installed on one side of the fourth transfer module 1011. The output end of the second servo motor 1004 is connected to the surface of the fourth transfer module 1011. A control box 1002 is fixedly installed on one side of the top of the base plate 1005. The first servo motor 1018, the first stepper motor 1003 and the second servo motor 1004 are all electrically connected to an external power supply through the control box 1002.

[0137] The rotary shaping machine 2 includes a shaping frame 2001, a shaping table 2003 fixedly installed inside the shaping frame 2001, a turntable body 2011 rotatably connected to one side of the top of the shaping table 2003, a third length plate 2006 fixedly installed on the other side of the top of the shaping table 2003, shaping mold head assemblies 2012 installed on both sides of the top of the turntable body 2011, and a shaping component 2015 fixedly installed in the middle of the top of the shaping frame 2001. The shaping component 2015 includes two first lifting cylinders 20151 and a first height platform 20153. The movable ends of the two first lifting cylinders 20151 are fixedly connected to the two sides of the top of the first height platform 20153, and a pressure plate 20156 is provided at the bottom of the first height platform 20153.

[0138] A shaping auxiliary positioning cylinder 2005 is fixedly connected to the side of the first displacement block 2008. One side of the first positioning block 2010 is in contact with the side of the turntable body 2011. A first operation panel 2013 is fixedly installed on the top of one side of the shaping frame 2001. Exhaust fans 2014 are fixedly connected to both sides of the top of the shaping frame 2001. Inspection doors 2004 are hinged to the bottom of the four sides of the shaping frame 2001.

[0139] The flipping station 3 includes a flipping frame 3001. A first transfer module 3006 is fixedly installed at the bottom of the inner wall of the flipping frame 3001. A bottom color difference detection platform 3007 is slidably connected to the top of the first transfer module 3006. A cooling platform 3008 is fixedly installed on one side of the top of the bottom color difference detection platform 3007. A second transfer module 3005 is fixedly installed in the middle of the inner wall of the flipping frame 3001. Both sides of the top of the second transfer module 3005 are provided with cup-picking robotic arms 3010. Two cup-flipping grippers 3009 are installed on one end of each of the two cup-picking robotic arms 3010 on the opposite side. A color difference detector 3011 is fixedly installed on the other end of each of the two cup-picking robotic arms 3010 on the opposite side. A first cup-picking lifting mechanism 3012 is installed in the middle of the top of the second transfer module 3005. A third transfer module 3013 is fixedly installed at the top of the inner wall of the flipping frame 3001. A second cup-picking lifting mechanism 3002 is installed in the middle of the third transfer module 3013. A construction station loading gripper 3003 is provided at the bottom of the third transfer module 3013.

[0140] The first transfer module 3006 includes a fixed base 30061 and two second linear tracks 30062. The top two sides of the fixed base 30061 are fixedly connected to the bottom ends of the two second linear tracks 30062, respectively. Two first limiting plates 30063 are fixedly installed at the middle of the top of the fixed base 30061. A first lead screw 30065 is rotatably connected between the two first limiting plates 30063. A movable seat 30064, which is slidably connected to the fixed base 30061, is threadedly connected to the middle of the first lead screw 30065. A second lifting cylinder 30066 is fixedly installed at the top of the movable seat 30064. The movable end of the second lifting cylinder 30066 is fixedly connected to the bottom color difference detection platform 3007. The bottom end of the seat 30061 is fixedly connected to the tilting frame 3001. The second transfer module 3005 includes two first length plates 30051 and four first length rails 30052. The top sides of the two first length plates 30051 are fixedly connected to the bottom sides of the four first length rails 30052 respectively. A first length block 30053 is slidably connected to the middle of each of the four first length rails 30052. A first moving plate 30054 is fixedly installed between the four first length blocks 30053. A second length plate 30055 is fixedly installed on the top of the first moving plate 30054. A second length rail 30056 is fixedly installed on both sides of the top of the second length plate 30055. Two second length blocks are slidably connected to the middle of component 6. A second moving plate 30057 is fixedly installed between each pair of opposing second length blocks. The top of the second length plate 30057 is connected to the first cup-retrieving lifting mechanism 3012. The tops of the two second moving plates 30057 are respectively connected to the two cup-retrieving robotic arms 3010. The bottom ends of the two first length plates 30051 are fixedly connected to the flipping frame 3001. The third transfer module 3013 includes a moving platform 30131 and two moving tracks 30133. The two sides of the moving platform 30131 are respectively fixedly connected to one side of the two moving tracks 30133. A moving block 30134 is slidably connected to the middle of each of the two moving tracks 30133. A connecting platform 30135 is fixedly installed between 34. A second stepper motor 30132 that drives the moving block 30134 to slide is fixedly installed on the surface of the moving platform 30131. The top of the moving platform 30131 is fixedly connected to the flipping frame 3001. Each of the four cup-flipping grippers 3009 includes a clamping shell 30091 and two clamping plates 30092. The two ends of one side of the clamping shell 30091 are respectively connected to the two ends of the two clamping plates 30092. A first displacement rod 30093 is slidably connected inside the clamping shell 30091. The two ends of the first displacement rod 30093 are respectively rotatably connected to the opposite side of the two clamping plates 30092. One end of each of the four clamping shells 30091 is connected to the side facing the cup-retrieving robotic arm 3010.Both the first cup-retrieving lifting mechanism 3012 and the second cup-retrieving lifting mechanism 3002 include a positioning plate 30021 and four first sliding rods 30022. The four corners of the bottom end of the positioning plate 30021 are fixedly connected to the top ends of the four first sliding rods 30022. A cup-retrieving platform 30023 is installed between the bottom ends of the four first sliding rods 30022. A first sliding platform 30024 is slidably connected to the middle of the four first sliding rods 30022. Sliding sleeves 30025 are fitted at the connection points between the four first sliding rods 30022 and the first sliding platform 30024. The positioning plate 30021 on the first cup-retrieving lifting mechanism 3012 is fixedly connected to the second transfer module 3005, and the positioning plate 30021 on the second cup-retrieving lifting mechanism 3002 is connected to the third transfer module 3013. Symmetrically arranged sealing doors 3004 are hinged to the bottom end of the side of the flipping frame 3001.

[0141] The robotic trimming machine 4 includes a trimming machine frame 4001. A mold frame 4017 is fixedly installed on one side of the bottom of the inner wall of the trimming machine frame 4001. First movable blocks 4015 are slidably connected to both sides of the top of the mold frame 4017. A first cup mold 4002 and a second cup mold 4003 are respectively fixedly installed on the top of the two first movable blocks 4015. A slitting circular blade 4006 is installed in the middle of the inner wall of the trimming machine frame 4001. A blade holder 402 is fixedly installed on one side of the trimming machine frame 4001. 3. A trimming round knife 4024 is fixedly installed on one side of the knife holder 4023. Glue shell placement mechanism 4012 is installed on both sides of the top of the trimming machine frame 4001. Two trimming robots 4010 are installed on the trimming machine frame 4001, each located on one side of the glue shell placement mechanism 4012. Two waste receiving mechanisms 4013 are fixedly installed on one side of the middle of the trimming machine frame 4001. Several cup-shaped vacuum suction molds 4005 located on one side of the mold frame 4017 are fixedly installed on the trimming machine frame 4001.

