Automatic thread-pulling machine for separating flat knitted components in garment manufacturing

Abstract

The present invention relates to an automated thread-pulling machine for separating garment components bound by temporary threads, such as collars, sleeves, and neck pieces. The machine combines a servo motor-driven roller system with a spring-loaded mechanism for tension-controlled, damage-free thread removal. A pneumatic gripper with adjustable heads secures the fabric, ensuring precise and consistent operation. The modular configuration enables scalability, facilitates easy maintenance, and supports integration into production lines, allowing high-throughput processing, enhanced efficiency, and reduced manual labor and risk of injury compared to conventional methods.

Description

[0001] “AUTOMATIC THREAD-PULLING MACHINE FOR SEPARATING FLAT KNITTED COMPONENTS IN GARMENT MANUFACTURING” FIELD OF THE INVENTION

[0002] The invention relates to textile machinery for separating flat-knitted garment components joined by temporary stitching threads. It particularly concerns an automated thread-pulling machine employing pneumatic grippers and a spring-loaded roller mechanism for removing such threads from garment parts including collars, sleeves, and necklines. The present invention specifically focuses on automating the process of separating flat knitted components, i.e., garment components that are bound by threads during various stages of manufacturing, wherein, the Automated Thread-Pulling Machine includes a Pneumatic Grippers and Spring-Loaded Roller Mechanism for Garment Component Separation. BACKGROUND OF THE INVENTION

[0003] In the global garment manufacturing industry, one of the key bottlenecks in the production process is the labour-intensive task of thread removal. During the production of garments, various components such as collars, necklines, and sleeves are often sewn or bound together with temporary threads to facilitate the handling and transport of the parts throughout the assembly process. These threads serve as placeholders to keep garment components aligned, but before the garment can move to its final stages, the threads need to be removed cleanly and efficiently. In conventional garment manufacturing processes, various components such as collars, sleeves, and necklines are produced in flat knitted form and remain bound together by auxiliary threads. The removal of these threads is an essential step before the components can undergo further assembly and finishing.

[0004] In the textile and garment manufacturing industry, various components are often temporarily bound together by threads to facilitate handling during production processes like cutting, stitching, and packaging. These threads need to be removed efficiently to prepare garments for final assembly or shipment.

[0005] Traditionally, this thread removal process is performed manually by workers, leading to several limitations. This manual process involves workers cutting and pulling the threads by hand, which presents several inherent limitations, particularly in large-scale, high-volume production settings. The disadvantages associated with the manual thread pulling approach include:

[0006] 1. Labor-Intensive Operations: Manual thread removal requires dedicated personnel to handle the task, which is both time-consuming and physically demanding. Manual thread removal requires significant human labour, making the process inefficient in high-volume production environments. The amount of time taken for each garment, multiplied by the thousands of garments processed daily in a typical manufacturing plant, represents a significant labour cost. As a result, labour becomes a major component of the overall production cost, particularly in countries where wage rates are rising.2. Inconsistency in Quality: The manual nature of the process introduces variability, where the amount of force applied during thread removal may differ, potentially leading to damage in delicate fabrics or incomplete thread removal. Due to the manual nature of thread removal, quality control becomes a concern. Workers may apply varying degrees of force when pulling threads, leading to inconsistent results. In some cases, the threads may not be fully removed, leaving behind fragments that could affect the aesthetic or functional integrity of the final product. Additionally, excessive force applied during thread pulling can cause damage to the garment, especially when dealing with delicate fabrics such as silk, chiffon, or lace.

[0007] 3. Damage to Garments: The risk of damaging garments is significantly higher when the process is manual. Fabrics can easily tear or fray if workers do not handle them carefully or if threads are pulled with too much force. This is particularly problematic for high-end garments or fabrics with delicate textures, where even minor imperfections can render the garment unsellable. 4. Low Production Efficiency: As global demand for clothing continues to rise, manufacturers are increasingly pressured to produce more garments in less time. The manual thread removal process significantly slows down the production line. This added time negatively impacts the manufacturer’s ability to meet tight deadlines, increases lead times, and reduces the overall throughput of the production facility.

[0008] 5. Increased Labor Costs: As the demand for faster production grows, the need for a larger workforce also grows. Employing additional workers to perform repetitive tasks like thread pulling inflates labour costs. For manufacturers operating in countries with increasing minimum wage requirements or in regions where skilled labour is scarce, this further reduces profit margins. Relying on human labour for thread removal leads to higher labour costs, particularly as production scales up.

[0009] 6. Worker Fatigue and Error Rates: Thread removal is a monotonous and repetitive task that can cause worker fatigue over time. Fatigue contributes to higher error rates, including incomplete thread removal, inconsistent handling of the garment, and damage to the fabric. This not only impacts production output but also increases the chances of defects, leading to rework and wasted materials.

[0010] 7. Increased Production Time: Manually separating threads adds additional time to the production process, resulting in longer lead times and reduced production throughput.

[0011] Further, the advent of industrial automation has transformed many areas of garment production, from fabric cutting and stitching to dyeing and pattern printing. However, certain processes, such as thread removal, have not yet been fully optimized through automation. This has created a gap in the textile manufacturing industry where traditional manual labour remains dominant, particularly in developing economies where the cost of labour is still comparatively low. Nevertheless, as global wage rates riseand demand for fast fashion intensifies, there is a growing need to automate these labour-intensive processes.

[0012] Moreover, as garment manufacturers continue to scale up operations to meet global demand, machinery like the present thread-pulling machine becomes indispensable for maintaining high output levels while minimizing production costs and ensuring consistent quality. Furthermore, while some machines have been introduced to aid in fabric handling and assembly, many have not yet been fully adapted to the process of thread-pulling.

[0013] Current machinery tends to focus on the stitching and sewing phases, but few systems have been developed to specifically address thread removal. Those that do exist are often limited by their inability to adjust for varying fabric types, thread tensions, and garment components, resulting in inconsistent performance across different production lines.

[0014] The lack of automation in this area represents a missed opportunity for manufacturers to streamline their operations and increase throughput. Furthermore, existing solutions often fail to meet the precision requirements for high-end garments where fabric integrity is of paramount importance. Machines that apply too much force can cause irreversible damage, while machines that apply insufficient force may leave threads behind, requiring additional manual intervention.

[0015] Therefore, in order to address these challenges or to overcome the drawbacks associated with the prior arts, the inventors of the present invention by exhaustive research and development offers a fully automated thread-pulling machine capable of handling large batches of garments quickly and efficiently, wherein, the machine automates the task of separating garment components such as collars and sleeves by utilizing a motorized roller system combined with a spring reaction mechanism that ensures precision thread removal.

[0016] Accordingly, the present invention is directed towards an automatic thread-pulling machine for garment components, wherein automation of the thread-pulling process supports contemporary trends in the textile industry that focus on incorporating advanced machinery to minimize manual labour, enhance uniformity in production quality, and improve overall production efficiency. Thus, the present invention is designed to enhance production efficiency in the garment industry by automating the otherwise labour-intensive task of thread removal from garment parts such as collars, sleeves, and necklines. The present invention addresses these challenges by providing an automated thread-pulling Machine incorporating pneumatic grippers and a spring-loaded roller mechanism to achieve efficient garment component separation. This approach not only eliminates the inefficiencies of manual labour but also provides a safer, more cost-effective, and scalable solution compatible with future loT-based upgrades. Therefore, the present invention addresses the challenges and drawbacks associated with the known arts by introducing an automatic thread-pulling machine specifically designed for separating garment components such as collars, neck collars, and sleeves, wherein, a key innovation of an automaticmachine of the present invention lies in its motorized roller system combined with a spring reaction mechanism, which applies precise amounts of force to remove threads without damaging the fabric. Furthermore, the textile and garment manufacturing industry relies heavily on efficient post-production processes such as trimming and separation of garment components. One critical step in this workflow involves the removal of temporary stitching threads used during the attachment of parts like collars, sleeves, or panels. Conventional thread-pulling methods often fall short in terms of efficiency, safety, and adaptability to high-volume production environments.

[0017] Prior arts have attempted to address this issue through various means. For instance, US20140215956A1 discloses a garment separation device that utilizes thermal thread vaporization. While effective in thread removal, such systems involve high-temperature operations that pose risks to certain fabric types and raise safety and energy consumption concerns. Additionally, the use of heat introduces material compatibility limitations and often requires strict environmental controls.

[0018] Similarly, Indian Patent application IN202011012345 describes a manual thread separation station, which, although simpler and cost-effective, relies heavily on human labor, resulting in low throughput, inconsistent results, and ergonomic risks such as hand fatigue and injuries caused by high thread tension during manual pulling.

