Method of controlling garment folding machine
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Solution Overview
Problem
Garment folding machines lack a method to accurately detect and address garment lumping during the conveying and folding process, leading to potential drive motor overload, damage to garments, and components, with existing solutions failing to provide timely intervention.
Innovation Solution
A method for controlling garment folding machines that involves operating conveyor motors, detecting motor current values and delay times to determine if garment lumping occurs, stopping the motor when predetermined critical values are exceeded, and generating alarms to notify users of the issue, allowing for immediate action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drive motor continues to operate during garment lumping, then the folding process can continue without interruption, but the drive motor is likely to be overloaded and damaged
Solution Approach 1:
The control unit continuously monitors the operational state of the drive motor during garment folding and detects abnormal conditions such as increased current consumption or extended operation time. When lumping is detected through sensor feedback or motor parameter analysis, the system automatically adjusts motor operation or stops the folding process to prevent motor damage, thus resolving the contradiction between maintaining productivity and ensuring motor reliability
Solution Approach 2:
The system performs preliminary detection of garment lumping conditions before the drive motor becomes overloaded. By using sensors to detect garment position and fold completion status in advance, the control unit can preemptively adjust motor operation or issue warnings, preventing the harmful effect of motor overload while maintaining continuous folding operation when conditions permit
2Speed
If the drive motor operates continuously during garment lumping, then the folding process maintains speed, but the lumped garment and components are likely to be damaged
Solution Approach 1:
Sensors monitor the folding process in real-time to detect abnormal conditions such as increased resistance or unusual motor current patterns that indicate garment lumping. When lumping is detected, the control unit immediately adjusts the drive motor operation or stops the process, preventing damage to garments and components while minimizing interruption to the folding speed
Solution Approach 2:
When garment lumping is detected, the system rapidly transitions from normal folding operation to a protective state by quickly stopping the drive motor or bypassing the problematic fold. This rapid response minimizes the duration of harmful forces applied to the garment, effectively preventing damage while maintaining overall process efficiency
3Device complexity
If no detection method is implemented, then the system remains simple, but the drive motor overload and damage cannot be prevented
Solution Approach 1:
The system replaces complex mechanical detection mechanisms with electronic sensors and control units that monitor drive motor parameters and garment position. This substitution provides reliable lumping detection and motor protection while adding minimal complexity to the overall system, as the electronic monitoring can be integrated into the existing control architecture
Solution Approach 2:
The drive motor's own operational parameters (current consumption, operation time, speed variations) are used as indicators of lumping conditions. The control unit analyzes these self-generated signals from the motor to detect abnormal conditions, eliminating the need for separate complex detection systems while providing reliable protection against motor overload
Data Source
AI summary
The present disclosure relates to a method of controlling a garment folding machine, which may effectively prevent damage to a drive motor and a loss of power caused by an overload of the drive motor by accurately detecting and determining a situation in which garments are lumped during a process of conveying or folding the garments, may effectively prevent damage to the lumped garments and related components, and may significantly reduce the time for which the operation of the folding machine is stopped by accurately specifying the position at which the garments are lumped and then notifying a user of the position to allow the user to take an immediate action.