Dual-Robot Needle Sewing for Automated Steering Wheel Covers
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Solution Overview
Problem
The manual sewing of leather covers onto steering wheels is labor-intensive and time-consuming, necessitating an automated assembly process using industrial robots.
Innovation Solution
A robot system comprising two robotic arms and a controller that cooperatively control a needle to perform sewing operations, utilizing pre-stitches on the object surface to minimize scratches and employing a thread drawing device to manage thread tension, with an adjusting tool to enhance stitch quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sewing is used to fix leather cover to steering wheel, then stitching quality can be controlled by skilled workers, but the process is labor-intensive and time-consuming
Solution Approach 1:
The sewing system is divided into two independent robotic arms: the first robotic arm performs needle penetration and thread insertion, while the second robotic arm performs needle retrieval and thread pulling. This segmentation allows each arm to specialize in specific sewing actions, improving overall sewing speed and enabling full automation without requiring human intervention for quality control.
Solution Approach 2:
A needle magazine is introduced as an intermediary component that stores multiple needles and supplies them to the first robotic arm. This mediator enables continuous sewing operations by pre-positioning needles, eliminating downtime for needle replacement, and thus significantly improving productivity while maintaining automated operation.
2Extent of automation
If automated sewing with single robotic arm is implemented, then automation level increases, but control over needle penetration and thread tension becomes difficult
Solution Approach 1:
By dividing the sewing task between two robotic arms, each arm can be optimized for its specific function. The first arm focuses on precise needle penetration and thread insertion, while the second arm specializes in needle retrieval and thread tension control. This functional segmentation enables both high automation and precise stitch quality control.
Solution Approach 2:
Each robotic arm is equipped with specialized end effectors and control parameters tailored to its specific task. The first arm has needle-holding fixtures optimized for penetration accuracy, while the second arm has thread-gripping mechanisms optimized for tension control. This local optimization ensures high manufacturing precision in each aspect of the sewing process.
3Ease of manufacture
If needle penetrates object directly without pre-stitches, then sewing operation is simpler, but scratches may occur on the object surface
Solution Approach 1:
Pre-stitches are created on the leather cover before the automated sewing process begins. These pre-stitches serve as predetermined pathways that guide the needle through the material. By preparing these paths in advance, the needle follows established routes that minimize surface contact and reduce the risk of scratches, while still maintaining a relatively simple automated sewing operation.
4Productivity
If thread tension is not controlled during automated sewing, then the sewing process is faster, but stitch quality and joining strength deteriorate
Solution Approach 1:
The system dynamically adjusts thread tension parameters during the sewing process. The second robotic arm controls thread tension by adjusting its gripping force and pulling speed based on real-time feedback. This parameter control ensures optimal stitch quality and joining strength while maintaining high sewing speed through automated regulation rather than manual adjustment.
Data Source
AI summary
Embodiments of present disclosure relates to a robot and method for sewing an object. The robot includes a first robotic arm adapted to hold a needle, the needle carrying a length of a thread, a second robotic arm adapted to hold the needle, and a controller configured to move the first and second robotic arms to perform a plural of sewing operations so as to form a plural of stitches on the object A sewing operation includes moving the first robotic arm a first distance to cause the needle to penetrate a part of the object; and moving the second robotic arm to hold a penetration portion of the needle and pull the whole needle out of the object after the needle being released by the first robotic arm.