Sock Transfer Alignment for Reliable Automatic Seaming Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machines for automating the transfer and positioning of knitted tubular items like socks to the seaming step are inefficient, particularly for items without colored marks, leading to incorrect insertion and requiring human intervention, which reduces productivity and increases the number of operating stations needed.
Innovation Solution
A machine with an optical system that detects the position and orientation of generic socks without reference marks, using sensors to adjust the position and orientation of the socks on a loading tube, and a carousel structure with stations for positioning, orientation, and transfer to ensure accurate and automated insertion into the seaming machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual positioning by operator is used, then correct insertion is achieved, but productivity is reduced and human intervention is required
Solution Approach 1:
The system enables self-service automation where the machine automatically positions and transfers socks without human intervention. The optical detection system and actuators work autonomously to achieve correct insertion, eliminating the need for manual operator positioning while maintaining reliability and increasing productivity.
Solution Approach 2:
Manual mechanical positioning by operators is replaced with an automated system combining optical detection (sensors) and mechanical actuators. This substitution maintains the reliability of correct insertion while dramatically improving productivity by eliminating human intervention in the positioning process.
2Measurement precision
If optical system with colored marks is used, then position and orientation detection is achieved, but it cannot be used for generic socks without marks
Solution Approach 1:
The optical detection system is designed with universality to handle both marked and unmarked socks. By incorporating multiple sensor types (color sensors for marked socks and geometric/shape sensors for unmarked socks), the system achieves multi-functionality that maintains measurement precision across different sock types, thereby increasing versatility.
Solution Approach 2:
The system adapts to different sock types by changing detection parameters. For marked socks, it uses color-based parameters; for unmarked socks, it switches to geometric parameters such as shape, size, and structural features. This parameter adaptation allows the same optical system to maintain measurement precision across diverse sock types.
3Reliability
If multiple operating stations are used, then reliable transfer is achieved, but the number of stations increases system complexity
Solution Approach 1:
The system merges multiple functions into a single integrated operating station. The optical detection system, actuators for positioning, and transfer mechanisms are combined in one station, eliminating the need for multiple separate stations. This merging maintains reliable transfer while reducing system complexity.
Solution Approach 2:
A single operating station is designed with multi-functionality to perform detection, positioning, orientation, and transfer operations. This universal station consolidates what would traditionally require multiple specialized stations, reducing device complexity while maintaining the reliability of the transfer process.
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 reliable, automated transfer of socks to the seaming step without human intervention, increasing productivity and reducing the number of operating stations, while ensuring accurate positioning and orientation of generic socks, thus enhancing both quality and efficiency in the manufacturing process.
Implementation Method 1
an optical system for detecting the position and orientation of generic socks, i.e. without reference marks
Data Source
AI summary
A machine, and a related method, for automatically transferring tubular items for manufacturing men's socks, comprising a station (S1) for loading automatically the tubular items (1) arranged on a longitudinal axis thereof, a station (S2) for positioning the items in a direction parallel to the longitudinal axis thereof, a station (S3) for orienting angularly the items with respect to a rotation axis parallel to the longitudinal axis thereof, and a station (S4) for transferring along a transfer line (T) the oriented items, the transfer station comprising a first and a second leader for aligning a portion of the tubular items (1), in which the leaders are arranged one after the other along the transfer line (T) and are separated by a non-controlled section of said line, for correcting in the second leader possible errors of insertion of the item into said first leader.