Automatic edge positioning and fabric guiding for sewing machines
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Solution Overview
Problem
Existing systems for guiding and aligning moving textile webs, such as carpets, face challenges in accurately positioning the edges, especially with lighter and more flexible fabrics, and in hot and humid environments, where traditional methods are inadequate for continuous and automated edge alignment before sewing or embroidery.
Innovation Solution
An apparatus comprising two pairs of rolls adjacent to the edges of a conveyor system, with each pair capable of vertical movement and rotational motion, driven by motors, and equipped with photodiodes for edge detection and feedback, allowing for continuous adjustment and alignment of the web edges during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional guide rolls are used for heavy carpets, then the carpet sticks to the conveyor table and remains stable, but lighter and more flexible fabrics cannot be properly guided and positioned
Solution Approach 1:
The guide rolls are made movable along the vertical axis, allowing them to dynamically adjust their position to engage with lighter fabrics. The rolls can move vertically to apply appropriate pressure and grip lightweight materials that would otherwise slip, while maintaining stability for heavier fabrics.
Solution Approach 2:
Optical sensors detect the position of fabric edges and provide feedback to the control system, which automatically adjusts the vertical position of the guide rolls. This closed-loop control ensures accurate edge positioning for fabrics of varying weights and flexibility by continuously monitoring and correcting position deviations.
2Manufacturing precision
If guide rolls are positioned in the middle of the moving fabric, then guidance is provided, but the rolls cannot be placed close to the edges of the conveying system when folded configurations are present
Solution Approach 1:
The guiding function is divided between multiple independent guide rolls that can be positioned at different locations. This segmentation allows the system to place rolls close to conveyor edges for accurate edge alignment while managing the complexity through modular, independently controllable units rather than a single complex positioning mechanism.
Solution Approach 2:
Optical sensors serve as intermediaries between the fabric edge position and the guide roll positioning system. These sensors detect edge locations and translate them into control signals that automatically adjust roll positions, simplifying the overall system while achieving high precision edge alignment.
3Extent of automation
If manual edge positioning methods are used, then equipment is simple, but automated continuous steering and positioning cannot be achieved
Solution Approach 1:
Manual mechanical positioning methods are replaced with an automated system combining optical sensors and controlled guide rolls. The optical detection system identifies fabric edges, and the control system automatically adjusts roll positions, eliminating manual intervention while managing complexity through integrated sensor-actuator systems.
Solution Approach 2:
The system performs self-positioning through automatic control where the optical sensors and guide rolls work together without external intervention. The control system continuously monitors fabric position and automatically adjusts the rolls to maintain correct alignment, enabling continuous automated steering and positioning.
4Measurement precision
If simple detection methods are used, then equipment is robust for hot and humid environments, but precise continuous edge tracking and monitoring cannot be achieved
Solution Approach 1:
Optical sensors act as intermediaries that provide precise non-contact measurement of fabric edge positions. These sensors detect edge locations through light interaction without physical contact, achieving high measurement precision while maintaining robustness for hot and humid environments through their sealed, contactless design.
Solution Approach 2:
The optical detection system serves multiple functions: detecting fabric edge positions, monitoring fabric movement, and providing feedback for control adjustments. This multi-functionality achieves precise continuous edge tracking while managing system complexity by combining multiple capabilities in a single integrated detection system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and automated edge alignment and correction of misalignment for textile fabrics, addressing issues of bowing and edge processing challenges, while maintaining flexibility and adaptability to varying environmental conditions.
Implementation Method 1
equipped with photodiodes for edge detection and feedback
Implementation Method 2
two pairs of rolls adjacent to at least one edge side of the moving conveyor... capable of vertical movement and rotational motion
Data Source
Figure 1~2
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AI summary
The invention relates to automatic edge positioning and guiding of a moving web, such as a textile fabric or carpet, onto a conveyor system comprising manufacturing operations such as e.g. sewing. More in particular an apparatus is provided including mechanics, optics and control for steering and positioning the side edges of the moving web in order to correct for misalignment, and hence sewing can occur appropriately.