[0019] Existing solutions are either unsuitable for large-scale industrial application or involve compromises in safety, energy efficiency, or fabric compatibility. Accordingly, there is a continuing need for an automated thread-separation system that ensures safety, delivers high operational efficiency, and accommodates a wide range of garment components across varying production capacities

[0020] The present invention overcomes these limitations by offering an automatic thread-pulling machine that combines mechanical drive mechanisms, pneumatic gripping, and spring-based force control. This configuration enables precise thread removal while preserving fabric quality, minimizing operator hazards, and enhancing productivity. In addition, its modular construction with replaceable components facilitates maintenance and customization, providing a cost-effective and scalable solution for garment manufacturing

[0021] In addition, the present invention discloses that unlike traditional manual methods, the automated machine of the present invention is capable of processing up to 80 to 100 garments per batch, completing the cycle in approximately 45 seconds. The machine is designed for versatility, allowing it to handle a wide range of fabrics and thread tensions with ease. This flexibility makes it a valuable addition to any garment production line, from high-end fashion houses to large-scale manufacturing facilities producing mass-market apparel.

[0022] Automating the thread-pulling process enables manufacturers to achieve higher consistency in product quality, enhance production efficiency, and lower labour costs, while reducing the likelihood of fabricdamage. Incorporating this machine into the production line also allows manufacturers to future-proof operations in an increasingly competitive and rapidly evolving global market.

[0023] The invention enhances production efficiency by replacing manual or sublimation-based thread removal methods, and is designed for compatibility with future loT-based upgrades for real-time diagnostics, cycle counting, and predictive maintenance, in alignment with Industry 4.0 smart manufacturing standards. The present invention, thus replaces traditional manual or sublimation-based methods, offering a safer, more cost-effective, and industrially scalable solution for garment manufacturing. OBJECTIVES AND ADVANTAGES OF THE INVENTION

[0024] The primary objective of the present invention is to provide an automatic thread-pulling machine specifically configured for separating garment components such as collars, necklines, and sleeves. A key aspect of the invention is its integration of a motor-driven roller system with a spring-based reaction mechanism, enabling the application of controlled force to remove threads while preserving the integrity of the fabric.

[0025] Another object of this invention is to provide an automatic thread-pulling machine, comprising motorized roller system combined with a spring reaction mechanism, which applies precise amounts of force to remove threads without damaging the fabric

[0026] A further object of this invention is to provide an automated machine, capable of processing 80 to 100 garments per batch, with each processing cycle completed in approximately 45 seconds.

[0027] A further object of this invention is to provide an automated machine -designed for versatility, allowing it to handle a wide range of fabrics and thread tensions with ease. This flexibility makes it a valuable addition to any garment production line, from high-end fashion houses to large-scale manufacturing facilities producing mass-market apparel.

[0028] A further object of this invention is to provide an automated thread-pulling machine capable of handling large batches of garments quickly and efficiently.

[0029] A further object of this invention is to provide a machine that automates the task of separating garment components such as collars and sleeves by utilizing a motorized roller system combined with a spring reaction mechanism that ensures precision thread removal.

[0030] A further object of this invention is to automate the thread-pulling process, which aligns with modern trends in the textile industry, and aims to integrate advanced machinery to reduce reliance on manual labour, increase consistency in production quality, and optimize overall production timelines.

[0031] A further objective of the present invention is to provide an automatic thread-pulling machine for garment components, including shirt collars, necklines, and sleeves, incorporating a motor-driven roller system, a spring-based reaction mechanism, a safety mechanism, and a modular construction with replaceable parts, capable of processing 80 to 100 garments within a 45-second cycle.A further object of this invention is to provide a method for separating garment components by utilizing an automatic thread-pulling machine.

[0032] A further object of this invention is to provide an automated thread-pulling machine which utilizes a motor-to-roller drive system to pull threads and employs a spring reaction mechanism to ensure thread removal without damaging fabric.

[0033] A further object of this invention is to provide a method for separating garment components by utilizing an automatic thread-pulling machine, where the machine utilizes a motor-to-roller drive system for pulling and removing threads and employs a spring reaction mechanism to ensure complete thread removal without fabric damage.

[0034] A further object of this invention is to provide an automated thread-pulling machine which has the features of adjustable settings to accommodate different garment types and thread tensions.

[0035] A further object of this invention is to provide an automated thread-pulling machine which has replaceable components including rollers, motor, and pulleys, requiring minimal maintenance.

[0036] Another objective of the present invention is to provide automated control circuitry for a thread-pulling machine used in separating garment components, configured to ensure safe, adjustable, and dependable operation of the motor and roller drive.

[0037] Another objective is to provide a motor control system capable of managing variable speeds, enabling optimized thread pulling based on the type and tension of fabric.

[0038] Yet another objective is to incorporate safety features such as an emergency stop and future provisions for sensors and limit switches, thus improving operator safety and machine automation capabilities. Another objective of the present invention is to provide an automated thread-pulling machine that enables efficient, safe, and damage-free separation of garment components.

[0039] Another objective of the present invention is to incorporate a spring-loaded roller system in combination with pneumatic grippers to achieve tension-based, precision thread removal, thereby replacing manual extraction or high-temperature thread sublimation techniques

[0040] A further objective of the present invention is to provide adjustable gripper width to suit various garment sizes, along with the use of durable, industrial-grade materials to ensure extended operational life. Another objective of the present invention is to provide an automated thread-pulling machine with Pneumatic Grippers and Spring-Loaded Roller Mechanism for Garment Component Separation. Some or all these and other objects of the invention can be achieved by way of the invention described hereinafter.

[0041] ADVANTAGES:

[0042] Automating thread-pulling machine of the present invention offers several critical benefits such as:1. Mass production environments: the present machine offers mass production environments where large volumes of garments are processed quickly and with minimal labour.

[0043] 2. High-precision garment manufacturing: the present machine offers high-precision garment manufacturing where, maintaining the integrity of delicate fabrics (such as silk, chiffon, or lace, etc) is critical, and the need for controlled, consistent thread removal is paramount.

[0044] 3. Versatile applications where the machine has the capacity to handle a wide range of garment components (collars, sleeves, and necklines), fabric types, and thread tensions, making it a valuable asset across multiple phases of the garment production pipeline.

[0045] 4. Increased Efficiency: By automating the thread removal process, manufacturers will significantly increase their production rates. Machines will operate continuously without fatigue, working at consistent speeds that surpass manual labour, thereby accelerating the production timeline.

[0046] 5. Enhanced Quality Control: Automated systems provide greater precision in thread removal, ensuring consistent results. Machines will be fine-tuned to apply exactly the right amount of force, minimizing the risk of garment damage and ensuring that threads are removed completely.

[0047] 6. Cost Savings: Automation reduces the reliance on manual labour, cutting down on labour costs and associated overheads. Additionally, fewer defective garments result in less waste and lower rework rates, further improving the bottom line.

[0048] 7. Adaptability to Different Fabrics: Automated machines are designed to handle a variety of fabric types and garment components, making them highly versatile. Whether dealing with delicate fabrics or heavier textiles, automation will adjust to the specific needs of the material.

[0049] 8. User / Worker Safety: the present machine offers user / worker safety, as it prevents users / workers from getting cuts on their hands / fingers, as due to the high tension, while pulling manually, the friction led to cause cuts on the hands / fingers of the user or workers.

[0050] 9. The circuitry of the present invention allows for future enhancements, such as integration with limit switches for roller positioning and sensors for thread tension or garment alignment. This provides potential for semi- or fully-automated operation while maintaining safety and adaptability.

[0051] 10. The entire control system is designed for simplicity, ease of maintenance, and upgradability, ensuring adaptability for industrial use with minimal technical complexity.11. A pneumatic gripper system with adjustable silicon-lined heads in the present invention securely holds fabric during operation, allowing precise and consistent performance.

[0052] 12. The machine of the present invention can process 80 to 100 components within 45 seconds, thereby substantially increasing production throughput while minimizing manual labour and the risk of injury. Its modular construction facilitates easy maintenance and enables scalability

[0053] SUMMARY OF THE INVENTION

[0054] Accordingly, a principal aspect of the present invention is to provide an automatic thread-pulling machine configured to efficiently and accurately separate garment components, such as collars, sleeves, and necklines, which are bound by threads during different stages of garment manufacturing.

[0055] In another aspect, the present invention provides an automatic thread-pulling machine that is powered by a 550-watt motor, which drives a set of rollers that pull the threads from the garment components in a controlled and consistent manner.

[0056] In another aspect, the present invention provides that a key feature of the present invention is its spring reaction mechanism, which ensures the precise and complete removal of threads without damaging the fabric. This mechanism works by providing a final, calibrated tug on the threads after they pass through the rollers, ensuring that all remnants are removed, even from delicate fabrics like silk or lace. The spring mechanism is adjustable, allowing it to handle a wide range of thread tensions and fabric types, which makes the machine versatile and suitable for different garment production environments.

[0057] In another aspect, the present invention offers an automatic thread-pulling machine capable of processing 80 to 100 garments per batch and completing an entire cycle in about 45 seconds, thereby providing an efficient solution for high-volume production environments.

[0058] In addition to increasing production speed, the machine of the present invention significantly reduces labour costs by automating a traditionally manual task, freeing up workers for more complex tasks and reducing the risk of human error.

[0059] In another aspect, the present invention provides an automatic thread-pulling machine comprises a modular design that allows for easy maintenance and part replacement. Components such as the rollers, pulleys, and motor can be swapped out quickly, minimizing downtime and ensuring that the machine remains operational for longer periods.

