Template-less Robotic Sewing System for Arbitrary Seam Paths
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Solution Overview
Problem
Existing pattern sewing machines require multiple custom templates for each product size and style, limiting manufacturing flexibility and increasing tooling costs, as they are not well-suited for sewing complex or arbitrary seam shapes.
Innovation Solution
A robotic system with a material holding apparatus and adaptive control schemes that can secure and position layered materials for automated sewing, allowing for the sewing of multiple or infinite seam paths without the need for traditional pallets, using a robotic system with a processor, automated sewing machine, and material movers to maintain material orientation and position during sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional pattern sewing machines use custom templates (pallets) for each product size and style, then sewing accuracy is maintained, but manufacturing flexibility is limited and tooling costs increase
Solution Approach 1:
The patent implements a universal template-less sewing system where a single apparatus can sew multiple seam paths and arbitrary shapes through software control and adaptive material holding, eliminating the need for dedicated custom templates for each product size and style while maintaining sewing accuracy
Solution Approach 2:
The system uses dynamic material holding and manipulation hardware that can actively reconfigure during sewing to accommodate different seam paths and product configurations, allowing the same apparatus to adapt to various sewing requirements without physical template changes
2Manufacturing precision
If multiple custom templates are created for different product sizes and styles, then specific sewing paths are achieved, but tooling costs increase
Solution Approach 1:
The system replaces physical custom templates with digital seam path definitions and software-controlled material manipulation, where virtual copies of sewing paths can be stored and executed without requiring physical template manufacturing, thereby eliminating tooling costs while maintaining seam path accuracy
Solution Approach 2:
The patent substitutes the mechanical template system with a software-controlled adaptive system that uses digital models and electronic control to define and execute sewing paths, eliminating the need for physical template manufacturing and reducing tooling costs
3Device complexity
If traditional pallets with limited seam paths are used, then manufacturing simplicity is maintained, but adaptability to different seam shapes is reduced
Solution Approach 1:
The system employs dynamic material holding and manipulation capabilities that allow the same apparatus to adapt to different seam paths and arbitrary shapes through active reconfiguration during sewing, maintaining system simplicity while dramatically increasing seam path variety
Solution Approach 2:
The system changes operational parameters through software control and adaptive material manipulation rather than physical template changes, allowing the same apparatus to execute different seam paths by modifying control parameters and material holding configurations
Data Source
AI summary
Various examples are provided related to transporting and sewing material in, e.g., automation of sewing robots. Multiple pieces of layered materials can be transported on a flat planar surface while maintaining the material layer's position and orientation relative to one another during a sewing procedure of these materials along any arbitrary seam shape. In one example, among others, a method includes positioning a second piece of material on a first piece of material located on a sewing plane, positioning a material holding apparatus over the pieces of material to secure position and orientation between the pieces of material, locating the pieces of material with respect to an automated sewing machine by repositioning the material holding apparatus, and sewing the second piece of material to the first piece of material. The methods can eliminate the need of custom-made templates for sewing arbitrarily shaped seams with an automated sewing machine.