Multi-Thread Winding Head for Faster Custom Apparel Production
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Solution Overview
Problem
Existing methods for manufacturing apparel struggle to balance durability, comfort, and performance while allowing for customizable characteristics and efficient large-scale production.
Innovation Solution
A system comprising a winding head with multiple thread guides that simultaneously dispense continuous threads around projections on a plate, utilizing actuators to move the head and form thread layers, allowing for customizable thread patterns and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-thread winding methods are used, then manufacturing simplicity is maintained, but productivity and manufacturing time are reduced
Solution Approach 1:
The winding head is segmented into multiple independent thread guides (at least four), each capable of dispensing a separate continuous thread simultaneously. This segmentation allows parallel winding operations without requiring a completely separate machine for each thread, thus increasing productivity while keeping the overall device structure manageable.
Solution Approach 2:
Multiple thread guides and their corresponding spools are merged into a single integrated winding head assembly that operates as one coordinated unit. This merging allows simultaneous winding of multiple threads onto the same article, dramatically increasing manufacturing throughput without requiring multiple separate winding stations.
2Loss of time
If multiple threads are wound sequentially, then device complexity is minimized, but manufacturing time increases
Solution Approach 1:
The winding head is designed to perform continuous useful action by having multiple thread guides operate simultaneously throughout the winding process. All threads are wound onto the article at the same time during a single pass, eliminating idle time between thread windings and maintaining continuous productive action.
Solution Approach 2:
The invention transitions from sequential (one-dimensional time progression) winding to parallel (multi-dimensional) winding by arranging multiple thread guides in space. This spatial arrangement allows multiple threads to be wound simultaneously, converting a time-based sequential process into a space-based parallel process.
3Adaptability or versatility
If customizable thread patterns are implemented, then apparel characteristics are improved, but manufacturing complexity increases
Solution Approach 1:
Different thread guides can be assigned different thread types, colors, or materials to create localized variations in the wound article. This allows customization of specific regions or patterns without requiring complete redesign of the entire winding system, maintaining simplicity while achieving versatility.
Solution Approach 2:
The winding head incorporates movable components that can be dynamically adjusted during operation to create different thread patterns. The ability to change positions, speeds, or activation of individual thread guides provides adaptability for various patterns without permanently complexifying the device structure.
Data Source
AI summary
A system for manufacturing an article of apparel includes a plate with a plurality of projections. The system also includes a winding head with a plurality of adjacent thread guides. The thread guides among the plurality of thread guides are configured to simultaneously dispense respective continuous threads. The system also includes an actuator configured to move the winding head over the plate to wind the continuous threads around the plurality of projections on the plate.