[0060] In another aspect, the present invention provides an automatic thread-pulling machine comprising the emergency stop switch, which further enhances safety, allowing operators to immediately halt the machine in case of a malfunction.

[0061] In an aspect, the present invention provides an automated thread-pulling machine with Pneumatic Grippers and Spring-Loaded Roller Mechanism for Garment Component Separation.In another aspect, the present invention provides a control circuitry system integrated into an automatic thread-pulling machine, comprising a motor control circuit designed to regulate the start, stop, speed, and emergency shutdown of the motor. The control system includes a motor start / stop button, a speed regulator (such as an AC variable drive or voltage step-down system), and an emergency stop switch to ensure immediate shutdown in hazardous conditions.

[0062] In another aspect, the present invention relates to an automated thread-pulling machine designed for separating garment components such as collars or sleeves, wherein, the machine incorporates:

[0063] • A spring-loaded roller mechanism for thread pulling,

[0064] • A set of pneumatic grippers to securely hold the fabric in place, and

[0065] • A modular adjustment mechanism / system enabling lateral movement of the grippers to accommodate different garment widths.

[0066] In another aspect, the present invention discloses an operational sequence wherein the garment is first loaded, then pneumatically clamped, followed by thread extraction through motor-driven rollers. A controlled tension is applied, and a spring-activated final pull / tug ensures complete separation of the threads, resulting in accurate and damage-free detachment of garment components.

[0067] In another aspect, the gripper assembly is laterally adjustable through a manual knob mechanism, permitting width variations ranging from about 5 cm to 25 cm. The machine’s frame and working table are fabricated from materials such as mild steel, aluminum, stainless steel, and mica-laminated plyboard, thereby ensuring durability and industrial-grade strength.

[0068] The novelty of the present invention lies in its distinctive integration of mechanical and pneumatic systems, showcasing technical advancement through the combined use of a tension-responsive spring release mechanism and a multi-cylinder pneumatic fabric holding system, features not disclosed in any prior art.

[0069] Constructed from durable materials such as mild steel for the frame and aluminium for the rollers, the machine is built to withstand the rigors of industrial use. It is suitable for a wide variety of fabrics and garment types, making it a flexible and highly effective solution for modern garment manufacturing facilities.

[0070] Thus, the present invention provides an automated solution for thread removal that improves operational efficiency, ensures uniform product quality, and reduces manufacturing costs, thereby delivering a significant technical advantage over conventional manual or semi-automated methods.

[0071] In summary, the present invention discloses an automated thread-pulling machine that uniquely integrates mechanical, pneumatic, and spring-based systems to enable precise and efficient separation of garment components. The invention enhances production throughput, ensures consistency in product quality, reduces operator intervention and associated risks, and minimizes operational costs. Themodular construction further supports easy maintenance, adaptability across garment sizes, and longterm industrial applicability, thereby offering a distinct technical advancement over prior art methods of thread removal.

[0072] BRIEF DESCRIPTION OF DRAWINGS

[0073] Through the following detailed descriptions with reference to the accompanying drawings, the above and other objectives, features and advantages of the example embodiments disclosed herein will become more comprehensible. In the drawings, several exemplary embodiments disclosed herein will be illustrated in an example and in a non-limiting manner, wherein:

[0074] Fig. 1 illustrates front view of an automated thread pulling machine;

[0075] Fig. 2 illustrates top view of an automated thread pulling machine;

[0076] Fig. 3 illustrates side view of an automated thread pulling machine;

[0077] Fig. 4 illustrates isometric view of an automated thread pulling machine.

[0078] Fig. 5 illustrates adjustable pneumatic gripper mechanism with lateral sliding knobs

[0079] Fig. 6 illustrates the complete automated thread-pulling machine with dimensional layout and integrated subsystems.

[0080] Fig. 7 illustrates Labeled schematic of the automated thread-pulling machine showcasing key mechanical and pneumatic subsystems.

[0081] Fig. 8 illustrates Side elevation view of the automated thread-pulling machine illustrating the transmission layout and roller-gripper alignment.

[0082] Fig. 9 illustrates Perspective view of the spring-loaded roller assembly for tension control in the drive system.

[0083] Fig. 10 illustrates Top view of the automatic thread-pulling machine showing alignment of gripping units and roller.

[0084] Fig. 11 illustrates Side view illustrating the pneumatic and mechanical drive integration of the threadpulling machine.

[0085] Fig.12 illustrates Process flow diagram illustrating the sequential operation of the automated threadpulling machine.

[0086] DETAILED DESCRIPTION OF THE INVENTION

[0087] In describing the embodiments of the invention, specific terminology is resorted for sake of clarity. However, it is not intended that the invention be limited to specific terms so selected and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

[0088] Accordingly, the main embodiment of the present invention is to provide an automatic thread-pulling machine designed to efficiently and precisely separate garment components, for instance collars, sleeves, necklines, etc. that are bound by threads during various stages of garment production.

[0089] In a further embodiment, the invention discloses an automatic thread-pulling machine incorporating a 550-watt motor configured to actuate a roller assembly, the roller assembly being arranged to effect controlled and uniform removal of threads from garment partsIn another embodiment, the invention provides an automatic thread-pulling machine comprising: a 550-watt motor; a roller assembly driven by said motor; wherein the roller assembly is configured to perform controlled and uniform thread extraction from garment components.

[0090] In an embodiment, the present invention provides an automatic thread-pulling machine specifically designed for garment manufacturing.

[0091] In another embodiment, the machine of the present invention automates the process of separating garment components (such as collars, sleeves, and neck piece, etc) that are bound by threads, replacing traditional manual methods.

[0092] In yet another embodiment, the invention relates to an automatic thread-pulling machine including a 550-watt motor and a roller assembly driven thereby, wherein said roller assembly is adapted to achieve consistent and regulated removal of threads from garment elements.

[0093] In another embodiment, an automatic thread-pulling machine features a spring reaction mechanism for precise thread removal, an emergency stop switch, for safety, and a modular design with replaceable components.

[0094] In another embodiment, an automatic thread-pulling machine has minimal maintenance requirements and the ability to process various garment types, the machine is designed for high efficiency in industrial applications.

[0095] In another embodiment, the present invention provides that a key feature of the present invention is its spring reaction mechanism, which ensures the precise and complete removal of threads without damaging the fabric. This mechanism works by providing a final, calibrated tug on the threads after they pass through the rollers, ensuring that all remnants are removed, even from delicate fabrics like silk or lace. The spring mechanism is adjustable, allowing it to handle a wide range of thread tensions and fabric types, which makes the machine versatile and suitable for different garment production environments.

[0096] In yet another embodiment, the invention incorporates a spring reaction mechanism adapted to perform a calibrated terminal pull on threads after roller passage, thereby ensuring complete thread removal without fabric damage. The adjustability of the spring mechanism permits operation with a wide range of thread tensions and fabric varieties, including delicate materials, enhancing the versatility of the machine for varied garment manufacturing applications

[0097] In another embodiment, the present invention provides an automatic thread-pulling machine comprises a modular design that allows for easy maintenance and part replacement. Components such as the rollers, pulleys, and motor can be swapped out quickly, minimizing downtime and ensuring that the machine remains operational for longer periods.In yet another embodiment, the invention discloses a modular automatic thread-pulling machine wherein key components such as rollers, pulleys, and the motor are replaceable in a quick-change manner, thereby reducing maintenance time and ensuring prolonged operability.

[0098] In another aspect, the present invention provides an automatic thread-pulling machine comprising the emergency stop switch, which further enhances safety, allowing operators to immediately halt the machine in case of a malfunction.

[0099] In an embodiment, figure 1 illustrates the front view of the automated thread-pulling machine featuring a multi-clamp assembly positioned above a roller-supported work surface. The clamps are uniformly spaced along a horizontal support structure, enabling simultaneous processing of multiple garment components. A motor-driven roller system operates beneath the surface to facilitate controlled thread removal. The setup highlights the structural alignment and integration of key mechanical components, providing stability and synchronized operation during the thread-pulling process.

[0100] In an embodiment, the figures 2, 3 and 4 provides a comprehensive perspective view, side view and isometric view, respectively of the automated thread-removal machine, highlighting the integration of pneumatic actuators, clamp assemblies, spring-loaded mechanisms, motor-driven rollers, and threadguiding elements. The arrangement demonstrates the operational synergy between component loading, clamping, thread entanglement with a roller-rivet, and final thread extraction. The system's modular structure ensures scalability for multiple garment components, supporting high-throughput and consistent processing in textile manufacturing or finishing lines.

[0101] In an embodiment, the figure 5 illustrates the adjustable gripper mechanism incorporated into the automated thread-pulling machine. The system comprises a cross beam mounted with multiple pneumatic gripper heads, each fitted with a silicon-lined contact surface to safely hold garment components. These grippers are attached via slider blocks integrated with manually operable adjustment knobs, allowing lateral movement along the beam. The red arrows denote the range of adjustability, enabling the spacing between grippers to be configured between approximately 5 cm to 25 cm to accommodate different garment widths. This modular and reconfigurable setup ensures the machine can handle a wide variety of garment sizes and shapes in a production environment, while maintaining firm and damage-free clamping during thread separation.