[0142] An upper auxiliary positioning cylinder 4004 is fixedly installed on one side of the top of the inner wall of the trimming machine frame 4001. A third servo motor 4009 located below the upper auxiliary positioning cylinder 4004 is fixedly installed on the trimming machine frame 4001. A cutting servo rotating shaft 4008 is fixedly installed at the output end of the third servo motor 4009. A lower auxiliary positioning cylinder 4007 is installed in the middle of the cutting servo rotating shaft 4008. The glue shell placement mechanism 4012 includes an assembly table 401207 and a connecting frame 401206. One side of the bottom of the assembly table 401207 is fixedly connected to the top of the connecting frame 401206. Two second displacement rods 401208 are fixedly installed at both ends of one side of the connecting frame 401206, and the two second displacement rods 401208 are slidably connected. The assembly platform 401207 has a second displacement block 401209. A lifting motor 401213 is installed at the top of the assembly platform 401207. The output end of the lifting motor 401213 passes through the assembly platform 401207 and the second displacement block 401209, and a second lead screw 401210 is fixedly installed thereon. Second height rods 401212 are fixedly installed on both sides of the bottom end of the second displacement block 401209. A second height platform 401211 is threaded onto the surface of the second lead screw 401210. The top two sides of the second height platform 401211 are slidably connected to the middle of the two second height rods 401212, respectively. A rubber suction cup 401201 is fixedly installed at the bottom end of the second height platform 401211. A second positioning block is fixedly installed on one side of the connecting frame 401206. 401205, the bottom end of the connecting frame 401206 is provided with a sliding plate 401203, and a plastic shell recycling storage shell 401202 is fixedly installed on the surface of the sliding plate 401203. Two length rods 401204 are slidably connected inside the second positioning block 401205. The bottom ends of the two length rods 401204 are respectively fixedly connected to the two sides of the top of the sliding plate 401203. The bottom end of the assembly table 401207 is fixedly connected to the trimming machine frame 4001. Both waste receiving mechanisms 4013 include a receiving frame 40131 and a waste platform 40134. A third lifting cylinder 40132 is fixedly installed at the top of the receiving frame 40131. The movable end of the third lifting cylinder 40132 is connected to the bottom end of the waste platform 40134. Waste baffles 40135 are connected to both sides of the top of the material platform 40134. An opening and closing cylinder 40133 is installed between the two waste baffles 40135. A tilting cylinder 40136 is installed between the waste platform 40134 and the two waste baffles 40135. The bottom end of the receiving frame 40131 is fixedly connected to the trimming machine frame 4001. A third stepper motor 4016 that drives the two first movable blocks 4015 to slide is fixedly installed on the trimming machine frame 4001. A waste conveying frame 4018 is located on the bottom side of the inner wall of the trimming machine frame 4001 away from the mold frame 4017. An active conveying roller 4021 is rotatably connected to one side of the inner wall of the waste conveying frame 4018, and a driven conveying roller 4022 is rotatably connected to the other side of the inner wall of the waste conveying frame 4018.A motor 4020 is fixedly mounted on the surface of the waste conveyor frame 4018. A waste conveyor belt 4019 is connected to both the output end of the motor 4020 and the drive conveyor roller 4021, and between the drive conveyor roller 4021 and the driven conveyor roller 4022. A second operation panel 4011 is fixedly mounted on the surface of the trimming machine frame 4001. An emergency stop button 4014 is fixedly mounted inside the trimming machine frame 4001.

[0143] The color difference sorting machine 5 includes a sorting frame 5001. A cup-picking mechanism 5013 is fixedly installed on one side of the bottom of the inner wall of the sorting frame 5001. A clip-type packaging bubble machine 5014 located on one side of the cup-picking mechanism 5013 is fixedly installed on the sorting frame 5001. A marking machine 5011 is fixedly installed in the middle of the bottom of the inner wall of the sorting frame 5001. A rotating platform 5010 located on one side of the marking machine 5011 is rotatably connected to the sorting frame 5001. An arch detection camera 5015 is fixedly installed at the top of one side of the inner wall of the sorting frame 5001. A top appearance detection camera 5009 is fixedly installed at the top of the inner wall of the sorting frame 5001. On the other side of the bottom of the inner wall of the sorting frame 5001, from left to right, color difference A placement area 5003, color difference B placement area 5004, and color difference C placement area 5005 are fixedly installed. Several [other components] are fixedly installed on the sorting frame 5001. A defective product placement area 5002 is located on one side of color difference A placement area 5003, one side of color difference B placement area 5004, and one side of color difference C placement area 5005. A bottom appearance contour detection column 5012 is installed inside the sorting frame 5001. A color difference detection mechanism 5016 is installed at the top of one side of the sorting frame 5001. The cup picking mechanism 5013 includes a picking platform 501317 and two connecting seats 501313. The top two sides of the picking platform 501317 are fixedly connected to the bottom ends of the two connecting seats 501313 respectively. Two linear conveyors 501308 are fixedly installed on the picking platform 501317, each located on one side of the connecting seats 501313. The top of each of the two linear conveyors 501308 is provided with a third displacement block 501307. Each of the two third displacement blocks 501307 is provided with a suction cup body 501301 on one side.

[0144] Pushing cylinders 5006 are fixedly installed on one side of the inner wall of color difference A placement area 5003, one side of the inner wall of color difference B placement area 5004, and one side of the inner wall of color difference C placement area 5005. Pushing plates 5007 are fixedly installed on the movable ends of the three pushing cylinders 5006. Second limit plates 5008 are rotatably connected to both sides of the three push plates 5007. A fourth stepper motor 501314 is fixedly installed on the surface of the picking platform 501317. A drive roller 501311 is rotatably connected to one side of the inner wall of the two linear conveyors 501308. A driven roller 501309 is rotatably connected to the other side of the inner wall of the two linear conveyors 501308. The two drive rollers 501311 and the two driven rollers 501309 are connected to each other. A transmission belt 501310 is connected between each of the 309 components. A Y-axis 501312, passing through the connecting seat 501313, is fixedly installed between the two drive rollers 501311. A drive wheel 501315 is fixedly installed at the output end of the fourth stepper motor 501314. A connecting belt 501316 is connected between the drive wheel 501315 and the Y-axis 501312. The bottom end of the picking platform 501317 is fixedly connected to the sorting frame 5001. The two transmission belts 501310 are slidably connected to the two third displacement blocks 501307 respectively. A second cylinder base 501306 is fixedly installed at the top of each of the two third displacement blocks 501307. A fourth lifting cylinder 501305 is fixedly installed on one side. A third height platform 501304 is fixedly installed on the movable end of each of the two fourth lifting cylinders 501305. A second sliding platform 501303 is fixedly installed on the top of each of the two third height platforms 501304. A second sliding rod 501302 is slidably connected to the middle of each of the two second sliding platforms 501303. A suction cup body 501301 is fixedly installed at the bottom end of each of the two second sliding rods 501302. The color difference detection mechanism 5016 includes a detection frame 50161, an X-axis with a color difference detector 50162, and a positioning stage 50165. The top end of the detection frame 50161 is fixedly connected to the bottom end of the X-axis with the color difference detector 50162. A second movable block 50168 is slidably connected to the middle of the X-axis 50162 of the color difference detector. A Z-axis cylinder 50167 is fixedly installed on the top of one side of the second movable block 50168. The movable end of the Z-axis cylinder 50167 is fixedly connected to one side of the top of the positioning table 50165. A positioning frame 50166 is fixedly installed in the middle of the top of the positioning table 50165. A rotary cylinder 50164 is fixedly installed on the top of the positioning frame 50166. A sorting suction cup 50163 is fixedly installed through the positioning table 50165. A labeling cylinder 50169 is fixedly installed on the surface of the positioning table 50165. The bottom of the detection frame 50161 is fixedly connected to the sorting frame 5001.

[0145] In the first embodiment of this application, the production line includes a feeding station, a rotary shaping machine, a flipping station, a robotic trimming machine, and a color difference sorting machine. The feeding, shaping, and cooling processes are carried out in sequence, while flipping, robotic trimming, and color difference sorting are performed simultaneously. Then, manual packaging is carried out to complete the production of the bra cup.

[0146] Example 2

[0147] Production System

[0148] Figure 22 shows a bra cup production system 999 according to one embodiment, which basically includes a shaping station 100 and a trimming station 200. The shaping station 100 shapes the cut pieces fed into it into shaped cut pieces; the trimming station 200 trims the received shaped cut pieces into bra cups of predefined sizes and profiles. In one embodiment, the bra cup production system further includes a loading station 300, which distributes cut pieces to the shaping station 100 at a predefined frequency. The cut pieces may include multiple main materials, such as a first main material, a second main material, and a third main material. The shaped cut pieces may be formed by heat-setting multiple main materials through one or more processes at the shaping station. In one embodiment, the bra cup production system further includes a transfer station 400, which extracts the shaped cut pieces from the shaping station 100 and transports them to a designated location in the trimming station 200. In one embodiment, the bra production system further includes a quality inspection station 500, which performs color difference detection on the bras trimmed or cut by the trimming station 200 and sorts and places them according to the color difference detection results.

