Braiding Wig Cap Embroidery Automation
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Solution Overview
Problem
Traditional braiding wig production is inefficient and costly due to the manual implantation of hair into a three-dimensional net wig cap, requiring nearly 40 hours per unit and resulting in high labor and production costs, making the wigs expensive and less marketable.
Innovation Solution
A net wig cap with embroidered patterns using an embroidery machine, allowing for the decomposition of the cap into pieces, embroidery of patterns, cutting, and splicing into a cap, followed by crocheting hair or pre-woven braids onto the embroidered threads, significantly reducing manual workload and enabling batch production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual crocheting, knitting and knotting is used to implant hair into the net wig cap, then the wig can be produced with traditional methods, but the production time is extremely long (nearly 40 hours per unit) and labor costs are very high
Solution Approach 1:
The patent replaces the manual mechanical system (hand crocheting, knitting and knotting) with an automated embroidery machine system. The embroidery machine uses programmable mechanical movements to automatically create patterns and implant hair, eliminating the need for manual operations and dramatically reducing production time from 40 hours to a fraction of that time.
Solution Approach 2:
The patent changes the operational parameters from manual control to automated programmable control. The embroidery machine operates with predetermined patterns, speeds, and stitching parameters that can be precisely controlled and replicated, enabling consistent high-speed production while maintaining quality standards.
2Ease of manufacture
If manual implantation method is used, then traditional production processes can be maintained, but the labor costs and time costs become extremely high making wigs expensive and less marketable
Solution Approach 1:
The patent replaces complex manual implantation processes with a simplified automated embroidery machine system. The machine handles pattern creation, hair placement, and stitching in one integrated process, making the manufacture easier to standardize and scale while dramatically improving productivity.
3Productivity
If automated embroidery machine is used to embroider patterns on net pieces, then batch production can be realized and efficiency improved, but the device complexity increases
Solution Approach 1:
The patent divides the net wig cap into multiple separate net pieces that can be independently embroidered and then spliced together. This segmentation allows the embroidery machine to work on smaller, more manageable sections, improving efficiency while the modular approach also makes the overall system easier to control and maintain despite the increased automation.
Data Source
AI summary
A net wig cap for processing a braiding wig includes a plurality of net pieces, where each of the net pieces is provided with patterns composed of wig threads. A method for processing a braiding wig includes: step 1: processing the net wig cap; and step 2: crocheting hair or pre-woven single-dreadlock braids onto embroidered wig threads. The present disclosure creatively applies an embroidery machine to the field of wig processing. The present disclosure first embroiders a layer of patterns composed of wig threads on a base layer of a wig by the embroidery machine, and then crochets pre-woven single-dreadlock braids onto the embroidered wig thread patterns one by one. The present disclosure does not need to manually fix the wig threads on the wig, which greatly reduces the manual workload, improves the processing efficiency and reduces the cost.