[0102] In an embodiment, the figure 6 illustrates a detailed embodiment of the automated thread-pulling machine, including its key components and their dimensional layout. The machine comprises a horizontal worktable (1200 mm x 1200 mm x 825 mm height) with an integrated spring-loaded roller mechanism (1150 mm length) driven by a 550-watt motor and a 4-stage pulley system (350 mm, 250 mm, and two 50 mm pulleys). The pneumatic gripping system includes six silicon-lined grippers mounted on a cross beam with lateral sliding adjustment (280 mm travel), enabled via knobs to suit varying garment widths. A regulated compressed air supply, routed via PU pipes and controlled by a valve and FRL unit, powers the pneumatic cylinders. The frame is constructed for industrial durabilityand ergonomically designed for efficient operator interaction. The labeled measurements provide guidance for fabrication, installation, and ergonomic integration within a garment production line. In an embodiment, the figure 7 illustrates a comprehensive embodiment of the automated thread-pulling machine with clearly labeled components and subsystems. The machine is powered by a 550-watt servo motor that drives a spring-loaded roller via a multi-stage pulley and belt transmission system comprising 50 mm, 250 mm, and 350 mm diameter pulleys connected with A40 and A52 belts. The roller, embedded with rivets, provides controlled thread traction during the separation of garment components. Mounted on a cross beam above the table are six pneumatic grippers with silicon-lined adjustable heads, which securely hold the garment pieces. These grippers are laterally adjustable using knobs to accommodate garments of various widths. The pneumatic system, powered through input and output PU pipes, is controlled by a valve mechanism to ensure uniform actuation of the gripping heads. The machine’s modular layout ensures ease of maintenance, adaptability for future upgrades, and safe operation in industrial textile environments.

[0103] In an embodiment, the figure 8 represents a side elevation view of the automated thread-pulling machine, providing insight into the mechanical layout and spatial configuration of its transmission and gripping subsystems. The 550-watt motor transfers power to the main roller using a series of pulleys (50 mm, 250 mm, and 350 mm in diameter) and belts arranged in a 4-stage reduction system to increase torque and reduce output speed. The roller, located 40 mm below the gripper bar, is embedded with rivets to facilitate soft but firm thread traction. Above the roller, six pneumatically operated grippers are mounted on a 1200 mm wide cross beam, allowing for the secure holding of garment sections during operation. The coordinated motion between the roller and grippers enables efficient and damage-free pulling of threads from garments. This view highlights the precision alignment and dimensional accuracy required for effective operation of the thread-separating process.

[0104] In an embodiment, the figure 9 illustrates the spring-loaded roller assembly utilized within the transmission system of the automated thread-pulling machine. The roller comprises a grooved circular pulley mounted on a central shaft, which is integrated with a helical compression spring mechanism. This spring mechanism allows axial displacement of the pulley to absorb shock and maintain belt tension dynamically during machine operation. The assembly ensures consistent power transmission from the motor to the driven components (e.g., the riveted roller), compensating for variations in belt stretch or load. This tension-regulating feature improves system durability and prevents belt slippage, which is essential for maintaining the precision and uniformity of the thread removal process from garment materials.

[0105] In an embodiment, the figure 10 presents a top view of the automatic thread-pulling machine, emphasizing the spatial alignment between the gripping mechanisms and the rotating roller with rivets. The gripping units, mounted on a cross beam and actuated pneumatically, are equally spaced to ensure synchronized engagement with multiple sections of the garment simultaneously. The output air pipe and control valve system are also visible, forming the pneumatic control network that drives the verticalmovement of the grippers. Below the gripping assembly lies the roller, horizontally aligned, which serves as the rotating element responsible for pulling the threads post-gripping. The precise layout optimizes thread extraction efficiency, accommodates garments of varied widths, and ensures uniform thread removal across the length of the fabric.

[0106] In an embodiment, the side-view figure 11 showcases the comprehensive integration of both pneumatic and mechanical subsystems in the automated thread-pulling machine. At the base, a compressor supplies pressurized air through PU pipes to a control valve that regulates the vertical actuation of the pneumatic grippers fixed above the working table. These grippers engage with threads on garments, mounted on a roller with rivets positioned horizontally across the working surface. To the right, a 550-watt servo motor transmits rotational motion via pulleys and belts to the main roller shaft, driving the thread-pulling action. Large and small pulleys with a spring-loaded tensioner maintain belt alignment and torque transfer efficiency. This embodiment effectively demonstrates the machine’s dual-system operation — pneumatic for gripping control and electromechanical for roller actuation — ensuring synchronized and precise thread removal in garment recycling or refurbishing processes.

[0107] In an embodiment, the figure 12 represents a stepwise operational flowchart of the automated threadpulling machine designed for separating thread-bound garment components such as collars and sleeves. The process begins with garment component loading onto the machine, followed by pneumatic clamping using adjustable silicon-lined grippers. The garment thread is then entangled with a roller rivet rotating via a motor-driven shaft. As the roller continues, thread tension builds up, after which a spring mechanism is triggered to aid in rapid and controlled thread release. Once the thread is fully removed, the processed garment is unloaded. This flow ensures a safe, efficient, and high-throughput automation cycle that minimizes manual labor and enhances consistency in thread separation for garment manufacturing and recycling applications.

[0108] In another embodiment, the present invention provides an automatic thread-pulling machine for garment components, comprising:

[0109] i) a motor, driving a roller system;

[0110] ii) a safety mechanism; and

[0111] iii) a modular design.

[0112] In an embodiment, the motor is a motor-to-roller drive system, and comprising 550-watt motor. In an embodiment, the safety mechanism includes an emergency stop switch and the modular design having a replaceable part.

[0113] In an embodiment, the present invention provides an automatic thread-pulling machine for garment components, comprising:

[0114] i) a 550-watt motor, driving a roller system;

[0115] ii) a safety mechanism including an emergency stop switch;

[0116] iii) a modular design with replaceable parts;wherein the machine functions through a spring reaction mechanism and is configured to process approximately 80 to 100 garment components within a cycle duration of about 45 seconds.

[0117] In one of the embodiments, the automatic thread pulling machine comprising the 550-watt motor driving a roller system is to pull and remove threads connecting garment components.

[0118] In one of the embodiments, the automatic thread pulling machine utilizing the spring reaction mechanism to ensure complete separation of threads.

[0119] In one of the embodiments, the automatic thread pulling machine comprising the safety mechanism including an emergency stop switch for immediate shutdown in case of malfunction.

[0120] In one of the embodiments, the automatic thread pulling machine comprising the modular design with replaceable parts including the rollers, motor, and pulleys, that reduces downtime and maintenance costs.

[0121] In one embodiment, the automatic thread-pulling machine is configured to process approximately 80 to 100 garment components, including collars, sleeves, or similar parts, within a cycle time of about 45 seconds

[0122] In yet another embodiment, the present invention provides a method for separating garment components by an automatic thread-pulling machine, wherein the machine comprises:

[0123] i) a motor-to-roller drive system;

[0124] ii) an adjustable setting;

[0125] iii) modular design;

[0126] wherein, the machine operates by a spring reaction mechanism;

[0127] In one of the embodiments, the automatic thread pulling machine comprising the motor-to-roller drive system to pull threads.

[0128] In one of the embodiments, the automatic thread pulling machine employs a spring reaction mechanism to ensure thread removal without damaging fabric.

[0129] In one of the embodiments, the automatic thread pulling machine has the features of adjustable settings to accommodate different garment types and thread tensions.

[0130] In one of the embodiments, the automatic thread pulling machine has the modular design having replaceable components including rollers, motor, and pulleys, requiring minimal maintenance.

[0131] In yet another embodiment, the present invention provides a method for separating garment components by an automatic thread-pulling machine, where the machine:

[0132] i) utilizes a motor-to-roller drive system for pulling and removing threads; and

[0133] ii) employs a spring reaction mechanism to ensure complete thread removal without fabric damage.In one of the embodiments, the automatic thread pulling machine comprising:

[0134] i) a motor;

[0135] ii) a roller;

[0136] iii) a pulley;

[0137] iv) a spring and a pneumatic cylinders.

[0138] In an embodiment, the pulley is a mild steel pulley.

[0139] In an embodiment, the motor drives a series of rollers responsible for pulling the threads connecting the garment components.

[0140] In an embodiment, the spring and pneumatic cylinders are used to hold down the fabrics.

[0141] In yet another embodiment, the present invention provides that the machine is constructed from durable, high-quality materials to ensure longevity and reliable operation in industrial settings.

[0142] In one embodiment, the present invention provides an automatic thread-pulling machine for separating garment components, comprising:

[0143] a) a motor;

[0144] b) a safety mechanism;

[0145] c) a modular design with replaceable components;

[0146] d) a spring reaction mechanism; and

[0147] e) a pneumatic system;

[0148] wherein the machine is configured to process approximately 80 to 100 garment components within a cycle duration of about 45 seconds.