[0149] Standardization Station

[0150] Figures 23-25 ​​show a schematic diagram of the structure of a shaping station 100A according to one embodiment. The shaping station 100 includes a support frame (not shown), a rotating work platform 14 and a driver 15, a breast cup shaping mold 20, a mold opening and closing control assembly 11 corresponding to each breast cup shaping mold, and a controller, either independently or shared with other equipment, including a processor and a memory. Two breast cup shaping molds 20 are disposed on the rotating work platform 14; in one embodiment, one breast cup shaping mold 20 is disposed on the rotating work platform 14; in one embodiment, four breast cup shaping molds 20 are disposed on the rotating work platform; in one embodiment, three breast cup shaping molds 20 are disposed on the rotating work platform; in one embodiment, the driver 15 is a motor; each breast cup shaping mold 20 is used to guide at least one piece of fabric placed in the mold. Partially heat-set into pre-defined bra cup shapes; each bra cup shaping mold 20 includes an upper mold head 16 and a lower mold head 13, which are opposite to each other. In this embodiment, the upper mold head 16 has a protruding bra cup shape 15, and the lower mold head 13 has a recessed bra cup shape 12. The size and shape of the upper mold head 16 and the lower mold head 13 are configured to define a space between them that forms a predefined bra cup shape. The lower mold head 13 is disposed on a rotating work platform 14, and the upper mold head 16 is disposed on a mold opening and closing control assembly 11. The mold opening and closing control assembly 11 is driven by a cylinder 10 to open and close according to a predefined time. When the mold is open, a pre-defined bra cup shape can be placed or removed between the upper mold head 16 and the lower mold head 13. When the mold is closed according to a predefined time, the bra cup shaping mold 20 heat-sets the placed bra cup shape. The rotating work platform 14 is driven by the driver 15 to rotate at a predefined angle. The memory stores parameters including the predefined angular velocity of the rotating work platform, the start and pause times of rotation, the heat-setting time of each bra cup shaping mold, and the heat-setting temperature. The processor outputs control commands to cause the rotating work platform to rotate at the predefined angular velocity and to start and pause rotation according to the predefined start and pause times. The processor controls each bra cup shaping mold to heat-set the fabric pieces placed in it according to the predefined heat-setting time and temperature parameters, so that while the rotating work platform is operably rotating, at least two bra cup shaping molds are heat-setting the fabric pieces placed in them. When the rotating work platform 14 is equipped with two bra cup shaping molds, the heat-setting time of each bra cup shaping mold corresponds to the time required for the rotating work platform 14 to rotate 180 degrees.

[0151] Figure 26 shows a shaping station 100B according to another embodiment. This shaping station 100B includes only one bra cup shaping mold for heat-setting the cut pieces. This mold does not need to be mounted on a rotating work platform; instead, the upper mold head 16 and lower mold head 13 are respectively mounted on a support frame. The upper mold head 16 is mounted on a mold opening and closing control assembly. The mold opening and closing control assembly is driven by a cylinder to open and close according to a predefined time. When the mold is open, cut pieces can be placed between the upper mold head 16 and the lower mold head 13, or the shaped cut pieces can be removed. One bra cup shaping mold includes two sets of predefined bra cup shapes, thus one heat setting can produce shaped cut pieces including two sets of bra cups. Correspondingly, shaped cut pieces with multiple sets of bra cups are divided at the transfer station into each shaped cut piece containing only one pair of bra cups.

[0152] Figure 27 shows another embodiment of the shaping station 100C. The shaping station 100C basically includes two rotary work platforms 14 as shown in Figure 23. Each rotary work platform 14 is equipped with two bra cup shaping molds and corresponding drivers 15. Each bra cup shaping mold includes an upper mold head 16 and a lower mold head 13. Between each upper mold head 16 and lower mold head 13 are two predefined bra cup shapes. Therefore, one shaping station can handle the shaping tasks of 16 sets of bra cups, exhibiting high production efficiency. The shaping station 100C can also be used to produce pre-shaped fabric pieces with complex structures. For example, when producing a pre-shaped fabric piece requires multiple materials, the shaping station 100C can shape one type or two combinations of materials separately, and then combine each material to form the final pre-shaped fabric piece. The specific structure of each rotary work platform 14 can be referred to the structural description of the embodiment shown in Figure 23, and will not be repeated here. In one embodiment, each bra cup shaping mold is further provided with presser foot assemblies at its four corners or opposite corners. Each presser foot assembly includes an upper presser foot 17 and a lower presser foot 18. The lower presser foot 18 is fixed to the fixed platform of the lower mold head 13, and the upper presser foot 17 is fixed to the fixed platform of the upper mold head 16. A pressure spring is provided on the upper presser foot 17 to create pressure between the upper presser foot 17 and the lower presser foot 18. When the bra cup shaping mold is opened, due to the slow release of the spring pressure, the distal end of the upper presser foot 17 will continue to press on the lower presser foot 18, applying pressure to the shaped piece located on the lower mold head 13 for a certain period of time, such as 3 seconds, until the spring pressure is completely released, and then it will detach from the lower presser foot 18, thereby preventing the shaped piece from being taken out of the mold or displaced by the upper mold head 16 when the bra cup shaping mold is opened.

[0153] Trimming Station

[0154] Figures 28 and 29 show schematic diagrams of the trimming station 200 of one embodiment from different perspectives. Figures 28 and 29 also show schematic diagrams of different states of the partial structure of the trimming station 200. The trimming station 200 includes: a positioning bracket 20, a trimming component, and a support frame. The positioning bracket 20 includes a left bracket 21 and a right bracket 22, which are respectively fixed to different pillars and maintain a certain spatial distance. The shapes of the left bracket 21 and the right bracket 22 correspond to the shapes of two arched portions on the shaped fabric piece, respectively, and are used to hold the shape and relative position of the bra cup on the shaped fabric piece and to form a certain adsorption force on the arched portions of the shaped fabric piece. The adsorption force can come from negative pressure adsorption or special material friction. The trimming components correspond to the left bracket 21 and the right bracket 22, and include a left trimming component and a right trimming component. Each trimming component is used to trim the shaped cut piece held on the positioning bracket into a predefined size and profile, and includes a cutter 25 and a robotic arm 23. The robotic arm 23 has multiple interconnected joints that can move 360 ​​degrees, and the end of the robotic arm 23 is connected to the cutter 25. Under the control of the robotic arm 23, the cutter 25 can rotate, move forward, move backward, and move up and down within a 360-degree range. The robotic arm 223 and the cutter 25 are controlled by the controller to perform activities along a predefined activity trajectory. The trimming station 200 also includes a controller, which can be a dedicated controller for the trimming station or a controller shared with other equipment. The controller includes a memory and a processor. The memory at least pre-stores predefined motion trajectory parameters of the trimming components as well as predefined cutting force and cutting angle parameters. The processor outputs robotic arm control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle parameters to the cutter, so that the robotic arm moves according to the predefined motion trajectory. At the same time, the cutter applies predefined cutting force and cutting angle to the shaped piece, thereby trimming the shaped piece into a bra cup of predefined size and contour.

[0155] The trimming station 200 also includes a second cutter 29, which is used to cut the shaped fabric piece into a left half and a right half along the midline of the spatial distance between the left bracket 21 and the right bracket 22. Before the second cutter 29 performs the cutting, the positions of the left bracket 21 and the right bracket 22 are shown in Figure 30. They cooperate with the auxiliary positioning bracket 30 to accurately position the shaped fabric piece, so that the second cutter 29 can accurately perform the cutting along the midline of the spatial distance between the left bracket 21 and the right bracket 22. After the second cutter 29 performs the cutting, the shaped fabric piece is cut into a left half and a right half, and the left bracket 21 and the right bracket 22 are separated by a certain distance, as shown in Figure 31, to provide sufficient space for the cutter 25 and the robotic arm corresponding to the left half and the right half to perform cutting according to a predefined motion trajectory, thereby trimming the desired contour of the bra cup. In one embodiment, the contour of the edge of the left bracket and / or the right bracket is consistent with the predefined motion trajectory.

