Robotic Thread Adjustment for Steering Wheel Cover Stitch Pitch
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Solution Overview
Problem
The manual assembly process of fixing a leather cover to a steering wheel is labor-intensive and time-consuming, necessitating the automation of the sewing process to improve efficiency and reduce human error.
Innovation Solution
A robot system equipped with a robotic arm and an adjusting tool that can hold and tension sewn threads, allowing for the adjustment of stitch pitches to enhance joint strength and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sewing is used to fix the leather cover to the steering wheel, then the assembly can be completed with simple tools and techniques, but the process is labor-intensive and time-consuming
Solution Approach 1:
The robot system performs the sewing operation autonomously without requiring human operators to manually guide each stitch. The robotic arm automatically positions the needle, penetrates the leather cover, and forms stitches according to pre-programmed paths, enabling the system to serve itself in completing the assembly task
Solution Approach 2:
The patent replaces the manual mechanical sewing operation with an automated robotic system. The robotic arm with integrated sewing mechanism substitutes human hands and traditional sewing tools, using programmable motion control to achieve precise stitch placement and consistent sewing quality at higher speeds
2Productivity
If the adjusting tool moves directly across the thread section, then the pitch adjustment can be performed efficiently, but scratches may occur on the flexible material surface
Solution Approach 1:
The adjusting tool approaches and moves across the thread section from a lateral dimension rather than directly from above. By offsetting the tool path laterally and approaching the thread at an angle, the tool can adjust the stitch pitch without the tool body contacting and scratching the flexible material surface
Solution Approach 2:
The lateral offset position acts as an intermediary approach path. The tool reaches the adjustment position indirectly by moving laterally offset from the direct vertical path, allowing it to perform the pitch adjustment function while maintaining a safe distance from the material surface to prevent scratches
3Object-affected harmful factors
If the adjusting tool is depressed toward the outer surface to prevent scratches, then surface protection is improved, but the tool may encounter barriers when moving across the thread section
Solution Approach 1:
The tool moves in a three-dimensional path that combines lateral offset movement with controlled vertical depression. By changing from a simple horizontal motion to a composite lateral-and-vertical path, the tool maintains close proximity to the material surface for protection while creating sufficient clearance to pass through the thread section without encountering barriers
Data Source
AI summary
Embodiments of present disclosure relate to a robot and a method for adjusting sewn threads. The robot includes a robotic arm configured to hold an adjusting tool, and a controller configured to cause the adjusting tool to partially go across a thread section along a path defined between a bottom side of the thread section and an outer surface of an object. The sewn threads have a first end fixed to the object and a second end, a plural of stitches formed across a sewing zone on the object between the first end and the second end, and each stitch has the thread section including a top side and the opposite bottom side. Then the adjusting tool moves upward away from the outer surface so as to adjust pitches between the stitches.