[0149] In another embodiment, the automatic thread-pulling machine comprising:

[0150] a) a motor that is operatively coupled to a roller system via a motor-to-roller drive system; b) a safety mechanism which includes an emergency stop switch;

[0151] c) a modular design with replaceable components, including at least one of the rollers, motor, and pulleys;

[0152] d) a spring reaction mechanism for applying calibrated force during thread pulling without damaging fabric; and

[0153] e) a pneumatic system comprising one or more pneumatic cylinders, a polyurethane (PU) air pipe, a hand lever valve, and a filter, regulator, and lubricator (FRL) unit,

[0154] wherein, the pneumatic system actuates the garment hold-down mechanism during operation.

[0155] In another embodiment, the motor is a 550-watt servo motor configured to deliver torque.

[0156] In another embodiment, the roller system comprises spring-loaded rollers configured to pull and remove threads connecting garment components.

[0157] In another embodiment, the pneumatic cylinders are configured to clamp the garment components during thread pulling.In another embodiment, the PU air pipes have a diameter ranging from about 5 cm to 8 cm and deliver compressed air to the pneumatic cylinders.

[0158] In another embodiment, the automatic thread-pulling machine, further comprises a frame and stand made of mild steel, providing structural integrity for industrial operations.

[0159] In another embodiment, the automatic thread-pulling machine further comprises a table surface made of plyboard laminated with mica, providing a smooth and durable surface for garment handling.

[0160] In another embodiment, the pulleys are made from mild steel and configured to transmit motor power reliably to the roller system.

[0161] In another embodiment, the pneumatic cylinders are constructed from aluminum for lightweight and durable performance.

[0162] In yet another embodiment, the present invention provides an automatic thread-pulling machine comprising:

[0163] a) a motor;

[0164] b) a roller drive system driven by the motor; and

[0165] c) a control circuitry configured to regulate motor operation,

[0166] In another embodiment, the control circuitry comprises:

[0167] i. a motor start / stop push button;

[0168] ii. a speed regulator selected from an AC variable drive or step-down voltage regulator; iii. an emergency stop switch that disconnects motor power during malfunction;

[0169] and

[0170] iv. optionally, includes one or more limit switches for detecting roller endpoint positions;

[0171] and sensors for monitoring thread tension or garment alignment.

[0172] In still another embodiment, the present invention provides an automated thread-pulling machine for separating garment components, comprising:

[0173] a) a motor;

[0174] b) a spring-loaded roller system driven by said motor for pulling threads;

[0175] c) at least one pneumatic cylinder with fabric-gripping heads for clamping garment components during thread pulling;

[0176] wherein, the spring-loaded mechanism applies a final pulling force based on thread tension buildup to effectuate thread separation.

[0177] In another embodiment, the pneumatic cylinders are constructed from aluminum.

[0178] In another embodiment, the automated thread-pulling machine, further comprising an adjustable gripper system with a lateral sliding mechanism operable via a manual knob to vary the clamping width between approximately 5 cm to 25 cm.In another embodiment, the adjustment mechanism includes visual detents or scale markings.

[0179] In another embodiment, the frame is constructed from powder-coated mild steel, the cross beam is stainless steel, and the working table surface comprises plywood laminated with mica.

[0180] In one another embodiment, the automated thread-pulling machine, operates in the following sequence:

[0181] i. loading a garment,

[0182] ii. activating the pneumatic clamp,

[0183] iii. initiating roller-based thread pull,

[0184] iv. triggering spring-based final tug, and

[0185] v. unloading the garment after thread detachment.

[0186] In another embodiment, the automated thread-pulling machine is configured to operate in a sequential manner comprising:

[0187] i. loading of the garment,

[0188] ii. engagement of the pneumatic clamping system,

[0189] iii. activation of the roller assembly for thread extraction,

[0190] iv. application of a spring-actuated final tug, and

[0191] v. unloading of the garment upon complete thread detachment.

[0192] In yet another embodiment, the present invention provides an automated thread-pulling machine for separating garment components, the machine comprising:

[0193] i. a 550-watt motor;

[0194] ii. a spring-loaded drive mechanism;

[0195] iii. a belt transmission system;

[0196] iv. a pneumatic gripping mechanism;

[0197] v. an adjustable gripper system; and

[0198] vi. a safety control feature.

[0199] In another embodiment, the present invention provides the automated thread-pulling machine, wherein, i. the 550-watt motor is operatively connected to a roller system via a 4-gear transmission assembly;

[0200] ii. the spring-loaded drive mechanism is configured to apply a controlled, soft pulling force to threads connecting garment components;

[0201] iii. the belt transmission system comprising a pair of belts (A40 and A52) and a belt tension adjuster;

[0202] iv. the pneumatic gripping mechanism which comprises six pneumatic cylinders lined with silicon rubber pads, said cylinders being operable through a valve-controlled compressed air distributor for clamping fabric during thread pulling;

[0203] v. the adjustable gripper system which comprises a lateral sliding mechanism with a manually operable knob, configured to accommodate garment widths ranging from approximately 5 cm to 25 cm; andvi. the safety control feature including an emergency stop switch for immediate machine shutdown.

[0204] In another embodiment, the pneumatic system operates at a regulated air pressure of around 5.5 bar and includes a Filter, Regulator, and Lubricator (FRL) unit.

[0205] In another embodiment, the machine is configured to process up to 80 to 100 garment components, such as collars, sleeves, or neckpieces, within a single 45-second operation cycle.

[0206] In another embodiment, the spring-loaded roller mechanism is configured to deliver a calibrated final tug upon reaching a predefined thread tension threshold, enabling clean thread separation without damaging the fabric.

[0207] In another embodiment, the modular construction comprises replaceable parts including rollers, pulleys, and motor assemblies, and supports future retrofitting with loT sensors for cycle counting, motor diagnostics, and predictive maintenance aligned with Industry 4.0 protocols.

[0208] In another embodiment, the present invention relates to an automated thread-pulling machine designed for the efficient and safe separation of garment components such as collars, sleeves, and neck pieces connected by threads. Its modular design supports easy maintenance and scalability. Additionally, the system is compatible with future loT-based upgrades for real-time diagnostics, cycle counting, and predictive maintenance, aligning it with Industry 4.0 smart manufacturing standards. This invention replaces traditional manual or sublimation-based methods, offering a safer, more cost-effective, and industrially scalable solution for garment manufacturing.

[0209] In one embodiment, the present invention relates to a control circuit implemented in an automatic thread pulling machine for garments. The machine includes mechanical, pneumatic, and spring-driven subsystems for thread separation, and the control system manages the motor responsible for roller drive. In an embodiment, the control circuitry of the present invention comprises:

[0210] a) Motor Start / Stop Push Button: This button allows the user to initiate or terminate the motor’s operation in a controlled manner.

[0211] b) Speed Regulator: An AC Variable Drive or Step-Down Voltage Regulator is used to vary the motor speed. This allows precise control over the pulling speed of the roller to suit different garment types or thread strength.

[0212] c) Emergency Stop Switch: A critical safety component that immediately disconnects power from the motor, halting the roller to prevent fabric damage or injury in case of malfunction. d) Optional Limit Switches: These can be mounted near the ends of the roller path to detect endpoint positions, halting the roller to avoid over-extension. These are envisioned for future inclusion in advanced models.

[0213] e) Optional Sensor Integration: The design accommodates future addition of sensors for:

[0214] o Detecting thread tensiono Monitoring garment alignment

[0215] These sensors may feed data to a microcontroller or Programmable Logic Controller (PLC) to allow semi-automated thread pulling operations and real-time error correction.

[0216] In one of the embodiments of the present invention, a machine is designed to automate the process of thread pulling for garment separation by the following key components:

[0217] a) Motor and Spring-Loaded Roller System: A motor drives the roller that initially engages the thread. A spring mechanism provides a final tension-based pull once thread tension reaches a threshold, enabling clean thread breakage.

[0218] b) Pneumatic Clamping System: Multiple pneumatic cylinders fitted with grippers clamp the garment securely onto the table surface to prevent displacement during the pulling operation. c) Gripper Adjustment Mechanism: A lateral sliding system enables grippers to be moved across a width of approximately 5-25 cm. A manual knob allows fine control, and detents or scale markers ensure repeatable positioning.

[0219] In yet another embodiment, the present invention provides that an automatic thread pulling machine includes:

[0220] a) Frame and Stand;

[0221] b) Table Surface;

[0222] c) Pulleys;

[0223] d) Pneumatic Cylinder;

[0224] e) Polyurethane (PU) air pipe;

[0225] f) Hand lever valve; and

[0226] g) Filter, regulator, and lubricator (FRL) unit

[0227] In an embodiment, the pneumatic cylinders in the machine of the present invention employs to clamp the cloth down, for effective and easy separation of the string.

[0228] In an embodiment, the polyurethane (PU) air pipes are around 5cm to 8cm thick and PU pipes in the present machine is employed to supply compressed ait to cylinder.

[0229] In an embodiment, the Hand Lever valve in the machine of the present invention employs for operating the cylinders to move up and down by regulating air flowing through the polyurethane (PU) pipes, i.e., when open, air flows through, going to the cylinders, and thereby holding down the cloth and when closed, air is discharged out, and cylinders remain up.

