Fly And Fastener Sewing Line for Stable Edge Overcasting
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Solution Overview
Problem
Existing sewing devices require manual skill and result in unstable product quality and limited production due to the need for manual work in sewing and edge processing of flies and fasteners, with pressing positions often causing overlap issues.
Innovation Solution
A sewing device that automates the process by using a fly base, fastener base, first conveying device, first sewing machine, supplying and conveying device, and second sewing machine to perform edge overcasting and sewing, with features like fly and fastener positioning, tape guiding, and thread cutting to stabilize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual work is used for sewing and edge processing of flies and fasteners, then the process can be completed, but the product quality is unstable and production efficiency is limited
Solution Approach 1:
The sewing device enables self-service automation where the system automatically feeds, positions, sews, and trims the fly and fastener without manual intervention. The automated feeding mechanism supplies workpieces to the sewing zone, the positioning mechanism aligns components precisely, the sewing machine stitches the fly and fastener together, and the trimming device cuts excess material - all operations are performed autonomously to eliminate manual work and ensure consistent quality and high productivity
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems. The manual feeding and positioning actions are substituted with automated feeding mechanisms and positioning devices that use mechanical arms, conveyors, and alignment systems. The manual sewing and trimming are replaced with automated sewing machines and trimming devices that perform these functions through programmed mechanical motions, thereby improving both quality stability and production efficiency
2Manufacturing precision
If the sixth pressing plate presses one side portion of the sewn workpieces against an element row of the fastener, then the fabric edge can be processed, but the pressing position causes overlap issues and complicates the structure
Solution Approach 1:
The pressing function is extracted and separated from the sewing and trimming operations. A dedicated pressing mechanism with multiple pressing plates is introduced that can independently press different portions of the workpiece at different stages. This allows the pressing operation to be optimized for quality without adding complexity to the sewing and trimming mechanisms, as each function has its own specialized component
Solution Approach 2:
The pressing mechanism is segmented into multiple pressing plates (first pressing plate, second pressing plate, third pressing plate) that can operate independently at different positions and times. The first pressing plate presses the fly and fastener during feeding, the second pressing plate presses during sewing, and the third pressing plate presses during trimming. This segmentation allows precise control of pressing forces at different stages, improving edge processing quality while maintaining clear functional separation that reduces overall system complexity
Data Source
AI summary
A sewing device includes: a fly base on which a fly is to be placed; a fastener base on which a fastener is to be placed; a first conveying device configured to convey the fly on the fly base; a first sewing machine configured to perform edge overcasting on the fly during conveyance by the first conveying device; a supplying and conveying device configured to supply the fastener from the fastener base onto the fly, on which the edge overcasting is finished, in an overlapped manner, and configured to convey the fly and the fastener together; and a second sewing machine configured to sew the fly and the fastener during conveyance aby the supplying and conveying device.