Parallel Cord Switching for Tampon Sewing Efficiency
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Solution Overview
Problem
The conventional production method for sanitary tampons is limited by the sewing machine's performance, making it difficult to increase production efficiency beyond its sewing speed, as it typically sews a single continuous string-like cord to cotton pad pieces at predetermined intervals.
Innovation Solution
The method involves placing two continuous string-like cords in parallel on cotton pad pieces and switching them between sewing steps, allowing for simultaneous sewing and cutting of threads, thereby increasing production efficiency by doubling or tripling the production rate using the same sewing machine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single continuous string-like cord is sewn to cotton pad pieces sequentially, then the sewing process is simple and easy to operate, but the production efficiency is limited by the sewing machine's speed
Solution Approach 1:
The single cord sewing process is segmented into multiple parallel cord streams. Instead of sewing one cord to multiple pad pieces sequentially, the invention places multiple continuous cords in parallel and sews each cord to adjacent pad pieces simultaneously, dividing the production stream into multiple independent sewing lines that operate in parallel on the same machine
Solution Approach 2:
The production process transitions from a one-dimensional sequential sewing approach to a two-dimensional parallel arrangement. Multiple cords are placed side-by-side in the transverse direction, allowing the sewing machine to process multiple pad pieces simultaneously across the width of the material rather than moving only in the longitudinal direction
2Productivity
If multiple continuous cords are placed in parallel and sewn simultaneously, then the production rate increases several fold, but the cord switching and thread cutting operations become more complex
Solution Approach 1:
The cords are pre-positioned in parallel alignment before the sewing process begins. This preliminary arrangement ensures that when the sewing machine needs to switch between cords or cut threads, the cords are already in the correct positions, reducing the complexity of switching operations and enabling automated control
Solution Approach 2:
A cord switching mechanism acts as an intermediary between the multiple parallel cords and the sewing machine needle. This intermediary device automatically transfers the needle between different cords at predetermined intervals, eliminating the need for manual intervention and simplifying the operation of managing multiple cords
Data Source
AI summary
A production method for producing sanitary tampons implements a cord placement step of placing at least two continuous string-like cords in parallel on surfaces of at least two cotton pad pieces sequentially placed along a sewing line in a sewing direction of a sewing machine, a first cord sewing step of sewing the cord to one of two cotton pad pieces placed in an adjacent manner, a second cord sewing step of sewing the cord to the other of the two cotton pad pieces, and a cord switching step of switching the cords to be sewn to the cotton pad piece between the first cord sewing step and the second cord sewing step.