Fluorescent printing on fabric for use as control input to automated positioning equipment
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Solution Overview
Problem
The textiles industry faces challenges in automating fabric positioning due to the flexible nature of fabric materials and the need for pattern-specific tooling, which limits production efficiency and flexibility, especially in the apparel industry with frequent fashion cycles and high product variability.
Innovation Solution
An automated process using a fluorescent pattern, known as a UV-signature, printed on the fabric is read by ultraviolet light to guide fabric positioning equipment, allowing for flexible automation and improved sewing process quality without the need for hard fixturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pattern-specific carriers are used to secure fabric for assembly, then positioning precision is improved, but adaptability to different patterns and fabric materials deteriorates
Solution Approach 1:
The patent applies universality by replacing pattern-specific carriers with a single automated carrier that can handle multiple fabric patterns and materials. The fluorescent pattern printed on the fabric serves as a universal interface that works with any pattern type, eliminating the need for dedicated tooling for each design.
Solution Approach 2:
The patent replaces the mechanical fixture system with an optical detection system. Instead of using physical carriers with mechanical positioning features, the system uses fluorescent patterns detected by UV light and image processing to achieve positioning, thereby eliminating the need for pattern-specific mechanical tooling.
2Adaptability or versatility
If manual interaction is used for fabric positioning, then adaptability to different patterns is improved, but productivity deteriorates
Solution Approach 1:
The patent applies self-service by enabling the fabric to carry its own positioning information through the fluorescent pattern. The fabric piece itself provides the reference markers needed for positioning, eliminating the need for external pattern-specific tooling and manual positioning operations.
Solution Approach 2:
The patent implements feedback through the fluorescent pattern that provides real-time positioning information to the automated system. The UV detection system reads the fluorescent markers and provides feedback for automated adjustment, enabling both high speed and adaptability without manual intervention.
3Adaptability or versatility
If frequent pattern changes are implemented to meet fashion cycles, then adaptability is improved, but device complexity increases due to need for new tooling
Solution Approach 1:
The patent applies parameter changes by using variable fluorescent patterns that can be digitally printed in different configurations. Instead of changing physical tooling parameters, the system changes the optical parameters (fluorescent pattern design) to accommodate different fashion requirements, maintaining simple hardware while achieving high adaptability.
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
This approach enables accurate and adaptable fabric positioning, supporting changeovers between various patterns and reducing manual interaction, thereby enhancing production efficiency and flexibility in textile manufacturing.
Implementation Method 1
A desired pattern is the basis for a 'pattern signature,' which is the fluorescent ink printing of a pattern on the fabric to be positioned. The pattern signature is read and used as control input to fabric positioning equipment.
Data Source
AI summary
A method of using an automated system to position a fabric piece. A pattern is printed onto a fabric piece with fluorescent ink, and detected with a fluorescence-detecting camera, such as a UV camera. The detected pattern is stored in a controller as a pattern signature and compared to a stored target pattern. The results of the comparing step are used to generate control signals for the automated system to move the piece into the position of the target pattern.