[0156] In one embodiment, the cutter 25 is a circular cutter. In another embodiment, the cutter 25 is a scissor-shaped cutter. The motion assembly that drives the left bracket 21 and the right bracket 22 to move separately is a horizontal motion assembly 28. The structure of the horizontal motion assembly 28 can be the structure shown in Figure 28, or other mechanical structures in the prior art that realize horizontal motion. The motion assembly that controls the movement of the robotic arm 23 can refer to the mechanical structures in the prior art that realize the XYZ three-axis motion of the robotic arm.

[0157] In one embodiment, the trimming station 200 further includes a waste recycling device, which includes a waste receiving tray disposed at the bottom of the trimming station, a conveyor belt, and a recycling station for storing waste; the conveyor belt is operatively connected to the waste receiving tray and the recycling station; the waste receiving tray receives waste generated from trimming at the trimming station, and the conveyor belt transfers the waste from the waste receiving tray to the recycling station.

[0158] loading station

[0159] In one embodiment, the specific structure of the loading station 300 can be referred to Figures 2-5. The loading station 300 also includes a storage device, a first transport component, a material preparation platform, a first translation module, and a support frame. The storage device stores multiple cut pieces in a stacked manner, and the storage device can be a cylindrical structure. The storage device also includes a support platform and a support platform height adjustment device. The support platform is set on the support platform height adjustment device and stores multiple stacked cut pieces. The cut pieces can be multiple different main materials. For example, the support platform can include a first main material stacking area, a second main material stacking area, and / or a third main material stacking area. For example, the first main material is a first fabric, the second main material is a filling material, such as egg cotton, and the third main material is a second fabric. As needed, the loading station 300 can also provide other required materials. The platform height adjustment device, driven by a motor, moves the platform and the cut pieces at a predefined speed, so that the first transport component picks up the top cut piece from the platform at a preset vertical height. The first transport component, located above the loading station, includes a first XY-axis motion component and a cut piece gripper. The first XY-axis motion component moves vertically in the Y-axis to cause the cut piece gripper to pick up the cut piece from the platform or release it to the preparation platform, and also drives the cut piece gripper to move horizontally in the X-axis to transport the picked-up cut piece from the platform to the preparation platform. The preparation platform moves vertically... The movement allows the piece gripper to release the cut piece onto the preparation platform at a predefined vertical height, and the first translation module to clamp the edge of the cut piece at the same predefined vertical height. The first translation module also includes a first X-axis translation track assembly and multiple clamps. These clamps are mounted on the first X-axis translation track assembly and clamp the edge of the cut piece from the preparation platform and release it at the bra cup shaping mold. The first X-axis translation track assembly drives the clamps to move repeatedly in the X-axis, transporting the cut piece from the preparation platform to the bra cup shaping mold at the shaping station at a predefined frequency. Both the support platform and the preparation platform are flat structures, ensuring support for the cut piece at corresponding positions.

[0160] transfer station

[0161] In one embodiment, a transfer station 400 is located between a shaping station 100 and a trimming station 200, used to transport the shaped pieces produced by the shaping station 100 to the trimming station 200 for trimming. As shown in FIG32, the transfer station 400 includes a second translation module 41, a lifting transport platform 42, a second transport component 43, and a support frame. The second translation module 41 includes a second X-axis translation rail assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation rail assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation rail assembly. Since the shaped pieces produced at the shaping station have an arched portion facing downwards, after the clamping part clamps the edge of the shaped piece from the cup shaping mold, it flips the shaped piece 180 degrees so that the arched portion of the shaped piece faces upwards, so as to place it on the shaping bracket of the trimming station 200. The second X-axis translation rail... The component drives the clamping part to move repeatedly in the X direction to repeatedly transport the shaped fabric piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency. The lifting transport platform 42 also includes a third XY direction motion component and a transfer platform. The transfer platform is mounted on the third XY direction motion component and moves with the movement of the third XY direction motion component. The lifting transport platform moves up and down in the Y direction so that the second translation module places the shaped fabric piece on the transfer platform, and then moves in the X direction to transport the shaped fabric piece from one end near the shaping station to one end near the trimming station. The second transport component 43 is located above the transfer station and includes a second XY direction motion component and a shaped fabric piece gripper. The second XY direction motion component moves vertically in the Y direction so that the shaped fabric piece gripper grabs the shaped fabric piece from the transfer platform and moves horizontally in the X direction so that the shaped fabric piece gripper transports the grabbed shaped fabric piece to the trimming station. The second translation module 41, the lifting transport platform 42, and the second transport component 43 are all driven by corresponding power devices to move in corresponding directions. In one embodiment, the transfer station 400 further divides the shaped fabric piece, which includes multiple pairs or sets of bra cups, so that each divided shaped fabric piece includes only one pair or set of bra cups. In one embodiment, the transfer station 400 further cools the shaped fabric piece.

[0162] In one embodiment, the transfer station 400 further includes a first automatic color difference detection component 44, which is disposed on the second translation module 41 and includes a first camera and a first data transmission unit. After the clamping part of the second translation module clamps the shaped piece from the bra cup shaping mold and before flipping it, the first camera takes a picture of at least the inner side of the arched portion of the shaped piece to obtain a first image. The data transmission unit transmits the obtained first image to the controller, which detects the color difference of the bra cup according to a preset algorithm. The structure of the transfer station 400 can be referred to the structure shown in Figures 9-11. Multiple first cameras can be used. The first data transmission unit is a data cable or a wireless network.

[0163] Quality Inspection Station

[0164] As shown in Figures 33 and 34, the quality inspection station 500 is used to detect the color difference, shape, and contour of the bra cup. The quality inspection station 500 includes multiple second cameras 51, a second data transmission unit 52, an XYZ transport module 53, and a support frame. The multiple second cameras 51 are respectively set at multiple different positions and angles on the support frame of the quality inspection station, aiming at different positions of the bra cup from different directions to carry out multiple different shots. The second image obtained by each second camera is transmitted to the controller of the quality inspection station 500 through the second data transmission unit 52. The controller of the quality inspection station 500 detects the color difference of the bra cup according to a preset algorithm. The quality inspection station also includes a label unit 54, which is controlled by the controller. After the controller detects the color difference grade of a bra cup, the label unit 54 affixes a corresponding label to the bra cup. The controller of the quality inspection station 500 can be an independent controller or a controller shared with the trimming station. In one embodiment, the image obtained by the second camera 51 is also used to detect the shape and contour of the bra cup. The XYZ transport module 53 also includes a power unit, an XYZ motion component, and a suction cup component. The suction cup component is fixed to the XYZ motion component. The suction cup component grabs or releases the bra cup. The power unit drives the XYZ motion component to move according to the controller's instructions, and is an electric cylinder. Driven by the power unit, the XYZ motion component moves the bra cup on the suction cup component to the storage position of the bra cup of the corresponding color difference grade. For example, four grades, A, B, C, and D, are set, and each grade of product is assigned a storage position. The controller sends instructions to the XYZ motion component according to the determined color difference grade of the bra cup to control it to classify and place the bra cups of different color difference grades into the designated corresponding positions. Only one grade among the four grades can represent a defective product, such as grade D. The label unit 54 can only print defective product labels on products of grade D for subsequent processing of defective products.

[0165] Bra cup manufacturing method

[0166] Figure 35 shows a method 600 for producing a breast cup according to an embodiment, including the following steps:

[0167] S1. The shaping station shapes the cut pieces into shaped pieces, wherein at least one of the bra cup shaping molds heat-shapes at least a portion of the cut pieces placed in the mold into shaped pieces having a predefined bra cup shape;

[0168] S2. The trimming station trims the pre-shaped pattern piece fed therein into a breast cup of a predefined size and profile, wherein: at least one positioning bracket holds the breast cup shape and relative position of the pre-shaped pattern piece thereon; and the trimming assembly trims the pre-shaped pattern piece held on the bracket into a predefined size and profile.

