Sewing Direction Control via Rotating Plate and Toothed Rack
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic sewing machines face challenges in maintaining accurate sewing direction due to the need for high-cost manipulator arms with excellent acceleration and precise distance control, and existing solutions are not applicable to sewing machines with cylinder bed heads, leading to poor stitching and deviation issues.
Innovation Solution
A sewing direction control apparatus featuring a circular ring-shaped transmission element with a servo motor-driven disc-shaped driving unit, utilizing teeth engagement for accurate and fast movement, suitable for various automatic sewing machines, ensuring the sewing product is aligned correctly with the needle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a manipulator arm with excellent acceleration ability and precise distance control is used, then sewing direction accuracy is improved, but manufacturing and maintenance cost increases significantly
Solution Approach 1:
The patent replaces the complex manipulator arm mechanical system with a simplified rotational drive system consisting of a rotating plate, driving wheel, and toothed rack. This substitution maintains sewing direction accuracy through precise toothed engagement while dramatically reducing manufacturing and maintenance costs by eliminating the need for expensive multi-axis manipulator hardware.
Solution Approach 2:
The patent changes the control parameter from complex spatial positioning (x, y, z coordinates) to a simpler rotational angle parameter. By controlling the rotation angle of the rotating plate, the sewing product's orientation is precisely adjusted, reducing the complexity of control systems and lowering overall system cost while maintaining accuracy.
2Speed
If a manipulator arm with excellent acceleration ability is used, then sewing speed and responsiveness are improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent segments the movement function into two independent parts: the sewing head maintains fixed directional sewing capability, while the rotating plate handles all orientation adjustments. This segmentation allows the sewing head to operate at high speed without being burdened by complex movement mechanisms, improving overall sewing speed while reducing device complexity.
Solution Approach 2:
The patent extracts the orientation control function from the sewing head and places it on a separate rotating plate. This extraction allows the sewing head to focus solely on high-speed stitching operations, while the rotating plate independently handles acceleration and deceleration for orientation changes, reducing the complexity of the main sewing mechanism.
3Manufacturing precision
If the sewing product is moved rapidly in small intermittent distances, then sewing precision is improved, but the control system becomes more complex and costly
Solution Approach 1:
The patent introduces a toothed rack as an intermediary between the driving wheel and the rotating plate. This intermediary provides precise positional control through toothed engagement, ensuring the rotating plate moves exactly the required distance in controlled increments, thereby achieving high sewing position precision without requiring a complex control system.
Solution Approach 2:
The patent employs periodic intermittent motion through the engagement and disengagement of the toothed rack with the driving wheel. The driving wheel rotates in discrete steps, engaging the toothed rack to move the rotating plate precisely, then disengaging to allow rapid repositioning. This periodic action achieves high precision at low cost by using simple mechanical indexing rather than complex continuous control.
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
The solution provides low-cost, precise, and efficient sewing direction control, suitable for diverse automatic sewing machines, enhancing sewing speed and quality by maintaining the sewing product's alignment with the needle, thus improving overall sewing performance.
Implementation Method 1
The sewing direction control apparatus uses teeth engagement to perform highly accurate, intermittent and fast movement
Data Source
AI summary
A sewing direction control apparatus for sewing machine, comprising: a base plate (10), a circular ring-shaped transmission element (20) dispose on the base plate (10) and a driving element (50) with a driving unit (52). During sewing, the driving unit (52) drives the transmission element (20), rotating a sewing product (A) placed at the center of the transmission element (20) with the driving element (52), thereby controlling the sewing direction of the sewing product (A), and thus improving the sewing accuracy. The direction control apparatus has low cost, and is suitable for various types of automatic sewing machines.