CN110747586A - Improved looping machine and associated method - Google Patents
Improved looping machine and associated method Download PDFInfo
- Publication number
- CN110747586A CN110747586A CN201910251849.9A CN201910251849A CN110747586A CN 110747586 A CN110747586 A CN 110747586A CN 201910251849 A CN201910251849 A CN 201910251849A CN 110747586 A CN110747586 A CN 110747586A
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- fabric
- needle
- looping
- machine
- line
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B7/00—Linking machines, e.g. for joining knitted fabrics
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B19/00—Programme-controlled sewing machines
- D05B19/02—Sewing machines having electronic memory or microprocessor control unit
- D05B19/04—Sewing machines having electronic memory or microprocessor control unit characterised by memory aspects
- D05B19/08—Arrangements for inputting stitch or pattern data to memory ; Editing stitch or pattern data
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B79/00—Incorporations or adaptations of lighting equipment
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Sewing Machines And Sewing (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
Abstract
A looping machine (4) comprising a fabric (12) feeding device (16) along a longitudinal direction (Y-Y), a needle (10) positioning device (20) along a transverse direction (X-X), a needle (10) operating device (24) along a vertical direction (Z-Z) perpendicular to the longitudinal direction (Y-Y) and to the transverse direction (X-X) to perform a looping operation, characterized in that it comprises a camera (103) adapted to identify a guide wire (40) placed on at least one fabric (12) to be stitched, the guide wire (40) being inserted inside the fabric (12) to identify a plurality of line segments (dots) (44). The machine (4) comprises a processing and control unit (56) operatively connected to the camera (103) and to the actuators of the needle (10) positioning device (20) and of the needle (10) actuating device (24) of the fabric (12) feeding device (16); to determine in real time a target suturing position of the needle (10) according to a guide wire (40) and to control in real time the device (16, 20, 24) to reach the target suturing position of the needle (10).
Description
Technical Field
The present invention relates to an improved looping machine and a related looping operation method.
Background
As is well known, cuffs are a treatment used in the textile field involving joining two pieces of fabric together. For example, it is used to attach collars, cuffs and sleeves to the rest of the garment, enabling the manufacture of a finished product. The attachment of the flaps (flaps) is carried out by stitching together the two ends of the fabric, stitch by stitch. The tie thread is "knitted" between the end rows of the two flaps, so that a continuous stitch is obtained. The joint made in this way is very flat and practically imperceptible.
The looping operation appears to be a rather restrictive process:
looping operations are slow and expensive; in this respect, it is estimated to occupy more than 70% of the garment production time;
current loopers are not flexible, in fact require different settings when the fabric fineness changes, and therefore the setting time also limits its productivity;
the cuff operator requires a great deal of experience and skill to minimize errors and he/she can obtain certain speeds and skills after several months of practice;
one of the main problems encountered by people working in this sector is: excessive eye fatigue due to the manner in which the cuff is applied; if this fatigue is extended over time, it can lead to a gradual loss of vision for the operator.
For these reasons, a looper is provided which is capable of autonomously identifying where to perform sewing, improving the working conditions of a person using the machine, alleviating the work task and preventing accidents at the workplace, in addition to the advantages in terms of speed, cost and execution accuracy.
Fig. 1 shows a conventional looping machine. This is a circular machine and the operator must insert the stitches into the ends at both fabric ends. The machine then makes a cuff operating point at the pre-positioned suture.
There are also examples in the prior art of loopers of the automatic or semi-automatic type, which are intended to at least partially solve the above-mentioned problems of machines of the manual type.
However, these machines do not fully address the problem of preventing or limiting the correct operation of the machine.
For example, the algorithms of these known loopers represent a major limitation: as it calculates the average between the spacing of the holes where the needle must stitch the seam and then controls the motor/actuator to move the needle at a fixed spacing along the seam line. This solution is not very useful because the distance between the stitches is highly variable in the fabric. For example, one of the main reasons for the variation in the distance between the holes is the tension maintained by the fabric during its advancement. With this control option, a correct sewing pitch cannot be obtained at an arbitrary sewing speed, resulting in several errors.
