Robotic Baseball Cover Sewing for Consistent Seam Assembly
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Solution Overview
Problem
The manual process of sewing baseball covers is inefficient and labor-intensive, leading to high costs and inefficiencies in producing and restoring baseballs, with most balls being discarded due to worn covers rather than compressed cores.
Innovation Solution
A robotic device and system for sewing baseball covers in a two-dimensional configuration, using multiple arms and claws to stitch baseball cover halves on a film, with optional tubes and magnets for positioning, and a controller for precise needle paths, allowing assembly around a spherical core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual sewing process is used, then seam quality and consistency can be maintained through artisan skill, but production time and labor costs increase significantly
Solution Approach 1:
The patent replaces the manual mechanical sewing process with an automated robotic system. The robotic device uses computer-controlled needles and threads to stitch baseball covers, eliminating the need for manual artisan skill while maintaining consistent seam quality through programmed precision. The system automatically positions and sews multiple baseball covers simultaneously, dramatically increasing production throughput.
2Reliability
If baseball covers are discarded due to wear, then core performance can be preserved, but material waste and production costs increase
Solution Approach 1:
The patent enables recovery and reuse of baseball cores by making cover replacement efficient and economical. The automated sewing system allows quick replacement of worn covers on cores that have not yet reached the end of their performance life. This separates the disposable cover component from the reusable core, reducing material waste and extending the usable life of the baseball through multiple cover replacements.
3Productivity
If automated sewing system is implemented, then production efficiency increases, but device complexity and initial investment increase
Solution Approach 1:
The patent divides the baseball assembly process into separate functional modules: a platform for holding cover halves, multiple robotic arms for stitching operations, thread supply mechanisms, and a core insertion system. Each module performs a specific function and can be independently controlled or replaced. This modular segmentation manages system complexity while maintaining high automation and production efficiency.
4Productivity
If multiple baseball covers are sewn simultaneously, then production throughput increases, but control precision and seam consistency become more difficult to maintain
Solution Approach 1:
The patent incorporates sensors and computer control systems that monitor the positioning and stitching of each baseball cover in real-time. The system receives feedback on needle position, thread tension, and cover alignment, automatically adjusting parameters to maintain consistent seam quality across multiple simultaneously processed covers. This closed-loop control ensures precision is maintained despite increased throughput.
Data Source
AI summary
A robotic device for sewing a ball includes a platform, a first arm, a second arm, a first claw, a second claw, and a controller. The platform is configured to support a film for supporting two ball cover halves in a single plane. The first arm is positioned above the platform. The second arm is positioned below the platform. T first claw is supported by the first arm and is configured to releasably grasp a first needle. The second claw is supported by the second arm and is configured to releasably grasp the first needle. The controller is disposed in communication with the first arm, the second arm, the first claw, and the second claw, and is configured to move the first arm, the second arm, the first claw, and the second claw such that the first needle follows a first needle path.