Sock Transfer Alignment for Automatic Seaming Orientation

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Solution Overview

Problem

Existing automation systems for transferring and positioning socks to the seaming step are inefficient, particularly for generic socks without reference 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 socks using sensors, capable of working with both marked and unmarked socks, and a carousel structure with motorized wheels and sensors to automate the positioning and orientation of socks on a loading tube, ensuring accurate transfer to the seaming machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If an optical system detects colored marks on socks to determine position and orientation, then the positioning accuracy is improved, but the system cannot handle generic socks without reference marks

Engineering Contradiction:

Improvepositioning accuracyVSAvoidcompatibility with generic socks

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent uses optical sensors to detect colored reference marks on socks to determine their position and orientation. The system is designed to recognize specific color patterns and use them as reference points for accurate positioning during automated transfer operations.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The patent describes a positioning system that should work with both marked and unmarked socks. The optical detection system is designed to first attempt detection of reference marks, and if none are found, to use alternative methods such as detecting the sock's physical boundaries and shape characteristics to achieve positioning.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If manual positioning of socks is used in the seaming machine, then flexibility is maintained, but productivity decreases and human intervention is required

Engineering Contradiction:

Improveoperational flexibilityVSAvoidmanufacturing throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent implements an automated system where the sock positioning and transfer process is performed autonomously without human intervention. The optical detection system automatically identifies sock position and orientation, and the transfer mechanism automatically positions the sock for the seaming operation, eliminating the need for manual handling while maintaining operational flexibility through programmable control.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical positioning with an automated optical-mechanical system. Optical sensors detect sock characteristics, and this information is used to control motorized transfer mechanisms that automatically position and orient socks for seaming, substituting human operators with automated sensing and actuation systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple operating stations are used for sock transfer, then positioning accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidnumber of operating stations

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated transfer station that performs detection, positioning, and transfer operations. The optical detection system and mechanical transfer mechanism are integrated in one station, eliminating the need for separate positioning stations and reducing overall system complexity while maintaining positioning accuracy through coordinated operation of the integrated components.

Inventive Principle:

Principle #5Merging (Combining)

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, human-intervention-free automatic transfer of socks to the seaming step, increasing productivity and reducing the number of operating stations, while ensuring accurate positioning and orientation of generic socks without reference marks.

Implementation Method 1

an optical system for detecting the position and orientation of generic socks, i.e. without reference marks

Methodology Applied

Scientific EffectOptical detection: Light

Data Source

PatentUS7845526B2Machine and method for handling tubular manufactured items

Publication Date: 2010.12.07 SANTONI SPA

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.