Automated Flanging Machine Corner Radius Control
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Solution Overview
Problem
Automated sewing machinery struggles to consistently produce panels with straight edges and uniform corner radii, often resulting in trapezoid-shaped panels due to inaccurate automatic turning and sewing processes, requiring significant operator intervention.
Innovation Solution
An automated flanging machine with a table, sewing head, turning arm, rear conveyor, corner pivot mechanism, and material guide and encoding arm that minimizes operator intervention by automatically sewing flanges onto panels with consistent corner radii and straight edges, using a conveyor belt and pressure skid to advance the panel and a flange knife assembly to cut the flange post-sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated sewing machinery follows the cut edge of a work panel, then the sewing operation can be automated, but the sewn edges are not straight when the sides of the panel are not cut along a straight line
Solution Approach 1:
A laser guide system serves as an intermediary between the automated sewing machine and the work panel. The laser projects a reference line that the sewing machine follows, decoupling the sewing path from the panel's cut edge. This allows the machine to maintain straight edges by following the laser guide rather than the potentially irregular cut edge of the panel.
Solution Approach 2:
The system replaces mechanical following of the panel edge with an optical guidance system. Instead of the sewing machine mechanically tracking the cut edge, a laser optical field provides the reference path, and the machine's positioning system uses this optical information to maintain precise straight-line sewing paths.
2Extent of automation
If automatic turning of a work panel is used, then operator intervention is reduced, but the finished work panel is sewn with varying corner angles creating a trapezoid-shaped panel
Solution Approach 1:
The system incorporates feedback mechanisms including laser guides and sensors that continuously monitor the panel's position and orientation during automatic turning. This feedback allows the control system to detect and correct deviations from the intended corner angles, ensuring consistent 90-degree corners even during automated operation.
Solution Approach 2:
The laser guide system establishes the correct corner angles and sewing paths before the automatic turning begins. The system pre-calculates and pre-positions the panel and sewing head, ensuring that when automatic turning occurs, the panel is already oriented correctly and will maintain proper corner angles throughout the sewing process.
3Manufacturing precision
If manual manipulation by an operator is used, then panels can be sewn with attention to detail, but a high level of skill and attention is required during sewing and manipulation
Solution Approach 1:
The automated system performs the sewing operation itself with precision, eliminating the need for operator skill in manual manipulation. The machine automatically positions the panel, follows the laser guide, maintains consistent tension, and completes the sewing with uniform quality, making the process self-sufficient and removing the dependency on operator expertise.
Data Source
AI summary
An automated flanging machine is provided. More specifically, a machine for automatically sewing a flange onto a work panel having a consistent corner radius and a straight edge is provided. The machine has a table adapted to support a work panel, a sewing head mounted directly adjacent to the table for performing a sewing operation on the work panel, a turning arm mounted adjacent to the table, and a rear conveyor for selectively moving the work panel on the table. The table may include a corner pivot mechanism for stabilizing the panel while the turning arm turns the panel 90 degree relative to an initial position, and for maintaining a consistent corner radius for sewing. The machine may also include a rear material guide and encoding arm for measuring the progression of the work panel as it is sewn along a side by the sewing head.