Furthermore, the mechanical structure of the known machines has great limitations in terms of the choice of components that limit the maximum speed of the machine to a maximum of 400 needles per minute. These limitations are due, for example, to the following factors:
the use of motors is less versatile in the number and type of parameters that are modified to perform the movement. In particular, it is not possible to change the gain of the PID controller. Furthermore, it is not possible to distribute the position, velocity and acceleration profiles adopted by the motor as desired. With regard to diagnostics, it is not possible to monitor which is the reference position and the actual position the motor is in during the movement: this limitation is the reason why the stitch point is further inaccurate;
the only parameters that can be modified are the maximum acceleration and velocity used to derive the trajectory. The lack of versatility of these motors in trajectory planning is considered to be one of the most critical points for achieving high performance automation;
there is also the problem of excessive elasticity and backlash of the transmission system connected to the motor responsible for the advancement of the fabric. The movement of the fabric must take place in a very short time (about 20ms), the presence of elasticity (for example due to the belt used) causing a movement delay of the fabric with respect to the motor movement (such delay can be avoided by limiting the acceleration of the motor) and therefore limiting the movement time of the fabric. This limits the maximum speed of the overall cuff operation;
to accomplish the horizontal movement of the needle within a few milliseconds, the high inertia of the mobile unit forces the motor to work, always delivering the maximum available torque, limiting the minimum movement time to a minimum value that can no longer be reduced, and therefore limiting the overall speed of operation;
another key element determined in the movement of the movable part is the selection of the roller screw connected to the motor. In fact, the roller screw has a rather unfavourable transmission ratio, since the entire stroke of the mobile unit is completed by the motor for less than a full turn. This requires high torque to be applied by the motor to move quickly.
Disclosure of Invention
Accordingly, it is believed that a need exists to address the shortcomings and limitations noted with reference to the prior art.
The following patent allows to overcome all the technical problems of both manual and automatic looping machines used so far, as well as the mechanical and software limitations.
The need to overcome the drawbacks and limitations of the solutions of the prior art is met by a looper machine according to claim 1 and a looper operating method according to claim 15.
Drawings
Other features and advantages of the invention will become more apparent from the following description of preferred, non-limiting embodiments of the invention, in which:
figure 1 shows a view of a manual looping machine of conventional type;
figure 2 shows a perspective view of a looping machine according to the invention;
figure 3 shows a perspective view of a detail of the looping machine according to the invention;
figures 4 to 5 are schematic views of the operation of a looping machine according to the invention;
figure 6 shows a perspective view of a particular plate of the linking machine;
figure 7 shows a schematic view of the operation of the looping machine according to the invention.
Common elements or parts of elements in the embodiments described below are denoted by the same reference numerals.
Detailed Description
With reference to the accompanying drawings, the reference numeral 4 generally designates a schematic overall representation of a looping machine according to the invention.
The looper 4 comprises a fixed unit comprising a support frame 8 and a mobile unit 100 supported by said fixed unit so as to be able to move and suitably actuate the needles 10 to perform a looper operation on the fabric 12.
The movable unit 100 includes: a feeding device 16 of the fabric 12 along a longitudinal direction or axis Y-Y; the looping operation is performed by a positioning device 20 of the needles 10 along a transverse direction or axis X-X, perpendicular to the longitudinal direction or axis Y-Y and coplanar with the fabric 12, and by an actuating device 24 for said needles 10 along a vertical direction or axis Z-Z, perpendicular to the longitudinal direction Y-Y and to the transverse direction X-X.
The feeding device 16 of the fabric 12 comprises a blocking device 28 of the fabric 12 configured to keep the fabric 12 pressed against the feeding device 16 of the fabric 12.
According to a possible embodiment, the blocking means 28 of the fabric 12 comprise a two-way swivelling articulated foot 36 able to uniformly press the fabric 12, even in the case of non-uniform thickness of the fabric.
Preferably, the blocking device 28 is adjustable to adjust the pressure exerted by the foot 36 on the fabric 12.