[0230] In an embodiment, the filter, regulator, and lubricator (FRL) unit in the machine of the present invention employs regulation of pressure, removal of water and particles from air and lubricates it.

[0231] In one of the embodiments, the present invention provides that the frame and stand is constructed from mild steel, providing the structural integrity needed for industrial use.In one of the embodiments, the present invention provides user / worker safety, as it prevents users / workers from getting cuts on their hands / fingers, as due to the high tension, while pulling manually, the friction led to cause cuts on the hands / fingers of the user or workers.

[0232] In one of the embodiments, the present invention provides that the Table surface is made from plyboard laminated with mica, ensuring a smooth, durable surface for garment handling.

[0233] In one of the embodiments, the present invention provides that the pulleys are made from mild steel, ensuring reliable transmission of motor power to the rollers.

[0234] In one of the embodiments, the present invention provides that the pneumatic cylinder is of Aluminum construction, offering lightweight yet strong performance for the roller system.

[0235] In an embodiment, the present invention provides an automatic thread pulling machine, which comprises:

[0236] a) a power system,

[0237] b) a belt transmission system,

[0238] c) a roller system,

[0239] d) a gripper system,

[0240] e) a pneumatic actuation system,

[0241] In an embodiment, the present invention provides an automatic thread-pulling machine, which comprises:

[0242] a) a power system configured to provide rotational drive to operate the machine, wherein the power system may include a motor capable of adjustable speed and torque;

[0243] b) a transmission system, comprising one or more pulleys or similar rotational drive elements interconnected by flexible belts or equivalent mechanical linkages, optionally including a tensioning mechanism to maintain proper engagement and reduce slippage;

[0244] c) a roller system driven by the transmission system, wherein the rollers are adapted to engage threads or fabric, optionally incorporating spring-loading or other compliant mechanisms to allow controlled engagement and reduce the risk of thread or fabric damage;

[0245] d) a gripper system configured to hold garment components, wherein the grippers may include friction-enhancing surfaces and be mounted on an adjustable support structure, allowing lateral or positional adjustment to accommodate different component sizes;

[0246] e) an actuation system for the grippers, which may include one or more pneumatic, hydraulic, or electromechanical actuators, together with suitable control valves, pressure regulation units, and fluid distribution channels to control the movement of the grippers during operation. In another embodiment, the present invention provides an automatic thread pulling machine, which comprises:

[0247] a) a power system, wherein the power system includes a 550-watt servo motor configured to provide rotational drive with adjustable speed and torque for operating the machine;b) a belt transmission system, comprising a plurality of pulleys including a 350 mm pulley, a 250 mm pulley, and two 50 mm pulleys, interconnected via A52 and A40 belts, and further comprising a belt tensioner for maintaining tension and reducing belt slippage;

[0248] c) a roller system, wherein the roller is driven by the belt transmission system and includes rivets for mechanical engagement with the thread or fabric, and is further spring-loaded to enable soft engagement and disengagement, thereby reducing the risk of thread breakage;

[0249] d) a gripper system, comprising grippers lined with silicon rubber for increased friction, adjustable heads mounted on a cross beam, and a manual knob for lateral adjustment of the grippers to match different component widths;

[0250] e) a pneumatic actuation system, comprising a plurality of pneumatic cylinders for the upward and downward actuation of the grippers, a valve system for controlling airflow, an FRL unit to regulate air pressure at approximately 5.5 bar, a source of compressed air such as an air compressor (centralized or standalone), and a network of PU pipes for air distribution.

[0251] Working Mechanism:

[0252] In an embodiment, the present invention provides that an automatic thread pulling machine comprising a power system, belt transmission system, gripper mechanism, roller mechanism, and pneumatic actuation system, all operatively interconnected to perform synchronized thread-pulling operations on garment components.

[0253] 1. Power System

[0254] The machine utilizes a high-performance 550-watt servo motor, which serves as the primary power source for the thread pulling operation. This motor is precisely regulated via a speed control system, allowing for dynamic adjustment of torque and rotational speed. The servo motor ensures consistent and reliable torque output, essential for continuous industrial operation.

[0255] The motor’s output is transmitted through a pulley-based reduction system, which converts the highspeed rotation into a lower-speed, high-torque output. This configuration ensures optimal pulling force while maintaining the structural integrity of the garment and threads.

[0256] 2. Belt Transmission System

[0257] The belt transmission system connects the servo motor to the roller assembly via a series of pulleys, which include:

[0258] • One 350 mm diameter pulley

[0259] • One 250 mm diameter pulley

[0260] • Two 50 mm diameter pulleys

[0261] These pulleys are interconnected using industrial-grade A40 and A52 belts, which ensure strong mechanical coupling and operational durability.

[0262] A built-in belt tensioner maintains proper belt alignment and tension, minimizing slippage under high-torque conditions. The pulley arrangement enables a mechanical reduction that reduces the motor’s output speed and proportionally increases the torque transmitted to the roller. This system supports safe and efficient thread extraction, particularly in operations requiring repeated cycles over extended durations.

[0263] 3. Gripper MechanismThe gripper mechanism consists of adjustable gripping heads lined with high-friction silicon rubber. These gripping heads are mounted on a cross beam and are responsible for holding garment components such as collars and sleeves firmly during thread-pulling operations.

[0264] The system includes a manual lateral adjustment knob, enabling operators to reposition each gripper to accommodate different garment widths. The grippers are modular in design, allowing flexibility in placement and interchangeability. The movable gripper mounts provide adaptability for diverse production needs, accommodating a range of fabric types and component sizes.

[0265] 4. Roller Mechanism

[0266] At the core of the thread-pulling process lies a spring-loaded roller, which features a riveted surface designed for enhanced grip on the threads. This roller is driven by the aforementioned belt and pulley system and is responsible for applying controlled traction to pull threads from garments.

[0267] The inclusion of a spring-loading system ensures that the roller engages and disengages with the fabric gently and progressively, avoiding sudden jerks or thread snapping. This soft start and end motion is critical for maintaining the quality and appearance of delicate fabric materials during processing. 5. Pneumatic System

[0268] The pneumatic system powers six vertically actuated pneumatic cylinders, which function to press down garment components against the grippers during thread-pulling.

[0269] The system comprises:

[0270] • A valve and distributor assembly for controlling the actuation of each cylinder

[0271] • A centralized or standalone air compressor as the air source

[0272] • A Filter-Regulator-Lubricator (FRL) unit, which maintains air pressure at approximately 5.5 bar and ensures that the compressed air is clean, dry, and lubricated for consistent actuator performance

[0273] • A network of PU (polyurethane) pipes for distributing compressed air efficiently throughout the system

[0274] This configuration ensures responsive pneumatic actuation with minimal delay or pressure loss, contributing to the machine’s overall performance and cycle accuracy.

[0275] In summary, this embodiment of the automatic thread pulling machine offers a coordinated mechanical and pneumatic solution for thread separation applications in garment manufacturing. The integrated systems provide controlled force, precision gripping, smooth thread engagement, and high repeatability, making the machine suitable for industrial-scale textile processing.

[0276] Motor- to-Roller Drive Mechanism:

[0277] In an embodiment, the present invention provides that at the core of the machine is a powerful 550-watt motor, which drives a series of rollers responsible for pulling the threads connecting the garment components. The motor’s torque is transmitted to the rollers through a system of mild steel pulleys, ensuring smooth and controlled rotation. The rollers are designed to grip the thread securely, and the motor’s speed ensures that the process is completed within the targeted 45 -second cycle for 80 to 100 garment components.In an embodiment, the invention provides an automatic thread pulling machine comprising a motor drive mechanism and a gripping system designed to ensure precise, torque-controlled pulling of cotton threads without breakage, suitable for applications such as textile finishing or collar thread trimming.

[0278] Motor Drive Mechanism

[0279] In an embodiment, the machine is powered by a 550W electric motor, which is integrated with a variable speed control unit. This control system enables precise modulation of the motor’s output speed, thus allowing the operator to adapt the pulling force based on the type of thread or material being processed.

[0280] The motor is connected to the main roller assembly via a four-pulley transmission system. This system achieves a mechanical reduction ratio of approximately 35:1, significantly enhancing the torque output to provide sufficient force required for pulling threads from garments or fabric without causing breakage.

[0281] In an embodiment, the pulleys are coupled using two belts (Figure 7):

[0282] • Belt 1: Size A40

[0283] • Belt 2: Size A52

[0284] To maintain consistent engagement and prevent slippage during operation, the pulley system includes a belt tensioner. The tensioner dynamically adjusts to compensate for any slack or stretch in the belts, ensuring stable transmission throughout the working cycle.

[0285] Furthermore, the drive assembly is spring-loaded, allowing for a gradual engagement and disengagement of pulling force at both the initiation and termination of the thread pulling operation. This feature provides a soft start and stop, effectively reducing the risk of thread breakage, particularly with delicate or fine cotton threads.

[0286] Gripping Mechanism:

[0287] The thread pulling mechanism includes a gripping system actuated via pneumatic cylinders, which are powered by compressed air. The air supply is sourced either from a centralized compressor system or a standalone air compressor, depending on the installation requirements.

