Integrated Web Sewing and Trimming Carriage
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Solution Overview
Problem
Current carpet and textile web production processes require bulky, space-consuming sewing and trimming devices that necessitate manual handling and expose operators to safety hazards, as they need separate stations and manual transportation, which is time-consuming and inefficient.
Innovation Solution
A sewing system integrated with a spooling machine, featuring a horizontal carriage rail and retractable pins for automatic web support, allowing for direct trimming and sewing from the unwind system with a single operator, and enabling the trimming machine to be used independently of the sewing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate stand-alone sewing and trimming devices are used, then the sewing and trimming functions are performed, but the device occupies considerable space and requires manual handling by multiple operators
Solution Approach 1:
The patent combines the sewing machine, trimming device, and web support system into a single integrated apparatus. The sewing machine and trimming device are mounted on the same horizontal carriage that travels along a vertical rail, allowing both functions to be performed at one location directly at the unwind system without requiring separate stations or manual web transport.
Solution Approach 2:
The horizontal carriage serves multiple functions: it supports both the sewing machine and trimming device, provides a moving work surface that accommodates webs of various sizes, and integrates the web support pins into the same structure. This multi-functional design eliminates the need for separate dedicated stations for each operation.
2Stability of the object's composition
If exposed nails are used to hold the web in place, then the web is stabilized for alignment, but safety hazards are created for operators
Solution Approach 1:
The web support pins are designed to be movable rather than fixed. They can be raised to penetrate the web for stabilization during positioning and alignment, then lowered or retracted after the web is secured to the carriage, eliminating the safety hazard of exposed sharp points while maintaining their utility for web handling.
Solution Approach 2:
The pins are positioned and raised in advance to stabilize the web before the sewing and trimming operations begin. Once the web is properly aligned and secured, the pins are lowered, preparing the system for the next operation while removing the safety hazard.
3Productivity
If manual transport of the web to separate sewing and trimming stations is required, then the web can be processed, but time is consumed and operator efficiency is reduced
Solution Approach 1:
By integrating both the sewing machine and trimming device on the same movable carriage, the system eliminates the need to physically move the web between separate stations. The carriage itself moves to position both devices at the optimal location directly at the unwind system, allowing seamless transition between trimming and sewing operations without time-consuming manual web transport.
Data Source
AI summary
A sewing system is disclosed for facilitating the sewing together with a sewing machine ends of at least two webs that are held by a spooling machine. A substantially horizontal carriage rail is supported by a support mounting means in fixed relationship with the spooling machine and itself slidably supports a sewing carriage adapted to hold the sewing machine. A trimming carriage is also slidably supported on the carriage rail and supports a conventional trimming machine that trims the ends of each web ahead of the sewing machine. The trimming carriage is selectively and mechanically fixed with the sewing carriage with a mechanical fastener, so that as the sewing carriage is moved along the carriage rail, the trimming carriage is also moved along thereby. A substantially horizontal support platform is fixed with the carriage rail and adapted to hold each web fixed with respect thereto with a plurality of vertically-movable pins that traverse each web in a raised position.