The feeding device 16 of the fabric or cloth 12 comprises an electric motor 30.
The positioning device 20 of the needle 10 comprises an electric motor 30 connected to a roller screw or recirculating ball screw 101, which roller screw or recirculating ball screw 101 is in turn connected to a mobile unit 100, said mobile unit 100 performing a linear translation of the needle along the transverse direction X-X.
The actuation device 24 of the needle 10 comprises an electric motor 30 connected to the needle 10 with a connecting rod-crank mechanism for performing an alternating suturing movement of the needle 10.
Preferably, the needle 10 passes through a special plate 38 with holes 39 for the needle 10, which limits the deformation of the needle 10 and ensures a better seam.
The fabric 12 is preventively provided with a guide line 40 inserted inside the fabric 12 to show a plurality of line segments 44 (small dots).
The guide wire 40 is preferably made of a phosphorescent material so as to be easily identifiable by a suitable optical system or camera 103. For this purpose, the looper 4 is provided with an ultraviolet illumination system 52 with neon, so that the phosphorescent light guide lines 40, 48 are highlighted.
According to one embodiment, the ultraviolet illumination system 52 is mounted at the blocking means 28 of the fabric 12.
Preferably, the guide wire 40 is made of a water-soluble material so that it can be dissolved in a subsequent fabric wash without having to manually remove it.
Advantageously, the looping machine 4 comprises a camera 103 suitable for recognizing the guide wire 40. The looper 4 is also provided with a processing and control unit 56, the processing and control unit 56 being operatively connected to the camera 103 and to the actuator/electric motor arrangement of the feed device 16 of the fabric 12 and to the actuator/electric motor arrangement of the positioning device 20 of the needle 10 and to the actuator/electric motor arrangement of the actuation device 24 of the needle 10.
In this way, the processing and control unit 56 is able to determine in real time the target position of the needle 10 according to the guide wire 40 and to control in real time the feed device 16 of the fabric 12, the positioning device 20 of the needle 10 and the actuation device 24 of the needle 10 so as to reach said target stitching position of the needle 10.
In particular, the feeding device 16 of the fabric 12 and/or the positioning device 20 of the needles 10 and/or the actuating device 24 of the needles 10 comprise respective electric motors 30, which electric motors 30 perform a real-time feedback by means of said processing and control unit 56 according to the target stitching position of the needles 10.
Selecting and/or implying that: at least one of the feed device 16 of the fabric 12, the positioning device 20 of the needles 10 and the actuation device 24 of the needles 10 comprises a respective real-time feedback electric motor 30; preferably, at least two of the devices 16, 20, 24 include respective real-time feedback electric motors 30, and even more preferably, all of the devices 16, 20, 24 include respective real-time feedback electric motors 30.
According to a possible embodiment, the processing and control unit 56 is programmed so that said electric motor 30 is controlled in real time with variable pitch according to the target suturing position of the needle 10.
The operation of the looper according to the invention will now be described.
As described above, the looper machine according to the present invention is capable of performing a looper operation in a particularly efficient manner.
Specifically, the looping operation method of the fabric 12 comprises the following steps:
-providing a fabric 12 for performing a looping operation, said fabric 12 being provided with a fluorescent guide line 40, the fluorescent guide line 40 forming line segments (small dots) 44 in a manner to enter and exit the fabric 12;
-acquiring the fabric frame 12 by means of the camera 103, identifying the position of the line segment (dot) 44;
calculating a main centroid 104 representing the midpoint of the area of the line segment (small point) 44 of the guideline 40; the primary centroids 104 allow for identification of the target suture location 60 of the cuff or calculated suture by searching for intermediate locations between the primary centroids 104;
eliminating secondary centroids 68 that lead to errors in the identification of correct stitching points, such secondary centroids 68 being adjacent to the line segments (small points) 44;
performing a cuff suture at the calculated point of the target suture 64.
The step of performing stitching is provided with: the target stitching position of the needle 10 according to the guide line 40, the feed device 16 for actuating the fabric 12, the positioning device 20 for the needle 10 and the actuation device 24 for the needle 10 in real time are calculated in real time to reach said target stitching position of the needle 10.