[0169] S3. The processor outputs control commands to the robotic arm to control the robotic arm to move according to predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle to the cutter, so that the robotic arm moves according to the predefined motion trajectory parameters under the control of at least one controller, and the cutter applies a predefined cutting force and cutting angle to the pre-shaped cut piece under the control of at least one controller, thereby trimming the pre-shaped cut piece into a bra cup of predefined size and contour.

[0170] In one embodiment, step S1 is preceded by the step of distributing cut pieces from the feeding station to the shaping station at a predefined frequency.

[0171] In one embodiment, step S1 is followed by the step of: the transfer station extracting the shaped fabric piece from the shaping station and transporting it to a designated location at the trimming station.

[0172] In one embodiment, step S2 is followed by the step of: the quality inspection station performs color difference detection on the bra cups and classifies and places them according to the color difference detection results.

[0173] Numbered Examples

[0174] The present invention is further described with reference to the following numbered embodiments. 1. A breast cup production system, comprising:

[0175] The shaping station is configured to shape the cut pieces into shaped cut pieces.

[0176] The shaping station includes at least one bra cup shaping mold, configured to heat-shape at least a portion of a piece placed in the mold into a shaped piece having a predefined bra cup shape;

[0177] The trimming station is configured to trim received pre-shaped pattern pieces into bra cups of predefined sizes and profiles.

[0178] The pruning station includes:

[0179] At least one positioning bracket is configured to hold the cup shape and relative position of the shaped piece thereon;

[0180] A trimming assembly, comprising a cutter and a robotic arm operably connected to each other, is configured to trim the shaped cut piece held on a positioning bracket to a predefined size and profile; and

[0181] At least one controller, including memory and processor,

[0182] The memory contains at least pre-defined motion trajectory parameters of the trimming component, as well as pre-defined cutting force and cutting angle parameters.

[0183] The processor is configured to output robotic arm control commands to the robotic arm to control the robotic arm to move according to predefined motion trajectory parameters, and to output predefined cutting force and cutting angle parameters to the cutter, so that the robotic arm moves according to the predefined motion trajectory under the control of at least one controller, while the cutter applies a predefined cutting force and cutting angle to the pre-shaped pattern piece under the control of at least one controller, thereby trimming the pre-shaped pattern piece into a bra cup of predefined size and contour.

[0184] 2. The system according to Embodiment 1, wherein the shaping station further includes a rotary work platform and a drive; wherein:

[0185] The rotating work platform is driven by the driver to rotate at a predefined angle;

[0186] At least two of the aforementioned breast cup shaping molds are provided on the rotating work platform;

[0187] The memory also stores parameters including the angular velocity of the predefined rotating work platform, the start and stop times of rotation, the heat setting time and heat setting temperature of each breast cup shaping mold;

[0188] The processor is further configured to output control commands to cause the rotary work platform to rotate at a predefined angular velocity and to start and stop rotation according to parameters for the start and stop times of rotation; and

[0189] The processor is further configured to control each bra cup shaping mold to perform heat shaping on the cut pieces placed in the mold according to predefined parameters of heat shaping time and heat shaping temperature, so that while the rotating work platform can be rotated operably, the at least two bra cup shaping molds perform heat shaping on the cut pieces placed therein.

[0190] 3. According to the system described in Embodiment 2, the heat setting time of each breast cup shaping mold corresponds to the time required for the rotating work platform to rotate 180 degrees.

[0191] 4. The system according to Embodiment 2, wherein the shaping station further includes a mold opening and closing control component corresponding to the bra cup shaping mold;

[0192] The bra cup shaping mold further includes an upper mold head and a lower mold head, the size and shape of which are configured to define a space therebetween forming a predefined bra cup shape; the lower mold head is disposed on the rotary work platform, and the upper mold head is disposed on the mold opening and closing control assembly; and

[0193] The mold opening and closing control component is configured to be driven by a cylinder to open at a predefined time to place or remove a shaped cut piece between the upper and lower mold heads, and to close at a predefined time to heat-set the placed cut piece.

[0194] 5. The system according to any of the above embodiments further includes a feeding station configured to distribute cut pieces to the shaping station at a predefined frequency.

[0195] 6. The system according to Embodiment 5, wherein the loading station further includes a storage device, a first transport component, a material preparation platform, and a first translation module.

[0196] The storage device is configured to stack and store multiple cut pieces.

[0197] The storage device further includes a support platform and a support platform height adjustment device. The support platform is disposed on the support platform height adjustment device. The support platform is configured to store the stacked multiple pieces of fabric. The support platform height adjustment device is configured to be driven by a motor to move the support platform and the pieces of fabric at a predefined speed, so that the first transport component can grab the top piece of fabric from the support platform at a preset vertical height.

[0198] The first transport component is disposed above the loading station and includes a first XY-axis motion component and a piece gripper; the first XY-axis motion component is configured to move vertically in the Y-axis so that the piece gripper grips a piece of fabric from the support platform or releases the piece of fabric to the preparation platform; and is configured to drive the piece gripper to move horizontally in the X-axis to transport the gripped piece of fabric from the support platform to the preparation platform;

[0199] The material preparation platform is configured to move vertically, such that the piece gripper releases the piece onto the preparation platform at a predefined vertical height, and the first translation module grips the edge of the piece at a predefined vertical height; and

[0200] The first translation module further includes a first X-axis translation track assembly and a plurality of clamps. The plurality of clamps are disposed on the first X-axis translation track assembly. The plurality of clamps are configured to clamp the edge of the cut piece from the material preparation platform and release the clamped cut piece at the bra cup shaping mold. The first X-axis translation track assembly is configured to drive the clamps to move repeatedly in the X-axis to repeatedly transport the cut piece from the material preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

[0201] 7. The system according to any of the above embodiments further includes a transfer station configured to extract the shaped fabric piece from the shaping station and transport it to a designated location of the trimming station.

[0202] 8. According to the system described in Embodiment 7, the transfer station further includes a second translation module, a lifting and transporting platform, and a second transport component;

[0203] The second translation module further includes a second X-axis translation track assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation track assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly. The clamping part is configured to clamp the edge of the shaped piece from the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward. The second X-axis translation track assembly is configured to drive the clamping part to move repeatedly in the X-axis to repeatedly transport the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency.

[0204] The lifting and transporting platform further includes a third XY-axis motion component and a transfer platform. The transfer platform is mounted on the third XY-axis motion component and moves with the movement of the third XY-axis motion component. The lifting and transporting platform is configured to move vertically along the Y-axis to allow the second translation module to place the shaped cut piece on the transfer platform, and then move along the X-axis to transport the shaped cut piece from one end near the shaping station to one end near the trimming station.

[0205] The second transport component is configured to be positioned above the transfer station and includes a second XY motion component and a pre-shaped piece gripper; the second XY motion component is configured to move vertically in the Y direction so that the pre-shaped piece gripper grips the pre-shaped piece from the transfer platform; and is configured to drive the pre-shaped piece gripper to move horizontally in the X direction to transport the gripped pre-shaped piece to the trimming station.

[0206] 9. The system according to embodiment 7 or 8, wherein the transfer station further includes: a first automatic color difference detection component disposed on the second translation module, comprising a first camera and a first data transmission unit; the first automatic color difference detection component is configured such that: after the clamping part of the second translation module clamps the shaped piece from the bra cup shaping mold and before flipping it, the first camera takes a picture of at least the inner side of the arched portion of the shaped piece to obtain a first photo, and the data transmission unit transmits the obtained first photo to the controller of the at least one, wherein the controller of the at least one detects the color difference of the bra cup according to a preset algorithm.

[0207] 10. The system according to any of the above embodiments, wherein the positioning bracket is configured to hold the arched portion of the shaped cut piece upward and form a certain adsorption force on the arched portion.

