3D Component Stitching Head for Single-Side Complex Trim Sewing
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Solution Overview
Problem
Existing methods for applying decorative stitching on three-dimensional automotive trim components are labor-intensive, costly, and limited by the need for access to both sides of the part, making it difficult to place stitches on complex surfaces like brows, sharp corners, and small radii.
Innovation Solution
A stitching apparatus with a needle bar assembly, looper, and post assembly driven by a motor, allowing for reciprocating motion in a plane parallel to the component, enabling stitches to be applied from a single side and accommodating complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stitching methods are used on 3D components, then functional stitching can be achieved, but the process becomes labor intensive and costly
Solution Approach 1:
The patent applies simulated stitching that visually replicates the appearance of traditional functional stitching without requiring actual needle and thread penetration. This copying approach maintains the aesthetic quality and perceived functionality while eliminating the labor-intensive manual stitching process, thereby improving productivity without sacrificing the visual reliability of the stitching appearance
2Ease of manufacture
If access to both front and backside of the part is required for stitching, then traditional stitching can be applied, but stitch placement on complex surfaces is limited
Solution Approach 1:
The patent transitions from requiring access to both front and back sides of the component to achieving stitching effects from a single-sided approach. By using simulated stitching techniques that don't require needle penetration through the material, the system gains freedom to place stitches on complex surfaces, brows, sharp corners, and highly contoured areas without being constrained by the need to access both sides of the part
3Device complexity
If stitch plate depth requirements are predefined, then existing machines can operate, but conforming to small radii is precluded
Solution Approach 1:
The patent employs simulated stitching that eliminates the physical constraints of stitch plate depth requirements. By changing the fundamental parameter from mechanical needle penetration with fixed plate depth to a simulated appearance method, the system can adapt to small radii and highly contoured surfaces without being limited by predefined machine configurations
4Productivity
If simulated stitching is used, then production feasibility is improved, but contrasting color stitch capability is not available
Solution Approach 1:
The patent enhances the simulated stitching system to provide multi-functionality by enabling contrasting color stitch capability. The simulated stitching approach can now accommodate multiple thread colors and patterns, allowing the same production-feasible method to deliver both high productivity and color variety, thus resolving the limitation of single-color simulated stitching
Data Source
AI summary
An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. A head for applying stitches to a decorative component having a three dimensional configuration, including: a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion, the post assembly being operatively coupled to the head via a cylinder arm assembly and a downshaft assembly; and wherein the cylinder arm assembly is rotated in a synchronized manner with a rock frame through mechanical linkage connecting a rock frame drive shaft to the cylinder arm assembly.