Bag Envelope Sewing Machine With Sensor-Guided Seam Placement
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Solution Overview
Problem
Existing sewing machines for bag envelopes require manual operation, leading to inconsistent seam quality, increased production costs due to human error, and machine downtime, which affects productivity and efficiency.
Innovation Solution
A sewing machine equipped with a sewing head, grippers, and sensors that automate the sewing process, ensuring consistent seam placement and quality by detecting envelope edges and adjusting the sewing path using programmable logic controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used to position and sew envelope flaps, then the operator can handle the envelope directly, but the seam quality becomes inconsistent and positioning errors occur
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated system comprising a sewing head mounted on a movable carriage, sensor means for detecting envelope edges, and programmable logic controllers. The sewing head is automatically positioned relative to the envelope flaps through coordinated movement of the carriage along guides, eliminating manual positioning errors while maintaining operational capability.
2Manufacturing precision
If automated sewing is implemented, then seam consistency improves, but device complexity increases
Solution Approach 1:
The automated sewing system is divided into functionally independent modules: a sewing head unit, a movable carriage with sensor means, envelope holding means, and control systems. Each module can be adjusted, maintained, or replaced independently, reducing the impact of complexity on overall system maintenance and operation.
Solution Approach 2:
The sewing head and carriage assembly are designed to accommodate different envelope sizes and configurations through programmable control. The same hardware infrastructure can sew various flap arrangements by changing control parameters, reducing the need for multiple specialized devices.
3Ease of manufacture
If manual positioning is used, then setup is simple, but production speed decreases due to errors and redoing
Solution Approach 1:
The system performs preliminary detection of envelope edge positions using sensor means before the sewing operation begins. The programmable logic controller pre-calculates the optimal sewing path based on detected positions, allowing the sewing head to be quickly positioned without trial-and-error adjustments, thereby maintaining simple setup while increasing production speed.
4Measurement precision
If automated movement is implemented, then positioning accuracy improves, but maintenance requirements increase
Solution Approach 1:
The sensor means are designed to automatically detect and adapt to variations in envelope positioning and dimensions without requiring manual recalibration. The programmable logic controller continuously monitors sensor feedback and adjusts sewing parameters in real-time, enabling the system to maintain precision while reducing the frequency and complexity of maintenance interventions.
Data Source
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AI summary
Machine for sewing envelopes (100) into pouches, in correspondence with an opening delimited by two free overlapping flaps (101), which machine (1) includes a support base (2); a sewing head (3) mechanically mounted on said support base (2), configured to make a sewing line along a sewing direction; retaining means (4) for retaining said free flaps (101) of said envelope (100) like a bag; first movement means (5) for realizing a relative movement between said sewing head (3) and said holding means (4) along a first movement direction (X) substantially parallel to said sewing line; second movement means (6) for moving said sewing head (3) and / or said holding means (4) at least along a second movement direction (Y) orthogonal with respect to said first movement direction (X); at least a first sensor (8) configured to detect an extremal edge of said free edges (101); at least one electronic control unit for generating said relative motion between said support base (2) and / or said holding means (4) along said second movement direction (Y) at least for a predetermined length and to control said first means of movement (5) and said second movement means (6) to generate a relative movement between said sewing head (3) and said holding means (4) along said first movement direction (X) and said second movement direction ( Y) in such a way that said sewing line is made at a substantially constant distance with respect to said extremal edge of said free edges (101) and preferably at a distance substantially equal to said predetermined portion.