[0208] 11. The system according to embodiment 10, wherein the positioning bracket further includes a left bracket and a right bracket, the shapes of the left bracket and the right bracket corresponding to the shape of the arched portion on the pre-shaped cut piece; the left bracket and the right bracket are respectively fixed on different pillars and maintain a certain spatial distance.

[0209] 12. The system according to embodiment 10, wherein the cutter cuts the shaped piece into a left half and a right half along the midline of the spatial distance between the left bracket and the right bracket.

[0210] 13. The system according to embodiment 12, wherein the cutter cuts the left half and the right half respectively, the cutter moves according to a predefined motion trajectory and cuts according to a predefined cutting angle and cutting force, thereby trimming a bra cup with the desired contour.

[0211] 14. The system according to embodiment 13, wherein the contours of the edges of the left bracket and / or right bracket are configured to conform to the predefined motion trajectory.

[0212] 15. The system according to any of the above embodiments further includes a quality inspection station configured to perform color difference detection on the bra cup and classify and place it according to the color difference detection results.

[0213] 16. The system according to Embodiment 15, wherein the quality inspection station further performs detection of the shape and contour of the bra cup.

[0214] 17. The system according to embodiment 15 or 16, wherein the quality inspection station includes a plurality of second cameras, a second data transmission unit and an XYZ carrier module;

[0215] The plurality of second cameras are respectively set at multiple different positions and angles in the quality inspection station, aiming at different positions of the bra cup from different directions to carry out multiple different shots; the second photos obtained by each second camera are transmitted to the controller of the at least one through a second data transmission unit, and the controller of the at least one detects the color difference and / or shape and contour of the bra cup according to a preset algorithm;

[0216] The XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed to the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of the controller of at least one of the above-mentioned controllers; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the corresponding color difference grade bra cup under the drive of the power unit; and

[0217] The controller of at least one of them sends an instruction to the XYZ motion component based on the determined color difference grade of the bra cup to control it to classify and place bra cups of different color difference grades into designated positions.

[0218] 18. The system according to embodiment 17, wherein the quality inspection station further includes a labeling unit configured to affix a corresponding label to the bra cup after the controller of the at least one detects the color difference grade of a bra cup and determines it to be a defective product.

[0219] 19. The system according to any of the above embodiments, wherein the cutting tool is a circular cutting tool.

[0220] 20. The system according to any of the above embodiments, wherein the pruning station further comprises:

[0221] The waste recycling device includes a waste receiving tray, which is disposed at the bottom of the trimming station;

[0222] Conveyor belt; and

[0223] Recycling stations used for storing waste materials

[0224] The conveyor belt is operably connected to the waste receiving tray and the recycling station;

[0225] The waste recycling device is configured such that the waste receiving tray receives waste generated from trimming at the trimming station, and the conveyor belt transfers the waste from the waste receiving tray to the recycling station.

[0226] 21. The system according to any of the above embodiments, wherein the bra cup shaping mold further includes a presser foot assembly, the presser foot assembly being configured to apply pressure for a predefined duration to the shaped piece located within the bra cup shaping mold when the bra cup shaping mold is opened, so that the shaped piece does not change position as the bra cup shaping mold is opened.

[0227] 22. A method for producing a bra cup, using a bra cup production system as described in any of Examples 1-21, the method comprising the following steps:

[0228] (1) The shaping station shapes the cut pieces into shaped cut pieces, wherein at least one of the bra cup shaping molds heat-shapes at least a portion of the cut pieces placed in the mold into shaped cut pieces having a predefined bra cup shape.

[0229] (2) The trimming station trims the pre-shaped pattern pieces into bra cups of predefined sizes and profiles, wherein:

[0230] At least one positioning bracket holds the cup shape and relative position of the shaped piece thereon; and a trimming assembly trims the shaped piece held on the bracket to a predefined size and profile;

[0231] (3) The processor outputs robotic arm control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle to the cutter, so that the robotic arm moves according to the predefined motion trajectory parameters under the control of at least one controller, and the cutter applies a predefined cutting force and cutting angle to the pre-shaped cut piece under the control of at least one controller, thereby trimming the pre-shaped cut piece into a bra cup of predefined size and contour.

[0232] 23. The method for producing a breast cup according to Example 22, wherein the step (1) is preceded by the following step:

[0233] The feeding station distributes cut pieces to the shaping station at a predefined frequency.

[0234] 24. The method for producing a breast cup according to Example 22, wherein the step (1) is followed by the following step:

[0235] The pre-shaped cut pieces are retrieved from the shaping station by the transfer station and transported to the designated location of the trimming station.

[0236] 25. The method for producing a breast cup according to Example 22, wherein step (2) is followed by the step:

[0237] The quality inspection station conducts color difference testing on the bra cups and categorizes them according to the color difference test results.

[0238] 26. The method for producing a breast cup according to Embodiment 23, wherein the feeding station further includes a material storage device, a first transport component, a material preparation platform, and a first translation module;

[0239] The storage device is configured to stack and store multiple cut pieces.

[0240] The storage device further includes a support platform and a support platform height adjustment device. The support platform is disposed on the support platform height adjustment device. The support platform is configured to store the stacked multiple pieces of fabric. The support platform height adjustment device is configured to be driven by a motor to move the support platform and the pieces of fabric at a predefined speed, so that the first transport component can grab the top piece of fabric from the support platform at a preset vertical height.

[0241] The first transport component is disposed above the loading station and includes a first XY-axis motion component and a piece gripper; the first XY-axis motion component is configured to move vertically in the Y-axis so that the piece gripper grips a piece of fabric from the support platform or releases the piece of fabric to the preparation platform; and is configured to drive the piece gripper to move horizontally in the X-axis to transport the gripped piece of fabric from the support platform to the preparation platform;

[0242] The material preparation platform is configured to move vertically, such that the piece gripper releases the piece onto the preparation platform at a predefined vertical height, and the first translation module grips the edge of the piece at a predefined vertical height; and

[0243] The first translation module further includes a first X-axis translation track assembly and a plurality of clamps. The plurality of clamps are disposed on the first X-axis translation track assembly. The plurality of clamps are configured to clamp the edge of the cut piece from the material preparation platform and release the clamped cut piece at the bra cup shaping mold. The first X-axis translation track assembly is configured to drive the clamps to move repeatedly in the X-axis to repeatedly transport the cut piece from the material preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

[0244] 27. The method for producing a bra cup according to Embodiment 24, wherein the transfer station includes a second translation module, a lifting transport platform, and a second transport component;

[0245] The second translation module further includes a second X-axis translation track assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation track assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly. The clamping part is configured to clamp the edge of the shaped piece from the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward. The second X-axis translation track assembly is configured to drive the clamping part to move repeatedly in the X-axis to repeatedly transport the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency.

[0246] The lifting and transporting platform further includes a third XY-axis motion component and a transfer platform. The transfer platform is mounted on the third XY-axis motion component and moves with the movement of the third XY-axis motion component. The lifting and transporting platform is configured to move vertically along the Y-axis to allow the second translation module to place the shaped cut piece on the transfer platform, and then move along the X-axis to transport the shaped cut piece from one end near the shaping station to one end near the trimming station.

[0247] The second transport component is configured to be positioned above the transfer station and includes a second XY motion component and a pre-shaped piece gripper; the second XY motion component is configured to move vertically in the Y direction so that the pre-shaped piece gripper grips the pre-shaped piece from the transfer platform; and is configured to drive the pre-shaped piece gripper to move horizontally in the X direction to transport the gripped pre-shaped piece to the trimming station.

[0248] 28. The method for producing a breast cup according to Embodiment 25, characterized in that: the quality inspection station includes multiple second cameras, a second data transmission unit, and an XYZ transport module;

[0249] The plurality of second cameras are respectively set at multiple different positions and angles in the quality inspection station, aiming at different positions of the bra cup from different directions to carry out multiple different shots; the second photos obtained by each second camera are transmitted to the controller of the at least one through a second data transmission unit, and the controller of the at least one detects the color difference and / or shape and contour of the bra cup according to a preset algorithm;

[0250] The XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed to the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of the controller of at least one of the above-mentioned controllers; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the corresponding color difference grade bra cup under the drive of the power unit; and

[0251] The controller of at least one of the bra cups issues an instruction to the XYZ motion component based on the determined color difference grade of the bra cup to control it to classify and place bra cups of different color difference grades into designated positions; the labeling unit is configured to affix a corresponding label to the bra cup after the controller of at least one of the bra cups detects the color difference grade of a bra cup and determines that it is a defective product.

