Omni-chain and omni-belt material aligner for automated sewing
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Solution Overview
Problem
Automated sewing processes face challenges in aligning flexible and elastic materials, leading to misalignment issues that require operator intervention, as existing systems struggle to manage material feed without restricting movement through the sewing machine.
Innovation Solution
The implementation of a robotic system with omni-chain and omni-belt material aligners, which use circular roller chains and belts with motorized steering and controlled roller pressure to actively align and feed materials, allowing for seamless integration with automated sewing machines while minimizing operator assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If material is fed through the sewing machine without restriction, then material flexibility and elasticity are maintained, but material alignment deteriorates causing misalignment issues
Solution Approach 1:
The patent introduces a material aligner as an intermediary device between the material feed and the sewing machine. This aligner includes a support surface with a contour that complements the shape of the material stack, allowing the material to be guided and aligned properly without restricting its natural flexibility. The aligner acts as a mediator that shapes the material path while maintaining material properties.
2Manufacturing precision
If operator interaction is used to align material, then material alignment improves, but productivity decreases due to manual intervention requirements
Solution Approach 1:
The material aligner is designed to automatically align and guide the material through the sewing process without requiring operator intervention. The contour of the support surface self-adjusts to the material stack shape, and the system includes sensors and actuators that automatically detect and correct misalignment, enabling the system to serve itself and maintain high productivity.
3Manufacturing precision
If rigid material handling is used, then material alignment improves, but material damage increases due to restriction of natural movement
Solution Approach 1:
The material aligner uses a contour support surface that flexes and adapts to the shape of the material stack rather than imposing a rigid structure. The support surface is designed to accommodate the natural flexibility and elasticity of the material, allowing the material to maintain its natural movement while still achieving proper alignment through the complementary contour shape.
Data Source
AI summary
Various examples are provided related to transporting and sewing material in, e.g., automation of sewing robots. An automated sewing process feed control system is disclosed in which a material aligner is utilized. An omni-chain material aligner can include a circular roller chain in which the rollers allow for a controlling force to be applied to a material. An omni-belt material aligner can include a belt with attached perpendicular rollers which allow feed control and active motorized steering control. The material aligner can control the pressure applied onto the material to facilitate control of feeding the material.