Automated Ornamental Stitching Head for 3D Automotive Parts
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Solution Overview
Problem
Manual sewing of decorative ornamental stitches on large or complex 3D automotive parts, such as instrument panels, becomes increasingly difficult and often impossible as part size and shape complexity increase.
Innovation Solution
A method and apparatus for robotically sewing decorative ornamental stitches using a 6-axis robot with an ornamental chain stitching head that incorporates chain stitch technology and a redesigned post assembly to accommodate hooks in lieu of loopers, reducing the need for frequent thread bobbin changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sewing is used on large or complex 3D automotive parts, then the operator can control placement of the stitch, but the difficulty and impossibility of sewing increases with part size and shape complexity
Solution Approach 1:
The patent replaces the manual mechanical sewing system with an automated robotic system. A robotic arm equipped with a sewing head automatically positions and sews decorative stitches on 3D automotive parts, eliminating the need for manual operation while maintaining precise stitch placement control through programmable motion control.
2Ease of manufacture
If manual flatbed sewing machines are used, then flat stock material can be sewn, but the entire part must be flattened which limits applicability to 3D preformed parts
Solution Approach 1:
The patent employs a dynamic robotic arm with multiple degrees of freedom that can adapt its position and orientation to sew on complex 3D surfaces. The robotic system dynamically adjusts its approach to accommodate various part geometries, eliminating the need to flatten parts while maintaining sewing capability on preformed 3D components.
3Productivity
If chain stitch technology is used, then frequent lower thread bobbin changes are eliminated, but the needle bar cam assembly speed must be reduced through gear ratio
Solution Approach 1:
The patent utilizes chain stitch technology which fundamentally changes the stitching mechanism to eliminate bobbin changes. The system accepts a reduction in needle bar cam assembly speed as a trade-off, utilizing gear reduction to achieve the necessary speed adjustment while maintaining continuous operation and improved productivity through elimination of thread changes.
Data Source
AI summary
Disclosed is an ornamental chain stitching head, including: an upper head assembly, the upper head assembly controls movement of a needle bar and a walking foot mechanism; a walking foot eccentric configured to allow adjustment of a foot lift while a stitch length eccentric is configured to allow for adjustment of both a walking foot and a needle bar advancement via regulation of a rock frame the determines a length of a stitch created by the ornamental chain stitching head; a lower head assembly; and a needle bar cam assembly that drives rotation of the needle bar during each stitch cycle of the ornamental chain stitching head to achieve desired stitch patterns, the needle bar cam assembly is driven directly by an upper shaft through a pair of gears that reduce the needle bar cam assembly speed according to a size ratio of the pair of gears.