Programmable Sewing Unit with Dynamic Pin Rows for Trouser Fly Alignment
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Solution Overview
Problem
Existing automatic sewing machines for trousers are limited in versatility, as they can only sew on the right front panel of male trousers and lack mechanical alignment systems for sewing on the left front panel of female trousers, leading to imprecise processing and inability to manufacture flies with both buttons and zippers on female trousers.
Innovation Solution
An automatic unit with a loading device featuring independent double rows of pins integrated into the loading surface, allowing programmable sewing on both male and female trousers' front panels, with adjustable and movable pins for precise alignment and vacuum system for material retention, enabling sewing with buttons or zippers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical system with two grippers is used to align the panel with the sewing head, then sewing on the right front panel of male trousers is enabled, but sewing on the left front panel of female trousers is not possible
Solution Approach 1:
The loading device is designed with four rows of pins (first and second pairs of rows) that can be selectively activated. The control unit enables the same loading device to accommodate both right front panels of male trousers and left front panels of female trousers by selectively engaging different pin rows, making the system universal for both panel orientations without requiring separate mechanical alignment systems.
Solution Approach 2:
The pins are designed to be movable rather than fixed. The control unit independently moves the first and second pairs of pin rows between a first position (for right front panel loading) and a second position (for left front panel loading). This dynamic reconfiguration allows the system to adapt to different panel orientations by changing the pin positions rather than requiring complex mechanical alignment mechanisms.
2Adaptability or versatility
If the loader is fixed onto the right part of the loading surface, then right front panel loading is enabled, but left front panel loading is precluded
Solution Approach 1:
The loader is designed with dynamic positioning capability. The control unit independently moves the loader between a first position aligned with the first pair of pin rows (for right front panel loading) and a second position aligned with the second pair of pin rows (for left front panel loading). This dynamic repositioning enables the same loader to handle both panel orientations without requiring fixed installations for each side.
Solution Approach 2:
The loader is designed as a universal loading mechanism that can service both right and left front panels. By selectively positioning the loader at different locations on the loading surface and activating corresponding pin rows, the same loader performs multiple loading functions, eliminating the need for separate dedicated loaders for each panel type.
3Device complexity
If no mechanical alignment system is provided, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a programmable control system. The control unit independently controls the movement of pin rows and the loader based on programmed instructions. This substitution of mechanical alignment mechanisms with programmable control maintains high precision while reducing mechanical complexity, as the alignment is achieved through coordinated digital control rather than complex mechanical linkages.
Solution Approach 2:
The pin rows and loader are designed to self-align through programmable control. The control unit automatically positions the pins and loader in the correct configurations for different panel types without requiring external mechanical alignment devices. The system serves itself by using digital programming to achieve precise positioning, eliminating the need for separate mechanical alignment subsystems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and versatile programmable sewing on both male and female trousers' front panels, improving manufacturing accuracy and flexibility to accommodate different styles, including buttons and zippers, by integrating a mechanical system with independent pin rows and vacuum assistance.
Implementation Method 1
vacuum system for material retention
Data Source
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AI summary
An automatic sewing unit (20, 21) adapted to carry out a programmable sewing of a trouser fly, comprising a work surface (22) on which a loading device (23) for conveying a trouser panel is positioned and operates and a sewing head (26) positioned on a side opposite the work surface (22) relative to the loading device (23). The loading device (23) comprises a material loading gripper (24) hinged to a conveyor plate (24') for conveying a fabric panel and which is movable relative to the gripper (24) by means of an actuator (25) that enables the opening or closing of the gripper itself with a folding movement relative to the conveyor plate (24'). Acting on the work surface (22) there is a first row of pins (29) aligned with one another and movable only in a vertical direction relative to the work surface (22) and a second row of pins (30) movable both in a vertical direction and in a horizontal direction relative to the work surface (22), said pins (29, 30) being able to be shifted vertically from a working position wherein the pins come out of holes fashioned in the work surface (22) and a rest position wherein the pins go back inside the work surface (22) .