[0252] Having described several embodiments, those skilled in the art will recognize that various modifications, alternative structures, and equivalents can be used without departing from the essence of the invention. Accordingly, the above description should not be construed as limiting the scope of the invention as defined in the following claims.

[0253] Exemplary embodiments of the present invention have thus been fully described. Although the description refers to specific embodiments, those skilled in the art will understand that the invention can be practiced with variations in these specific details. Therefore, the invention should not be construed as being limited to the embodiments set forth herein.

Claims

1. A breast cup production system, comprising: The shaping station is configured to shape the cut pieces into shaped cut pieces. The shaping station includes at least one bra cup shaping mold, configured to heat-shape at least a portion of a piece placed in the mold into a shaped piece having a predefined bra cup shape; The trimming station is configured to trim received pre-shaped pattern pieces into bra cups of predefined sizes and profiles. The pruning station includes: At least one positioning bracket is configured to hold the cup shape and relative position of the shaped piece thereon; A trimming assembly, comprising a cutter and a robotic arm operably connected to each other, is configured to trim the pre-shaped cut piece held on a positioning bracket to a predefined size and profile; and At least one controller, including memory and processor, The memory contains at least pre-defined motion trajectory parameters of the trimming component, as well as pre-defined cutting force and cutting angle parameters. The processor is configured to output robotic arm control commands to the robotic arm to control the robotic arm to move according to predefined motion trajectory parameters, and to output predefined cutting force and cutting angle parameters to the cutter, so that the robotic arm moves according to the predefined motion trajectory under the control of at least one controller, while the cutter applies a predefined cutting force and cutting angle to the pre-shaped pattern piece under the control of at least one controller, thereby trimming the pre-shaped pattern piece into a bra cup of predefined size and contour.

2. The system according to claim 1, wherein, The shaping station also includes a rotary work platform and a drive; wherein: The rotating work platform is driven by the driver to rotate at a predefined angle; At least two of the aforementioned breast cup shaping molds are provided on the rotating work platform; The memory also stores parameters including the angular velocity of the predefined rotating work platform, the start and stop times of rotation, the heat setting time and heat setting temperature of each breast cup shaping mold; The processor is further configured to output control commands to cause the rotary work platform to rotate at a predefined angular velocity and to start and stop rotation according to parameters for the start and stop times of rotation; and The processor is further configured to control each bra cup shaping mold to perform heat shaping on the cut pieces placed in the mold according to predefined parameters of heat shaping time and heat shaping temperature, so that while the rotating work platform is operably rotating, the at least two bra cup shaping molds perform heat shaping on the cut pieces placed therein.

3. The system according to claim 2, wherein, The heat setting time for each bra cup molding mold corresponds to the time required for the rotating work platform to rotate 180 degrees.

4. The system according to claim 2, wherein, The shaping station also includes a mold opening and closing control component corresponding to the bra cup shaping mold; The bra cup shaping mold further includes an upper mold head and a lower mold head, the size and shape of which are configured to define a space therebetween forming a predefined bra cup shape; the lower mold head is disposed on the rotary work platform, and the upper mold head is disposed on the mold opening and closing control assembly; and The mold opening and closing control component is configured to be driven by a cylinder to open at a predefined time to place or remove a shaped cut piece between the upper and lower mold heads, and to close at a predefined time to heat-set the placed cut piece.

5. The system of claim 1 further includes a feeding station configured to distribute cut pieces to the shaping station at a predefined frequency.

6. The system according to claim 5, wherein, The loading station also includes a storage device, a first transport component, a material preparation platform, and a first translation module. The storage device is configured to stack and store multiple cut pieces. The storage device further includes a support platform and a support platform height adjustment device. The support platform is disposed on the support platform height adjustment device. The support platform is configured to store the stacked multiple pieces of fabric. The support platform height adjustment device is configured to be driven by a motor to move the support platform and the pieces of fabric at a predefined speed, so that the first transport component can grab the top piece of fabric from the support platform at a preset vertical height. The first transport component is disposed above the loading station and includes a first XY-axis motion component and a piece gripper; the first XY-axis motion component is configured to move vertically in the Y-axis so that the piece gripper grips a piece of fabric from the support platform or releases the piece of fabric to the preparation platform; and is configured to drive the piece gripper to move horizontally in the X-axis to transport the gripped piece of fabric from the support platform to the preparation platform; The material preparation platform is configured to move vertically, such that the piece gripper releases the piece onto the material preparation platform at a predefined vertical height, and the first translation module grips the edge of the piece at a predefined vertical height; and The first translation module further includes a first X-axis translation track assembly and a plurality of clamps. The plurality of clamps are disposed on the first X-axis translation track assembly. The plurality of clamps are configured to clamp the edge of the cut piece from the material preparation platform and release the clamped cut piece at the bra cup shaping mold. The first X-axis translation track assembly is configured to drive the clamps to move repeatedly in the X-axis to repeatedly transport the cut piece from the material preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

7. The system of claim 1 further includes a transfer station configured to extract the shaped fabric piece from the shaping station and transport it to a designated location at the trimming station.

8. The system according to claim 7, wherein the transfer station further comprises a second translation module, a lifting transport platform, and a second transport component; in, The second translation module further includes a second X-axis translation track assembly and a clamping part, the clamping part being rotatably connected to the second X-axis translation track assembly, such that the clamping part can rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly; the clamping part is configured to clamp the edge of the shaped piece from the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward; The second X-axis translational track assembly is configured to drive the clamping part to move repeatedly in the X-axis, so as to repeatedly transport the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency; The lifting and transporting platform further includes a third XY-axis motion component and a transfer platform. The transfer platform is mounted on the third XY-axis motion component and moves with the movement of the third XY-axis motion component. The lifting and transporting platform is configured to move vertically along the Y-axis to allow the second translation module to place the shaped piece onto the transfer platform, and then move along the X-axis to transport the shaped piece from one end near the shaping station to one end near the trimming station. The second transport component is configured to be positioned above the transfer station and includes a second XY motion component and a pre-shaped piece gripper; the second XY motion component is configured to move vertically in the Y direction so that the pre-shaped piece gripper grips the pre-shaped piece from the transfer platform; and is configured to drive the pre-shaped piece gripper to move horizontally in the X direction to transport the gripped pre-shaped piece to the trimming station.

9. The system according to claim 8, wherein, The transfer station further includes: a first automatic color difference detection component, which is disposed on the second translation module and includes a first camera and a first data transmission unit; the first automatic color difference detection component is configured such that: after the clamping part of the second translation module clamps the shaped piece out of the bra cup shaping mold and before flipping it, the first camera takes a picture of at least the inner side of the arched part of the shaped piece to obtain a first photo, and the data transmission unit transmits the obtained first photo to the controller of the at least one, and the controller of the at least one detects the color difference of the bra cup according to a preset algorithm.

10. The system according to claim 1, wherein, The positioning bracket is configured to keep the arched portion of the shaped cut piece upward and to form a certain suction force on the arched portion.

11. The system according to claim 10, wherein, The positioning bracket also includes a left bracket and a right bracket, the shapes of which correspond to the shape of the arched portion on the pre-shaped cut piece; the left bracket and the right bracket are respectively fixed on different pillars and maintain a certain spatial distance.

12. The system according to claim 10, wherein, The cutting tool cuts the pre-shaped piece into left and right halves along the midline of the spatial distance between the left and right brackets.

13. The system according to claim 12, wherein, The cutting tool cuts the left and right halves respectively, and the cutting moves according to a predefined motion trajectory and cuts according to a predefined cutting angle and cutting force, thereby trimming the bra cup with the desired contour.