[0288] Air pressure is regulated via a Filter-Regulator-Lubricator (FRL) unit, which maintains the air pressure at 5.5 bar. A dedicated valve manifold is used to control up to six pneumatic cylinders, providing synchronized actuation for the gripping units.

[0289] The machine further includes a compressed air distributor that ensures uniform air delivery to each cylinder, optimizing the performance of the gripping mechanism.Each gripper is lined with high-friction silicone rubber, providing superior grip on textile components, especially in applications involving collars or folded fabrics. The high-friction surface ensures that components remain securely pressed and do not slip out during thread pulling.

[0290] Further, an adjustable knob mechanism is incorporated to allow lateral movement of the gripper assembly. This adjustability enables the machine to accommodate components of varying widths, ensuring versatility across different product lines or fabric types.

[0291] Operational Summary:

[0292] During operation, the motor initiates rotation of the roller at a torque -optimized speed. The fabric or component is secured in place using the silicone-lined grippers. The controlled torque output combined with spring-loaded force application ensures that threads are pulled smoothly and efficiently, without damaging the fabric. Pneumatic control allows for quick clamping and releasing of components, enabling high throughput and precision in repetitive industrial applications.

[0293] In an embodiment, the present invention provides an automated thread-pulling machine for separating garment components, the machine comprising:

[0294] i. a 550-watt motor operatively connected to a roller system via a 4-gear transmission assembly configured to reduce speed and enhance torque output;

[0295] ii. a spring-loaded drive mechanism configured to apply a controlled, soft pulling force to threads connecting garment components;

[0296] iii. a belt transmission system comprising a pair of belts (A40 and A52) and a belt tension adjuster configured to maintain belt grip and prevent slippage under load;

[0297] iv. a pneumatic gripping mechanism comprising six pneumatic cylinders lined with silicon rubber pads, said cylinders being operable through a valve-controlled compressed air distributor for clamping fabric during thread pulling;

[0298] v. an adjustable gripper system comprising a lateral sliding mechanism with a manually operable knob, configured to accommodate garment widths ranging from approximately 5 cm to 25 cm; and

[0299] vi. a safety control feature including an emergency stop switch for immediate machine shutdown.

[0300] Thread Separation and Spring Reaction Mechanism:

[0301] In another embodiment, the invention emphasizes the spring reaction mechanism as one of the most innovative features of the automated machine. This mechanism enables precise and efficient removal of threads without harming the fabric. By adjusting to the tension that arises as the thread moves through the rollers, it ensures the separation process is smooth, consistent, and clean.

[0302] Working:In another embodiment, the present invention provides that as the garment components pass through the machine, the motor-driven rollers begin to pull the threads that connect these components. Over the course of the pulling process, the tension in the thread gradually increases. The key to efficient and damage-free thread separation is controlling this tension and releasing it at the right moment, which is exactly what the spring reaction mechanism accomplishes.

[0303] When the tension in the thread reaches a critical threshold, indicating that the thread is fully stretched and ready to be separated, the spring mechanism is triggered. The spring absorbs the excess tension and, once the threshold is exceeded, releases it in a controlled manner. This release provides a final, gentle tug on the thread, ensuring that it is completely removed from the garment without causing any tearing, fraying, or other damage to the fabric.

[0304] Response to Excessive Tension:

[0305] In another embodiment, the present invention provides that the machine is specifically designed to recognize when too much tension builds up in the thread. This is particularly important for delicate fabrics, where excessive pulling force could cause significant damage. As the tension reaches the preset threshold, the spring mechanism responds by releasing just enough of the built-up tension to complete the separation process without applying excessive force to the garment itself. This ensures that the fabric remains intact, even when processing sensitive materials like silk, chiffon, lace, or fine cotton.

[0306] The spring reaction mechanism effectively acts as a safeguard, ensuring that no excessive force is applied to the fabric at any point during the process. This makes the machine especially valuable in high-end garment production, where precision and fabric care are of utmost importance.

[0307] In another embodiment, the present invention provides that the key advantage of the spring reaction mechanism is its adjustability. Operators can fine-tune the tension threshold based on the specific characteristics of the fabric and the thread being processed. For example, when handling thicker or heavier fabrics, such as denim or wool, etc. the tension threshold can be increased to ensure the thread is pulled with the necessary force. Conversely, when processing more delicate fabrics, the tension threshold can be lowered to prevent any risk of damage.

[0308] This adjustability makes the machine versatile and capable of handling a wide range of garment types and fabric weights. Whether processing lightweight fabrics for summer garments or more robust materials for winter wear, the machine’s spring mechanism ensures that the process is optimized for each specific application.

[0309] In yet another embodiment, the spring reaction mechanism dynamically adapts to variations in thread thickness, type, and tension, ensuring a consistent, smooth, and clean separation process. By maintaining optimal thread engagement with the rollers and the gripper mechanism, the spring reaction system reduces the likelihood of thread breakage or fabric deformation, thereby improving the overall reliability, efficiency, and throughput of the machine. The mechanism also allows for adjustablecalibration, providing versatility across different garment types and post-production requirements, making it a significant advancement over conventional thread-removal systems.

[0310] In another embodiment, the present invention provides that the spring reaction mechanism not only protects the fabric but also ensures consistency in the thread removal process. In traditional manual methods, workers may apply varying amounts of force when pulling threads, leading to inconsistent results and an increased risk of fabric damage. With this automated system, the same amount of force is applied to each garment component, ensuring that threads are removed uniformly across the entire batch.

[0311] This consistent application of force also contributes to the machine’s efficiency. By automatically responding to tension and releasing it when necessary, the machine can operate at high speeds without compromising the quality of the garment. This combination of speed, precision, and care makes the machine ideal for large-scale garment production where efficiency and quality are equally important. Another important embodiment of the spring reaction mechanism is its ability to prevent thread breakage. In manual thread-pulling processes, threads can often break prematurely due to excessive force, leaving remnants attached to the garment. These remnants then require additional manual intervention to remove, which slows down the production process. The spring mechanism in this machine minimizes the risk of thread breakage by releasing the tension gradually, ensuring that the thread is pulled completely and cleanly without snapping.

[0312] In an embodiment, the present invention provides that the versatility of the spring reaction mechanism makes it applicable across a wide range of garment types and production environments. Whether separating the collars of formal shirts, the sleeves of jackets, or the necklines of dresses, the spring mechanism ensures that the thread removal process is both efficient and fabric friendly.

[0313] For high-end fashion designers, where delicate fabrics and intricate stitching are common, this mechanism is invaluable. It guarantees that the garments maintain their structural integrity throughout the production process. On the other hand, for mass-market manufacturers, the mechanism provides the speed and efficiency required to keep up with high production volumes while ensuring consistent quality.

[0314] In yet another embodiment, the present invention provides that the machine is designed to handle large batches, processing up to 80 to 100 garment components such as collars or sleeves, etc. in a single cycle. Each cycle takes approximately 45 seconds, making the machine highly efficient for industrial-scale production.

[0315] In another embodiment, the present invention provides that the 550-watt motor provides sufficient power to drive the entire machine’s operations, including the roller system and spring reaction mechanism. This power specification was chosen to balance the need for high processing speeds with energy efficiency, ensuring the machine operates at optimal performance levels without excessive power consumption.In another embodiment, the present invention provides that the safety is a key consideration in the machine's design. The emergency stop switch allows operators to immediately halt the machine in case of a malfunction or unexpected issue. This ensures that any potential hazards are mitigated promptly, reducing the risk of injury to workers or damage to the machine and garments.

[0316] One of the advantages of the machine of the present invention is the replaceability of key components. The rollers, motor, and pulleys are all modular, allowing for quick replacements in case of wear or damage. This modular design minimizes downtime, ensuring that the machine remains operational with minimal interruptions. Maintenance requirements are low, with the machine only needing to be oiled once a year.

[0317] In an embodiment, the automated thread-pulling machine is configured to provide:

[0318] 1. Modular Adaptability

[0319] • The machine features a modular mechanical structure that allows installation of devices to monitor and control physical parameters, such as:

[0320] o Load sensors for measuring thread tension,

[0321] o Counters for tracking operational cycles, and

[0322] o Temperature and current sensors for motor performance monitoring.

[0323] • These devices directly influence the mechanical operation of the machine, enabling timely maintenance, optimized performance, and reliable fault detection.

[0324] 2. Industrial Process Integration

[0325] • The machine is designed to interface with manufacturing systems through standardized industrial connectors, facilitating coordinated operation within production lines,

[0326] • It allows tracking of garments or components via physical identifiers such as QR or NFC tags, • Operational measurements from the machine are used to adjust mechanical parameters and improve efficiency, ensuring consistent thread removal and overall process reliability.

[0327] Material Construction:

[0328] In yet another embodiment, the present invention provides that the machine is constructed from durable, high-quality materials to ensure longevity and reliable operation in industrial settings.

[0329] The key components of the machine include:

[0330] a) Frame and Stand: Constructed from mild steel, providing the structural integrity needed for industrial use.

[0331] b) Table Surface: Made from plyboard laminated with mica, ensuring a smooth, durable surface for garment handling.

