Optical Mark Alignment for Edgeless Textile Pattern Pieces
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Solution Overview
Problem
Existing methods for precisely positioning and processing textile pattern pieces without an outer edge or pile edge are inadequate, leading to inaccuracies and inferior product quality due to manual errors and mechanical challenges in alignment and transportation.
Innovation Solution
A method and apparatus that utilize manual or automatic pre-alignment of pattern pieces followed by contactless sensory detection of marks on the pieces to correct deviations from the desired alignment, ensuring precise positioning through mechanical adjustments, allowing for high-quality processing without relying on edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical alignment is used to pull the textile web to a segmented guide bar, then the textile web can be oriented correctly, but this method is not possible without an outer edge or pile edge
Solution Approach 1:
The patent replaces the mechanical guide bar system with an optical detection system using sensors to detect marks on the textile. Instead of mechanically pulling the textile to a physical guide, the system uses optical fields to detect mark positions and calculates alignment deviations, thereby enabling alignment of edgeless textiles without mechanical contact.
Solution Approach 2:
The patent uses marks printed or formed on the textile as reference copies of the desired alignment pattern. These marks serve as optical templates that the sensor system detects and compares against the actual textile position, allowing the system to determine alignment deviations and correct them without requiring physical edges.
2Ease of operation
If manual transfer of pattern pieces is performed by a worker, then flexibility is maintained, but inexperience or inattentiveness results in inaccuracies in orientation and positioning
Solution Approach 1:
The patent implements an automated feedback system where sensors detect the actual positions of marks on pattern pieces, the system calculates deviations from desired positions, and actuators automatically adjust the piece alignment. This closed-loop feedback eliminates human error while maintaining operational flexibility through programmable parameters.
Solution Approach 2:
The system performs self-alignment by automatically detecting mark positions, calculating deviations, and adjusting piece positions without human intervention. The automated system serves itself by using its own sensor data to drive correction actions, eliminating dependence on worker skill levels.
3Productivity
If belt drives are used as conveyor to transport pattern pieces, then automatic delivery is achieved, but the pattern piece slips in the conveyor especially with thick and flexible textiles
Solution Approach 1:
The patent replaces reliance on mechanical friction-based belt drives with an optical-mechanical hybrid system. Instead of depending solely on belt friction to prevent slipping, the system uses optical sensors to continuously monitor mark positions and actuators to make real-time alignment corrections, compensating for slips that occur during conveyor transport.
4Manufacturing precision
If correction of alignment deviations is performed, then processing precision is improved, but additional processing time is required
Solution Approach 1:
The patent implements continuous alignment correction during the transport process itself. Sensors detect mark positions continuously as pieces move through the system, and actuators make real-time adjustments without stopping the production flow. This continuous correction approach maintains high precision while minimizing interruptions to the production cycle.
Data Source
AI summary
The invention relates to a method and a device (2) for exactly positioning and processing textiles or the like, in particular fitting pieces (1), having the following method steps:—orienting and/or positioning (2) the fitting piece (1),—supplying (3) the fitting piece (1) to a station (9),—checking (4) the orientation and/or positioning of the fitting piece (1), wherein markings on the fitting piece (1) are captured by sensor means and the actual marking sequence is compared with a setpoint marking sequence,—determining (5) correction requirements and—transmitting (6) the correction requirement to a correction station (12),—correcting (7) the orientation of the fitting piece (1) by means of the correction station (12) in accordance with the correction requirement,—supplying (8) the fitting piece (1) to a processing station (13),—optionally repeating individual method steps or several method steps.