Rolling-Up Fabric End-Effectors for Fixture-Free Tension Control
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Solution Overview
Problem
Existing automation systems for fabric handling require customized fixtures for each fabric part size and shape, leading to inefficiencies in high-mix low-volume production, and existing robotic grippers struggle to manage a wide range of fabric sizes and shapes effectively.
Innovation Solution
A dual-manipulator system with force sensors and vision sensors, equipped with rolling-up end-effectors, capable of grasping and controlling tension on fabric parts of different dimensions without fixtures, using suction-rollers supported by a fixed internal shaft and coordinated motion to maintain fabric shape and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If customized fixtures are used for each fabric part size and shape, then fabric handling precision is improved, but device complexity and production flexibility deteriorate
Solution Approach 1:
The patent employs a universal fixture design that can accommodate multiple fabric part sizes and shapes through adjustable components. The fixture includes movable clamping mechanisms and reconfigurable positioning elements that allow a single fixture structure to serve multiple functions for different garment components, thereby improving production flexibility while maintaining handling precision.
Solution Approach 2:
The fixture incorporates dynamic adjustment capabilities with movable and reconfigurable elements that can be modified during production runs. This allows the fixture to adapt its geometry and dimensions to match different fabric part configurations without requiring complete fixture replacement, thus resolving the contradiction between precision and flexibility.
2Manufacturing precision
If customized fixtures are designed for each fabric part, then fabric handling precision is improved, but manufacturing cost and time increase
Solution Approach 1:
By designing a universal fixture that can handle multiple fabric part types through standardized adjustable mechanisms, the patent eliminates the need to manufacture separate customized fixtures for each part type. This reduces manufacturing costs and lead time while maintaining the precision required for different fabric configurations.
Solution Approach 2:
The fixture is divided into modular, interchangeable components that can be reconfigured for different applications. This segmentation allows for easier manufacturing of standardized modules rather than custom fixtures, reducing both cost and production time while preserving the ability to achieve precise handling for various fabric parts.
3Manufacturing precision
If fixtures are installed and replaced between production runs, then fabric handling precision is maintained, but production time and cost increase
Solution Approach 1:
The dynamic reconfigurable fixture allows for quick adaptation between different fabric part types through simple adjustment mechanisms rather than complete fixture replacement. This reduces the time lost during production run changes while maintaining the precision needed for accurate fabric handling throughout the production process.
4Extent of automation
If mechanical grippers are used for fabric handling, then automation capability is improved, but ability to handle diverse fabric sizes and shapes deteriorates
Solution Approach 1:
The mechanical gripper system is enhanced with universal adaptive components that can accommodate diverse fabric sizes and shapes. The gripper includes adjustable clamping forces, variable positioning mechanisms, and adaptable finger configurations that allow a single automated system to handle multiple fabric types effectively, thereby maintaining high automation capability across diverse applications.
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 handling and positioning of various fabric parts, reducing the need for customized fixtures and minimizing reconfiguration efforts, enhancing production efficiency and reducing defects in garment manufacturing.
Implementation Method 1
a first rolling-up end-effector positioned by the first robot manipulator, the first rolling-up end-effector configured and adapted to grasp a first end of the subject fabric part with a roller having a suction port
Data Source
AI summary
A fabric handling manipulator system for handling a subject fabric part includes a first robot manipulator and a first rolling-up end-effector positioned by the first robot manipulator. The first rolling-up end-effector is configured and adapted to grasp a first end of the subject fabric part with a first roller having a first suction port. A first force sensor is configured and adapted to sense a force applied to the first rolling-up end-effector. The system further includes a vision sensor system configured and adapted to sense a fabric part pose of the subject fabric part and a first pose of the first rolling-up end-effector. A controller is configured and adapted to simultaneously control the fabric part pose and a tension in the fabric part via the first robot manipulator according to inputs from the vision sensor system and the first force sensor.