The excluding step of the secondary centroids 68 includes the step of eliminating the secondary centroids 68 positioned to the left of the primary centroid 104 of the line segment (small point) 44 of the guide line 40 with respect to the transverse direction X-X and at the same height as the primary centroid 104 along the vertical direction Z-Z.
Preferably, the cuff operating method also provides the step of eliminating the line segment (small dot) 44 having a small area with respect to the predetermined threshold value.
Having identified the principal centroids 104 of the line segments (small dots) 44, we interpolate the principal centroids by interpolating the lines.
Furthermore, to determine the next suture or cuff operating point, two successive line segments (small dots) 44', 44 "are identified by means of the camera 103: the longitudinal coordinate of the stitching point corresponds to the average of the longitudinal coordinates of the centroid 104 of the guide line 40 and the transverse coordinate of the stitching point is arranged along said interpolation line.
As can be understood from the description, the present invention allows overcoming the drawbacks of the prior art.
In fact, the looper of the present invention is an automated machine which is completely innovative in its way of operation with respect to the known manual loopers.
In particular, as described, thanks to a particular vision system, the machine is able to identify the stitches independently, calculate in real time the looping operation steps to be performed, and then position the needle at the point indicated following a specific control algorithm. In fact, the needle can be moved in all directions on the fabric to center the suture captured in real time by the camera.
The solution of the invention allows modernization of the looping operation, solves the limitations of the current technology, increases productivity, improves the quality of the processed fabric, reduces the processing costs and improves the working conditions of the workers involved in the looping work.
In fact, the looper can be used by untrained operators who simply position the fabric at the base of the needle and operate the looper with instructions. Thus, ease of use makes training time for personnel virtually nonexistent.
Furthermore, the looper of the present invention is flexible; the looper does not require any changes in the settings to change the fineness of the fabric because it automatically calculates the spacing between one stitch and another stitch in real time.
The processing speed is far higher than that of a manual looping machine; a person can easily perform speeds in excess of 700 Points Per Minute (PPM).
The quality of operation is no longer dependent on a person but is guaranteed by the reliability of the computer.
The looping operation is cheaper and easier to perform, while improving productivity and reducing processing time.
All the problems related to the health of the operator due to the manual cuff operation are solved.
In summary, as in the known automated solutions, the electric motors are no longer controlled at a fixed pitch, but receive real-time instructions on which the next movement to be performed by feedback control must be based. The mechanical structure is simplified to overcome all the speed limitations caused by the technical choice of known automated solutions, achieving and even exceeding 700PPM or even higher. The needle can be moved in all directions on the fabric to center the suture captured in real time by the camera.
A person skilled in the art may make several changes and adjustments to the above-described looping machine and looping method to meet specific and contingent needs, all falling within the scope of protection as defined by the following claims.
Claims (20)
1. A looper machine (4) comprising:
-a fixing unit comprising a support frame (8); and
-an activity unit (100) comprising:
-a feeding device (16) of the fabric (12) along a longitudinal direction (Y-Y);
-a positioning device (20) of the needles (10) along a transversal direction (X-X) perpendicular to the longitudinal direction (Y-Y) and coplanar with the fabric (12),
-an operating device (24) of the needle (10) along a vertical direction (Z-Z) to perform a looping operation, the vertical direction being perpendicular to the longitudinal direction (Y-Y) and to the transverse direction (X-X),
it is characterized in that the preparation method is characterized in that,
said looping machine (4) comprising a camera (103), said camera (103) being adapted to identify a guide line (40) arranged on at least one fabric (12) to be stitched, said guide line (40) being inserted inside said fabric (12) so as to display a plurality of line segments (small dots) (44),
the looper (4) comprising a processing and control unit (56), said processing and control unit (56) being operatively connected to the camera (103) and to the actuator of the feed device (16) of the fabric (12), the actuator of the positioning device (20) of the needle (10) and the actuator of the actuation device (24) of the needle (10),
so as to determine in real time a target position of the needle (10) according to the guide line (40) and to control in real time the feeding device (16) of the fabric (12), the positioning device (20) of the needle (10) and the actuation device (24) of the needle (10) to reach the target sewing position of the needle (10).
