Multi-needle Sewing Machine Transverse Web Alignment
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Solution Overview
Problem
Existing devices for producing multi-layer sewing materials, such as mattress panels, face challenges in achieving accurate hemming and cutting of longitudinal sides due to misalignment and wandering of the sewing material web, leading to inconsistent seam and cut edge positions relative to the sewing pattern.
Innovation Solution
The processing device is designed with movable sewing and cutting units that can be aligned transversely to the conveying direction using reference elements or signals independent of the sewing pattern, allowing for precise positioning and control to avoid integration of seams and cuts into the pattern, and includes a control unit with sensors to adjust positions automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the web of sewing material is conveyed from the multi-needle sewing device to the processing device, then the production process continues, but the web wanders and misaligns transversely to the conveying direction, causing inconsistent seam and cut edge positions
Solution Approach 1:
A sensor detects the position of the web in the transverse direction and provides feedback signals to actuators that adjust the position of the processing device or web, thereby maintaining accurate alignment and eliminating transverse wandering during conveyance
Solution Approach 2:
The mechanical alignment system is replaced with an automated control system comprising sensors, actuators, and control circuits that dynamically adjust positioning based on real-time detection, substituting passive mechanical guidance with active electromagnetic control
2Device complexity
If the processing device has fixed sewing and cutting units, then the device structure is simple, but the web wandering causes seams and cuts to integrate into the sewing pattern undesirably
Solution Approach 1:
The processing device transitions from a fixed structure to a dynamic one where sewing and cutting units can be adjusted in the transverse direction through actuators, allowing real-time positioning adjustments without significantly increasing overall device complexity
Solution Approach 2:
The transverse position of the processing device or web is dynamically changed based on sensor feedback, allowing the system to adapt to web wandering and maintain precise seam and cut edge positions relative to the sewing pattern
Data Source
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AI summary
The device (1) has a multi-needle sewing unit (2), particularly a multi-needle chain stitch sewing machine, and a processing unit (4) downstream to the multi-needle sewing unit in conveying direction (6) of a workpiece web. The processing unit has a sewing unit and a cutting unit for each longitudinal side of the workpiece web. The sewing units and the cutting units are formed to move lateral to the conveying direction of the workpiece web. An independent claim is included for a method for manufacturing multi-layer workpiece, particularly mattress sheets as section of a workpiece web.