Apparatus and method for continuous detection and cutting of fabric for items of clothing
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Solution Overview
Problem
Current fabric cutting machines for striped and/or checked patterns in clothing production are inefficient due to operator-dependent error-prone detection and sequential photography, cutting, and detection processes, leading to inaccuracies and prolonged production times.
Innovation Solution
A continuous detection and cutting system that uses a processing unit to compare theoretical and effective pattern points, allowing for simultaneous detection and cutting of fabrics, with a cutting head guided by a two-dimensional guide to ensure precise alignment and minimize operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operator manually selects pattern points using mouse after photographing fabric samples, then detection accuracy can be maintained, but production time increases dramatically and errors remain inevitable
Solution Approach 1:
The system performs automatic detection of pattern meeting points through computer vision algorithms, eliminating the need for operator intervention. The detection system independently identifies and selects pattern points without human assistance, achieving both high accuracy and fast processing speeds simultaneously
Solution Approach 2:
The manual mechanical operation of using a mouse to select points is replaced by an automated optical detection system with image processing algorithms. The system captures fabric images and automatically identifies pattern meeting points through computational methods, substituting human manual selection with automated digital processing
2Manufacturing precision
If sequential operations of photographing, operator selection, and cutting are used, then each operation can be performed carefully, but total execution time becomes dramatically slow
Solution Approach 1:
The system enables continuous operation where fabric feeding, pattern detection, and cutting operations proceed without interruption. The automated detection system processes patterns in real-time as fabric moves through the system, eliminating idle time between sequential operations and maintaining continuous productive action throughout the entire workflow
Solution Approach 2:
The system performs pattern detection and meeting point identification in advance before the cutting operation begins. By pre-processing the fabric pattern recognition and calculating optimal cut positions beforehand, the system prepares all necessary information ahead of time, allowing the cutting operation to execute immediately without delays
3Productivity
If small inaccuracies in operator pointing occur, then production speed might be maintained, but noticeable discontinuities appear in the pattern of the item of clothing
Solution Approach 1:
The system continuously monitors and measures the actual fabric pattern positions during operation, comparing detected meeting points against the theoretical pattern model. This feedback mechanism allows the system to automatically adjust and correct any deviations, ensuring precise pattern alignment while maintaining high production speeds through automated real-time correction
Data Source
Figure 1A~1B
Figure 2
Figure 2-1
AI summary
The invention describes an apparatus (1) for continuous detection and cutting of fabric (tes_i) bearing a predefined real striped and checked pattern (TexR_i), for making an item of clothing (Ci), it comprises a loading area (A1) for loading fabric (tes_i); movement means (10) for moving the fabric (tes_i); detection means (20) arranged to detect from the fabric (tes_i) at least effective points (P1_i) representative of meeting points detected in the predefined pattern (TexR_i); a processing unit (40) for processing effective (P1_i) and/or theoretical points (P0_i;i=1..n) configured to: receive the theoretical points P0_i, representative of a theoretical pattern (Tex_i) reproduced on component parts (Cij) of items of clothing (Ci); receive the effective points (P1_i) detected, representative of meeting points detected of the predefined real pattern (TexR_i) in the fabric (tes_i) detected; make a comparison by points between the theoretical points (P0_i) and the effective points (P1_i); determine real meeting points (PR_i) of the real pattern (TexR_i) in the component parts (Cij) at least according to the comparison by points; a cutting area (A2) arranged downstream of said loading area (A1); a cutting head (30) configured to cut the fabric (tes_i) according to the real meeting points (PR_i) determined. The invention also describes a corresponding method for continuous detection and cutting, a computer program configured to perform the method, and a graphical user interface configured to display on a display device the steps performed by the method and/or by the computer program.