14. The system according to claim 13, wherein, The contours of the left and / or right bracket edges are configured to conform to the predefined motion trajectory.

15. The system of claim 1 further includes a quality inspection station configured to perform color difference detection on the bra cups and classify and place them according to the color difference detection results.

16. The system according to claim 15, wherein, The quality inspection station also inspects the shape and contour of the bra cup.

17. The system according to claim 15, wherein, The quality inspection station includes multiple second cameras, a second data transmission unit, and an XYZ carrier module; The plurality of second cameras are respectively set at multiple different positions and angles in the quality inspection station, aiming at different positions of the bra cup from different directions to carry out multiple different shots; the second photos obtained by each second camera are transmitted to the controller of the at least one through a second data transmission unit, and the controller of the at least one detects the color difference and / or shape and contour of the bra cup according to a preset algorithm; The XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed to the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of the controller of at least one of the above-mentioned controllers; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the corresponding color difference grade bra cup under the drive of the power unit; and The controller of at least one of them sends an instruction to the XYZ motion component based on the determined color difference grade of the bra cup to control it to classify and place bra cups of different color difference grades into designated positions.

18. The system according to claim 17, wherein, The quality inspection station also includes a labeling unit, which is configured to affix a corresponding label to the bra cup after the controller of the at least one detects the color difference grade of a bra cup and determines it to be a defective product.

19. The system according to claim 1, wherein, The cutting tool is a circular tool.

20. The system according to claim 1, wherein, The pruning station also includes: The waste recycling device includes a waste receiving tray, which is disposed at the bottom of the trimming station; Conveyor belt; as well as Recycling stations used for storing waste materials The conveyor belt is operably connected to the waste receiving tray and the recycling station; The waste recycling device is configured such that the waste receiving tray receives waste generated from trimming at the trimming station, and the conveyor belt transfers the waste from the waste receiving tray to the recycling station.

21. The system according to claim 1, wherein, The bra cup shaping mold also includes a presser foot assembly, which is configured to apply pressure for a predefined duration to the shaped piece located inside the bra cup shaping mold when the mold is opened, so that the shaped piece does not change position as the mold is opened.

22. A method for producing a bra cup, using a bra cup production system as claimed in any one of claims 1-21, the method comprising the following steps: (1) The shaping station shapes the cut pieces into shaped pieces, wherein at least one of the bra cup shaping molds heat-shapes at least a portion of the cut pieces placed in the mold into shaped pieces having a predefined bra cup shape. (2) The trimming station trims the pre-shaped pattern pieces into bra cups of predefined sizes and profiles, wherein: At least one positioning bracket holds the cup shape and relative position of the shaped fabric piece thereon; and The trimming component trims the pre-shaped cut pieces held on the bracket to a predefined size and profile; (3) The processor outputs robotic arm control commands to the robotic arm to control the robotic arm to move according to the predefined motion trajectory parameters, and outputs predefined cutting force and cutting angle to the cutter, so that the robotic arm moves according to the predefined motion trajectory parameters under the control of at least one controller, and the cutter applies a predefined cutting force and cutting angle to the pre-shaped cut piece under the control of at least one controller, thereby trimming the pre-shaped cut piece into a bra cup of predefined size and contour.

23. The method for producing a bra cup according to claim 22, wherein the method further comprises the following steps prior to step (1): The feeding station distributes cut pieces to the shaping station at a predefined frequency.

24. The method for producing a breast cup according to claim 22, wherein the step (1) is followed by the following step: The pre-shaped cut pieces are retrieved from the shaping station by the transfer station and transported to the designated location of the trimming station.

25. The method for producing a bra cup according to claim 22, wherein after step (2), the method further comprises the step of: having a quality inspection station perform color difference detection on the bra cup and classify and place it according to the color difference detection results.

26. The method for producing a bra cup according to claim 23, wherein the feeding station further includes a material storage device, a first transport component, a material preparation platform, and a first translation module; in, The storage device is configured to stack and store multiple cut pieces; The storage device further includes a support platform and a support platform height adjustment device. The support platform is disposed on the support platform height adjustment device. The support platform is configured to store the stacked multiple pieces of fabric. The support platform height adjustment device is configured to be driven by a motor to move the support platform and the pieces of fabric at a predefined speed, so that the first transport component can grab the top piece of fabric from the support platform at a preset vertical height. The first transport component is disposed above the loading station and includes a first XY-axis motion component and a piece gripper; the first XY-axis motion component is configured to move vertically in the Y-axis so that the piece gripper grips a piece of fabric from the support platform or releases the piece of fabric to the preparation platform; and is configured to drive the piece gripper to move horizontally in the X-axis to transport the gripped piece of fabric from the support platform to the preparation platform; The material preparation platform is configured to move vertically, such that the piece gripper releases the piece onto the material preparation platform at a predefined vertical height, and the first translation module grips the edge of the piece at a predefined vertical height; and The first translation module further includes a first X-axis translation track assembly and a plurality of clamps. The plurality of clamps are disposed on the first X-axis translation track assembly. The plurality of clamps are configured to clamp the edge of the cut piece from the material preparation platform and release the clamped cut piece at the bra cup shaping mold. The first X-axis translation track assembly is configured to drive the clamps to move repeatedly in the X-axis to repeatedly transport the cut piece from the material preparation platform to the bra cup shaping mold of the shaping station at a predefined frequency.

27. The method for producing a breast cup according to claim 24, wherein, The transfer station includes a second translation module, a lifting and transporting platform, and a second transport component; The second translation module further includes a second X-axis translation track assembly and a clamping part. The clamping part is rotatably connected to the second X-axis translation track assembly, allowing the clamping part to rotate within a range of at least 180 degrees relative to the second X-axis translation track assembly. The clamping part is configured to clamp the edge of the shaped piece from the bra cup shaping mold and flip the shaped piece so that the arched portion of the shaped piece faces upward. The second X-axis translation track assembly is configured to drive the clamping part to move repeatedly in the X-axis to repeatedly transport the shaped piece from the bra cup shaping mold to the lifting transport platform at a predefined frequency. The lifting and transporting platform further includes a third XY-axis motion component and a transfer platform. The transfer platform is mounted on the third XY-axis motion component and moves with the movement of the third XY-axis motion component. The lifting and transporting platform is configured to move vertically along the Y-axis to allow the second translation module to place the shaped piece onto the transfer platform, and then move along the X-axis to transport the shaped piece from one end near the shaping station to one end near the trimming station. The second transport component is configured to be positioned above the transfer station and includes a second XY motion component and a pre-shaped piece gripper; the second XY motion component is configured to move vertically in the Y direction so that the pre-shaped piece gripper grips the pre-shaped piece from the transfer platform; and is configured to drive the pre-shaped piece gripper to move horizontally in the X direction to transport the gripped pre-shaped piece to the trimming station.

28. The method for producing a breast cup according to claim 25, characterized in that: The quality inspection station includes multiple second cameras, a second data transmission unit, and an XYZ carrier module; The plurality of second cameras are respectively set at multiple different positions and angles in the quality inspection station, aiming at different positions of the bra cup from different directions to carry out multiple different shots; the second photos obtained by each second camera are transmitted to the controller of the at least one through a second data transmission unit, and the controller of the at least one detects the color difference and / or shape and contour of the bra cup according to a preset algorithm; The XYZ transport module further includes a power unit, an XYZ motion component, and a suction cup component; the suction cup component is fixed to the XYZ motion component; the suction cup component is configured to grasp or release the bra cup; the power unit is configured to drive the XYZ motion component to move according to the instructions of the controller of at least one of the above-mentioned controllers; the XYZ motion component is configured to move the bra cup on the suction cup component to the storage position of the corresponding color difference grade bra cup under the drive of the power unit; and The controller of at least one of them sends an instruction to the XYZ motion component based on the determined color difference grade of the bra cup to control it to classify and place bra cups of different color difference grades into designated positions. The labeling unit is configured to affix a corresponding label to the bra cup after the controller of at least one of the bra cups detects the color difference grade of the bra cup and determines that it is a defective product.

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