Automatic Apparel Machine With Rail Stands for Precise Spring Winding
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Solution Overview
Problem
Current manual preparation of raw materials for air suspension springs leads to inefficiencies, including labor loss, product deviation, increased production time, and waste due to belt slippage and operator dependency, resulting in suboptimal product quality and reduced production volume.
Innovation Solution
An automatic apparel machine with independently moving stands controlled by a camera and a servo motor-driven mandrel, replacing the belt system, enables automated raw material preparation and positioning, reducing operator intervention and ensuring precise alignment and winding angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a belt system is used to transport raw materials, then the raw materials can be moved along the machine, but the belt may slip causing position deviation and machine breakdown
Solution Approach 1:
The patent removes the belt system entirely from the machine, replacing it with independent stands that move on rails. This extraction eliminates the source of slippage and position deviation while maintaining the transport function through an alternative mechanism.
Solution Approach 2:
The friction-based belt transport system is replaced with a rail-based mechanical guidance system. The stands move on rails with defined positions, substituting the unreliable friction mechanism with a precise mechanical constraint system that prevents slippage.
2Ease of operation
If the operator manually positions raw materials on the belt, then the materials can be placed, but the production duration increases and production volume decreases
Solution Approach 1:
The patent introduces a camera system that performs preliminary positioning verification before the winding process begins. The camera checks the position of raw materials on the stands, ensuring correct placement without requiring the operator to wait for the winding operation to complete before positioning the next material.
Solution Approach 2:
The independent stands enable continuous operation by allowing the operator to prepare and position raw materials on one stand while the winding process continues on another. This eliminates idle waiting time and maintains continuous productive action throughout the manufacturing cycle.
3Productivity
If the mandrel rotates by friction with the moving belt, then the winding process can proceed, but the product may be crumpled and damaged
Solution Approach 1:
The friction-based rotation drive is replaced with a servo motor that directly controls the mandrel rotation. This substitution eliminates the crumpling caused by friction while maintaining precise control over the winding speed and tension, protecting the product from damage.
Solution Approach 2:
The servo motor provides self-regulating rotation control, automatically adjusting the mandrel speed and tension to prevent product damage. The system monitors and controls the winding process itself, ensuring optimal conditions without external intervention or reliance on friction-based mechanisms.
4Manufacturing precision
If the operator waits for the winding operation to complete before positioning the next product, then the current product can be properly processed, but the production duration increases
Solution Approach 1:
The camera system performs preliminary position verification of raw materials before the winding process completes. This allows the operator to prepare and position the next raw material in advance, eliminating idle waiting time while ensuring positioning accuracy through automated optical verification.
Solution Approach 2:
The patent divides the production process into independent segments using separate stands. One stand can be dedicated to the winding operation while another is prepared for the next product, allowing parallel processing and eliminating the need for sequential waiting between operations.
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
This solution increases production efficiency by allowing continuous operation while the operator prepares the next material, reduces waste, and ensures consistent product quality by eliminating belt slippage issues and crumpling, thereby enhancing the overall manufacturing process.
Implementation Method 1
the rotation of the mandrel is driven by a servo motor
Implementation Method 2
the positions of the raw materials located on these stands are controlled by a camera
Implementation Method 3
2 stands that move independently from each other instead of a belt system
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention is an automatic apparel machine (10) used in the manufacture of air suspension springs characterized in that, it comprises the following; two movable tables (11) that move independently from each other on the rail system (17) and where the raw material is placed; movable winding mandrel (14) moving up-down and forward-backward on the movable table (11) by means of servo motor; automatic cutting bench grippers (15) that are positioned on the automatic rubber cutting bench (13) perpendicular to the axis of the movable tables (11) in the section where the movable winding mandrel (14) is located so as to adjust the lengths of the cut raw material; an automatic rubber cutting bench (13) that cuts the raw material in the direction of the length and angles required for the finished product saved in the system.