2. Looper (4) according to claim 1, wherein the feed device (16) of the fabric (12) and/or the positioning device (20) of the needles (10) and/or the actuating device (24) of the needles (10) comprise respective electric motors (30) with real-time feedback by the processing and control unit (56) according to the target sewing position of the needles (10).
3. The looper (4) according to claim 2, wherein the processing and control unit (56) is programmed such that the electric motor (30) is controlled at variable intervals in real time depending on the target stitch position of the needle (10).
4. Looping machine (4) according to any of the previous claims, wherein said fixed unit supports said devices (16, 20, 24) of said mobile unit (100).
5. Looping machine (4) according to any one of the previous claims, wherein said feeding device (16) of the fabric (12) comprises a blocking device (28) of the fabric (12), said blocking device (28) being configured to keep the fabric (12) pressed against a support plate (32).
6. Looping machine (4) according to claim 5, wherein said blocking means (28) of the fabric (12) comprise a foot (36) hinged with a bidirectional rotation able to uniformly press the fabric (12), which is able to uniformly press the fabric even in the presence of non-uniformity of the thickness of the fabric (12).
7. Looping machine (4) according to claim 6, wherein said blocking means (28) are adjustable so as to adjust the pressure exerted by said foot (36) on said fabric (12).
8. Looping machine (4) according to any one of claims 5 to 7, wherein said feeding device (16) of the fabric (12) comprises an electric motor (30) connected to said feeding device (16) of the fabric (12).
9. Looper (4) according to any one of the preceding claims, wherein the positioning device (20) of the needle (10) comprises an electric motor (30) connected to a roller screw or circulating ball screw (101) which is in turn connected to a mobile unit (100), the mobile unit (100) performing a linear translation of the needle (10) along the transverse direction (X-X).
10. Looper (4) according to any one of the preceding claims, wherein the actuating device (24) of the needle (10) comprises an electric motor (30) connected with the needle (10) with a connecting rod-crank mechanism to perform an alternating stitching movement of the needle (10).
11. Looping machine (4) according to any of the previous claims, wherein said looping machine (4) is equipped with a uv lighting system (52) to highlight said guide line (40), said guide line (40) being phosphorescent.
12. Looping machine (4) according to claim 11, wherein said ultraviolet light illumination system (52) is fitted at said blocking means (28) of said fabric (12).
13. Looping machine (4) according to any of the previous claims, wherein said guide wire (40) is made of a water-soluble material.
14. Looper machine (4) according to any one of the preceding claims, wherein the needles (10) pass through a plate (38) provided with holes (39) which limits the deformation of the needles (10) and ensures better stitching.
15. A method of looping operations of a fabric (12), the method comprising the steps of:
-providing a fabric (12) performing a looping operation, said fabric (12) being provided with a fluorescent guide wire (40), said fluorescent guide wire (40) entering and exiting said fabric (12) by means of a line segment (dot) (44);
-acquiring the fabric frame (12) by means of a camera (103) so as to identify the position of the line segments (dots) (44);
-calculating a principal centroid (104) of a line segment (small point) (44) of the guide line (40), and calculating an area of the line segment (small point) (44);
-identifying a target suture point (60) of a suture (64) to be subjected to a looping operation as an intermediate point between the main centroids (104);
-eliminating secondary centroids (68) adjacent to the primary centroid (104) that are not considered;
-performing a cuff suture at the target suture point (60) of a target suture (64).
16. A method of looping operations of a fabric (12) according to claim 15, wherein said step of performing said stitching is provided with: calculating the target suture position of the needle (10) in real time from the guide wire (40); -actuating in real time the feeding device (16) of the fabric (12), the positioning device (20) of the needle (10) and the actuating device (24) of the needle (10) so as to reach the target stitching position of the needle (10).