[0332] c) Pulleys: Made from mild steel, ensuring reliable transmission of motor power to the rollers. d) Pneumatic Cylinder: Aluminum construction, offering lightweight yet strong performance for the roller system.

[0333] These materials are chosen to ensure industrial durability, ease of cleaning, and operational stability in repetitive production environments.Industrial Applications:

[0334] The automatic thread pulling machine of the present invention is highly versatile, capable of processing various garment components. Its primary applications include:

[0335] Shirt Collars: Separating shirt collars bound by thread in production.

[0336] Neck Collars: Processing neck collars in different types of garments.

[0337] Sleeves: Pulling threads to separate sleeves from other components.

[0338] The present invention significantly advances the state of the art by offering modularity and smart manufacturing compatibility. In contrast to existing manual or semi-automated solutions, the inventors of the present invention designed an automated machine to support future retrofitting with loT-based smart sensors, thereby enabling:

[0339] • Cycle counting and productivity monitoring,

[0340] • Real-time diagnostics of critical components such as the motor, pneumatic systems, and control unit,

[0341] • Predictive maintenance through data-driven analysis of usage patterns and wear indicators. This makes the machine future-proof and capable of seamless integration into Industry 4.0 smart factory environments. With data collection and remote access, it enables centralized production oversight and decision-making, reducing downtime and improving operational efficiency.

[0342] Compared to the prior art, which either lacks automation or uses resource-intensive sublimation methods, the invention introduces a safe, scalable, and digitally compatible alternative for garment thread separation.

[0343] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the inventive embodiments described herein.

[0344] More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the inventive teachings is / are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein.

Claims

We Claim:

1. An automatic thread-pulling machine for separating garment components, comprising:a) a motor;b) a safety mechanism;c) a modular design with replaceable components;d) a spring reaction mechanism; ande) a pneumatic system;wherein, the machine is capable of processing up to around 80 to 100 garment components in around 45-second cycle.

2. The automatic thread-pulling machine as claimed in claim 1 or 2, comprising:a) a motor that is operatively coupled to a roller system via a motor-to-roller drive system; b) a safety mechanism which includes an emergency stop switch;c) a modular design with replaceable components, including at least one of the rollers, motor, and pulleys;d) a spring reaction mechanism for applying calibrated force during thread pulling without damaging fabric; ande) a pneumatic system comprising one or more pneumatic cylinders, a polyurethane (PU) air pipe, a hand lever valve, and a filter, regulator, and lubricator (FRL) unit,wherein, the pneumatic system actuates the garment hold-down mechanism during operation.

3. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the motor is a 550- watt servo motor configured to deliver torque.

4. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the roller system comprises spring-loaded rollers configured to pull and remove threads connecting garment components.

5. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the pneumatic cylinders are configured to clamp the garment components during thread pulling.

6. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the PU air pipes have a diameter ranging from 5 cm to 8 cm and deliver compressed air to the pneumatic cylinders.

7. The automatic thread-pulling machine as claimed in claim 1 or 2, further comprising a frame and stand made of mild steel, providing structural integrity for industrial operations.

8. The automatic thread-pulling machine as claimed in claim 1 or 2, further comprising a table surface made of plyboard laminated with mica, providing a smooth and durable surface for garment handling.

9. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the pulleys are made from mild steel and configured to transmit motor power reliably to the roller system.

10. The automatic thread-pulling machine as claimed in claim 1 or 2, wherein the pneumatic cylinders are constructed from aluminum for lightweight and durable performance.

11. An automatic thread-pulling machine comprising:a) a motor;b) a roller drive system driven by the motor; andc) a control circuitry configured to regulate motor operation,12. The automatic thread-pulling machine as claimed in claim 11, wherein, the control circuitry comprises:i. a motor start / stop push button;ii. a speed regulator selected from an AC variable drive or step-down voltage regulator;iii. an emergency stop switch that disconnects motor power during malfunction; andiv. optionally, includes one or more limit switches for detecting roller endpoint positions;and sensors for monitoring thread tension or garment alignment.

13. An automated thread-pulling machine for separating garment components, comprising: a) a motor;b) a spring-loaded roller system driven by said motor for pulling threads; andc) at least one pneumatic cylinder with fabric-gripping heads for clamping garment components during thread pulling;wherein, the spring-loaded mechanism applies a final pulling force based on thread tension buildup to effectuate thread separation.

14. The automated thread-pulling machine as claimed in claim 13, wherein the pneumatic cylinders are constructed from aluminum.

15. The automated thread-pulling machine as claimed in claim 13, further comprising an adjustable gripper system with a lateral sliding mechanism operable via a manual knob to vary the clamping width between approximately 5 cm to 25 cm.

16. The automated thread-pulling machine as claimed in claim 15, wherein the adjustment mechanism includes visual detents or scale markings.

17. The automated thread-pulling machine as claimed in claim 13, wherein the frame is constructed from powder-coated mild steel, the cross beam is stainless steel, and the working table surface comprises plywood laminated with mica.

18. The automated thread-pulling machine as claimed in claim 13, wherein the sequence of operation includes:i. loading a garment,ii. activating the pneumatic clamp,iii. initiating roller-based thread pull,iv. triggering spring-based final tug, andv. unloading the garment after thread detachment.

19. An automated thread-pulling machine for separating garment components, the machine comprising:i. a 550-watt motor;ii. a spring-loaded drive mechanism;iii. a belt transmission system;iv. a pneumatic gripping mechanism;v. an adjustable gripper system; andvi. a safety control feature.

20. The automated thread-pulling machine, as claimed in claim 19, wherein,i. the 550-watt motor is operatively connected to a roller system via a 4-gear transmission assembly;ii. the spring-loaded drive mechanism is configured to apply a controlled, soft pulling force to threads connecting garment components;iii. the belt transmission system comprising a pair of belts (A40 and A52) and a belt tension adjuster;iv. the pneumatic gripping mechanism which comprises six pneumatic cylinders lined with silicon rubber pads, said cylinders being operable through a valve-controlled compressed air distributor for clamping fabric during thread pulling;v. the adjustable gripper system which comprises a lateral sliding mechanism with a manually operable knob, configured to accommodate garment widths ranging from approximately 5 cm to 25 cm; andvi. the safety control feature including an emergency stop switch for immediate machine shutdown.

21. The automated thread-pulling machine as claimed in claim 19 or 20, wherein the pneumatic system operates at a regulated air pressure of around 5.5 bar and includes a Filter, Regulator, and Lubricator (FRL) unit.

22. The automated thread-pulling machine as claimed in claim 19 or 20, wherein the machine is configured to process up to 80 to 100 garment components, such as collars, sleeves, or neckpieces, within a single 45-second operation cycle.

23. The automated thread-pulling machine as claimed in claim 19 or 20, wherein the spring-loaded roller mechanism is configured to deliver a calibrated final tug upon reaching a predefined thread tension threshold, enabling clean thread separation without damaging the fabric.

24. The automated thread-pulling machine as claimed in claim 19 or 20, wherein the modular construction comprises replaceable parts including rollers, pulleys, and motor assemblies, and supports future retrofitting with loT sensors for cycle counting, motor diagnostics, and predictive maintenance aligned with Industry 4.0 protocols.

25. A method for automated thread removal from garment components, comprising the steps of:a) loading a garment component onto a support platform;b) securing the garment component using a gripper assembly;c) actuating a roller assembly to engage threads connecting the garment components; d) applying controlled tension to the threads via a spring-loaded mechanism;e) releasing the threads in a controlled manner once a predetermined tension threshold is reached; andf) unclamping and unloading the garment component,wherein the steps are performed in a synchronized manner to ensure precise thread removal without damaging the garment.

26. The method of claim 25, wherein the gripper assembly is actuated using pneumatic, hydraulic, or electromechanical cylinders.

27. The method of claim 25 or 26, wherein the roller assembly is driven by a motor through a transmission system comprising pulleys and belts.

28. The method of claim 27, wherein the motor speed and torque are adjustable to accommodate different thread types and fabric materials.

29. The method of any of claims 25-28, wherein the spring-loaded mechanism provides a final calibrated tug on the threads after passage through the rollers.

30. The method of any of claims 25-29, further comprising adjusting the gripper assembly laterally to accommodate garment components of varying widths.

31. The method of claim 30, wherein the lateral adjustment is performed via a manually operated knob.

32. The method of any of claims 25-31, further comprising monitoring the thread tension and fabric integrity using sensors.

33. The method of claim 32, wherein data from the sensors is used for predictive maintenance or operational analytics.

34. The method of any of claims 25-33, wherein the cycle time for processing 80 to 100 garment components is approximately 45 seconds.

35. The method of any of claims 25-35, wherein the roller assembly is spring-loaded to provide gradual engagement and disengagement with the threads.

36. The method of any of claims 25-35, further comprising stopping the machine immediately in response to an emergency stop signal.

37. The method of any of claims 25-36, wherein the steps are executed in a factory-scale production line integrated with Industry 4.0 systems for real-time monitoring and control.

38. The method of any of claims 25-37, further comprising replacing modular components of the machine such as rollers, belts, pulleys, or motors to minimize downtime.

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