Method and apparatus for the production of fabric or leather articles
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Solution Overview
Problem
Existing methods for producing padded fabric or leather articles face challenges in precision sewing and cutting, leading to difficulties in maintaining accurate seam alignment and identifying semi-finished products, which can result in production inefficiencies and errors.
Innovation Solution
A method and apparatus that involve feeding two superimposed cloths through an embroidery machine for automatic sewing along predefined lines, applying additional markings as seams, and then using optical capture and interpolation to determine the actual sewing line pattern, allowing for precise cutting adaptation to any fabric relaxations or wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic sewing is performed along predefined lines, then sewing efficiency is improved, but precision of seam alignment deteriorates due to fabric relaxations and wrinkles
Solution Approach 1:
The patent applies preliminary action by marking reference points on the fabric before sewing occurs. These markings serve as pre-established reference markers that will later be used to detect and compensate for any fabric displacement or deformation, allowing the system to adapt the cutting pattern after sewing while maintaining precision.
Solution Approach 2:
The patent implements feedback by using optical detection systems to scan the marked reference points on the sewn fabric, comparing their actual positions against the predefined template. This feedback loop enables the system to automatically calculate displacement vectors and adjust the cutting pattern accordingly, resolving the alignment precision issue while maintaining high sewing efficiency.
2Productivity
If cutting is performed at a fixed distance from sewing lines, then cutting speed is improved, but manufacturing precision deteriorates due to inability to adapt to fabric distortions
Solution Approach 1:
The patent applies dynamics by transitioning from a static, fixed-distance cutting approach to a dynamic cutting system. The cutting parameters are automatically adjusted based on real-time detection of fabric displacement through optical scanning of reference markings. This allows the cutting system to adapt its path and distance from sewing lines according to actual fabric conditions, maintaining both speed and precision.
3Device complexity
If semi-finished products are produced without distinctive markings, then production simplicity is improved, but ease of operation deteriorates due to difficulty in identification and cataloging
Solution Approach 1:
The patent applies the color changes principle by using visually distinctive markings (such as colored threads or contrasting markers) applied during the sewing process. These markings make semi-finished products easily identifiable and distinguishable, facilitating efficient cataloging and tracking without significantly increasing production complexity. The markings serve dual purposes: as reference points for precision cutting and as identification markers for operational ease.
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 ensures precise and efficient production of semi-finished products by maintaining accurate seam alignment and adapting cutting to fabric distortions, thereby improving production line efficiency and product quality.
Implementation Method 1
means for the optical capture of the cloths sewn by said embroidery machine
Data Source
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AI summary
A method and an apparatus for the production of fabric or leather articles, particularly articles to be padded, comprising the steps of: automatic sewing, at an embroidery machine (3), of superimposed cloths (20d) according to a stored template that contains a pattern of reference sewing lines (S1-S5); applying a plurality of markings in the form of respective additional seams, according to a corresponding arrangement of reference markings (M1-M4) provided in the stored template; optically capturing (5) a sewn portion of the cloths and determining any displacement of the markings applied with respect to the arrangement of the reference markings (M1-M4); on the basis of the displacement and of the mutual arrangement of the reference markings (M1-M4) and of the pattern of the sewing lines (S1-S5) that are stored, determining by interpolation the actual pattern of the sewing lines that is present on the sewn cloths (20d); automatically cutting (53) along the sewing lines on the basis of the actual pattern obtained with the interpolation.