17. A method of looping operations of a fabric (12) according to claim 15 or 16, wherein said step of excluding said secondary centroid (68) comprises: a step of eliminating a secondary centroid (68) located to the left of the centroid (104) of the line segment (small point) (44) with respect to the transverse direction (X-X) and located at the same height as the centroid (104) of the line segment (small point) (44) along the vertical direction (Z-Z); the steps are provided for calculating an interpolation line for all of the primary centroids (104), and verifying the location of the secondary centroids (68) at the interpolation line.
18. A method of looping operations of a fabric (12) according to claim 15, 16 or 17, wherein a step is provided of eliminating line segments (small dots) (44) having an area smaller than a predetermined threshold.
19. A method of looping operations of a fabric (12) according to claim 15, 16, 17 or 18, wherein, in case the main centroid (104) of said line segment (small point) (44) has been identified, it is interpolated by means of interpolation lines.
20. Method for the looping operation of a fabric (12) according to claim 19, wherein, during said looping operation, to determine the next sewing or looping operation point, two consecutive line segments (small points) (44', 44 ") are identified by means of said camera (103), and wherein the longitudinal coordinate of said sewing point corresponds to the average of the longitudinal coordinates of said main centroid (104) of said consecutive line segments (small points) (44', 44") of said guide line (40), and the transverse coordinate of said sewing point is set along said interpolation line.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IT102018000007417A IT201800007417A1 (en) | 2018-07-23 | 2018-07-23 | PERFECTED TRIMMING MACHINE AND RELATED TRIMMING METHOD |
| IT102018000007417 | 2018-07-23 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN110747586A true CN110747586A (en) | 2020-02-04 |
| CN110747586B CN110747586B (en) | 2023-07-11 |
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|---|---|---|---|
| CN201910251849.9A Active CN110747586B (en) | 2018-07-23 | 2019-03-29 | Improved looper and related methods |
Country Status (10)
| Country | Link |
|---|---|
| EP (1) | EP3599305B1 (en) |
| JP (1) | JP2020014831A (en) |
| CN (1) | CN110747586B (en) |
| ES (1) | ES2886878T3 (en) |
| IT (1) | IT201800007417A1 (en) |
| MA (1) | MA50419B1 (en) |
| MD (1) | MD3599305T2 (en) |
| MX (1) | MX2019003629A (en) |
| NI (1) | NI201900028A (en) |
| PT (1) | PT3599305T (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| PT3733945T (en) | 2019-04-30 | 2022-01-31 | Santex Rimar Group S R L | Linking machine comprising a guide for correctly positioning a single collar and a piece of knitwear with respect to one another |
| IT202100011552A1 (en) * | 2021-05-06 | 2022-11-06 | Santex Rimar Group S R L | LINKING MACHINE EQUIPPED WITH AN IMPROVED GUIDE FOR ALIGNING TWO EDGES OF FABRIC TO BE LINKED TOGETHER |
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- 2019-03-20 PT PT191641810T patent/PT3599305T/en unknown
- 2019-03-20 MA MA50419A patent/MA50419B1/en unknown
- 2019-03-20 EP EP19164181.0A patent/EP3599305B1/en active Active
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- 2019-03-27 JP JP2019059793A patent/JP2020014831A/en active Pending
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| CN205501596U (en) * | 2016-03-10 | 2016-08-24 | 常州市劲普自动化设备有限公司 | Automatic sewing machine material feeding unit |
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| Publication number | Publication date |
|---|---|
| MA50419A (en) | 2021-03-24 |
| NI201900028A (en) | 2020-04-02 |
| MX2019003629A (en) | 2020-01-24 |
| ES2886878T3 (en) | 2021-12-21 |
| MA50419B1 (en) | 2021-08-31 |
| EP3599305A1 (en) | 2020-01-29 |
| IT201800007417A1 (en) | 2020-01-23 |
| CN110747586B (en) | 2023-07-11 |
| MD3599305T2 (en) | 2021-11-30 |
| JP2020014831A (en) | 2020-01-30 |
| PT3599305T (en) | 2021-08-11 |
| EP3599305B1 (en) | 2021-06-02 |
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