Adjustable-Shape Fixtures for Layer Alignment in Stitching
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Solution Overview
Problem
Assembling layers of material, such as fabric or leather, into items like electronic device covers is challenging due to difficulties in aligning layers and forming joints, which can hamper the assembly process.
Innovation Solution
The use of adjustable-shape fixtures with computer-controlled positioning equipment to align and shape layers with holes, followed by stitching with a computer-controlled stitching head to form seams between the layers, allowing for precise alignment and joining of fabric or leather layers with holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed fixtures are used for assembly, then the device structure is simple, but the manufacturing precision and alignment accuracy of fabric layers deteriorate
Solution Approach 1:
The patent applies the dynamics principle by transforming fixed fixtures into adjustable-shape fixtures that can dynamically change their configuration. The fixtures include movable links and positioning elements that can be repositioned to match different fabric layer shapes and sizes, enabling precise alignment for various assembly requirements while maintaining a relatively simple base structure.
Solution Approach 2:
The patent implements parameter changes by allowing the fixtures to modify their geometric parameters (position, orientation, shape) to accommodate different fabric layers. The adjustable positioning elements can be moved to different locations and configured in various orientations, enabling the same fixture to achieve high manufacturing precision for multiple different assembly scenarios.
2Manufacturing precision
If adjustable-shape fixtures are used to transform layer shapes, then the manufacturing precision and alignment improve, but the device complexity and operation complexity increase
Solution Approach 1:
The adjustable-shape fixtures serve multiple functions: they can hold fabric layers in various positions, transform layers into different shapes, provide alignment references for stitching, and accommodate different layer configurations. This multi-functionality reduces the need for multiple specialized fixtures, thereby managing operation complexity while maintaining high manufacturing precision.
Solution Approach 2:
The fixtures are divided into modular components including multiple links, positioning elements, and support structures that can be independently adjusted. This segmentation allows operators to modify only the necessary portions of the fixture for each specific assembly task, reducing the overall operation complexity while maintaining precise alignment capabilities.
3Manufacturing precision
If computer-controlled positioning equipment is used to adjust fixture shapes, then the manufacturing precision and alignment accuracy improve, but the device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical control systems with a hybrid approach that uses computer-controlled positioning equipment in conjunction with mechanically adjustable fixtures. The control system provides precise positioning commands, but the actual shape transformation is achieved through mechanically actuated links and positioning elements, reducing the overall control system complexity while maintaining high manufacturing precision.
Data Source
AI summary
An item may be formed from structures that include holes. Stitching may be used to form a seam that joins the structures. The stitching may be formed from a chain stitch that passes through the holes. The holes may be formed from loops of knit fabric or other holes. Leather layers, polymer layers, fabric layers, and other structures with holes may be joined using the stitching. During fabrication, a layer of material with holes may be placed on an adjustable-shape fixture having a bed of needles. The shape of the bed of nails in the adjustable-shape fixture may then be changed. After the fixture has been used to transform the shape of one or more of the structures, the structures may be placed on needles in an assembly fixture and the stitching between the structures may be formed. The item may be an electronic device cover or other item.