JP7186624B2 - Production system and production method - Google Patents

Description

The present invention relates to production technology using an automatic sewing machine and an electronic paper pattern.

Sewing of cloth products such as clothes and products such as insulation materials for space is mainly done by hand using a sewing machine.
On the other hand, Patent Literatures 1 to 5 describe automatic sewing devices that automatically perform sewing without relying on manual labor.

A sewing operation requires a paper pattern indicating sewing positions, cutting positions, parts mounting positions, and the like. In particular, in the case of producing custom-made cloth products and individual space insulation materials, one paper pattern is required for each product. Further, depending on the sewing work, there is a case where the paper pattern is superimposed on the product and the product is sewn together with the paper pattern. In this case, the paper pattern must be removed after sewing.
On the other hand, Patent Literature 6 describes an electronic paper pattern that projects a paper pattern with a projector. By using the electronic paper pattern, printing and management of the paper pattern and removal of the paper pattern after sewing are unnecessary.

JP-A-61-079490 JP-A-61-079491 JP-A-61-079492 JP-A-61-079493 JP-A-61-079494 JP 2009-185398 A

In the production of products that require sewing, sewing and attachment of parts may be alternately and repeatedly performed. If the automatic sewing devices described in Patent Documents 1 to 5 and the electronic pattern paper described in Patent Document 6 are simply introduced, sewing by the automatic sewing device is performed every time sewing and parts attachment are switched. It is necessary to align the position with the projected position of the electronic template, which takes time.
An object of the present invention is to simplify the production of products that require sewing.

A production system according to the present invention includes:
a fabric fixing jig for fixing the fabric;
a sewing device that sews the fabric fixed to the fabric fixing jig in accordance with sewing data indicating a sewing position in a state where the fabric fixing jig is fixed at a sewing table specified position on the sewing table by a sewing table fixing portion; ,
a projection device for projecting and displaying the electronic pattern data on the fabric fixed to the fabric fixing jig in a state where the fabric fixing jig is fixed at the projection table specified position on the projection table by the projection table fixing part.

The present invention includes a sewing device that sews the fabric fixed to the fabric fixing jig, and a projection device that projects and displays electronic pattern data on the fabric fixed to the fabric fixing jig. Since both the sewing device and the projection device are provided, manual sewing and printing, management, and removal of patterns are not required.
Further, in the present invention, the fabric fixing jig to which the fabric is fixed is fixed by the sewing table fixing portion in the sewing apparatus, and is fixed by the projection table fixing portion in the projection apparatus. Therefore, once the fixed part of the sewing table and the fixed part of the projection table are aligned, when switching between sewing and attaching parts, simply move the fabric fixing jig to which the fabric is fixed. Alignment is possible.
As a result, according to the present invention, it is possible to easily produce products that require sewing.

1 is a configuration diagram of a production system 100 according to Embodiment 1; FIG. 4 is a flowchart showing processing of the production system 100 according to Embodiment 1; 2 is a diagram showing the flow of data in the production system 100 according to Embodiment 1; FIG. FIG. 4 is an explanatory diagram of sewing data 60 according to the first embodiment; FIG. FIG. 4 is an explanatory diagram of presetting of the projection device 30 according to the first embodiment; FIG. 4 is an explanatory diagram of an inspection by the imaging device 80 according to Embodiment 1;

Embodiment 1.
*** Configuration description ***
A configuration of a production system 100 according to Embodiment 1 will be described with reference to FIG.
A production system 100 includes a data generation device 10 , a sewing device 20 , a projection device 30 , and a fabric fixing jig 40 . The data generation device 10 is connected to the sewing device 20 and the projection device 30 via a transmission line 50 .

The data generator 10 is a computer such as a PC (Personal Computer). The data generation device 10 is a computer that generates sewing data 60 and electronic pattern data 70 .

The sewing device 20 is a device that sews a material 41 in accordance with sewing data indicating sewing positions. The sewing device 20 includes a sewing table 21 on which the fabric 41 fixed to the fabric fixing jig 40 is placed, and a sewing table fixing portion 22 to which the fabric fixing jig 40 is fixed. The sewing table fixing portion 22 is, for example, a jig that is fitted with the fabric fixing jig 40 to fix the fabric fixing jig 40 .

The projection device 30 is a device that displays the electronic paper pattern data as a shadow on the fabric 41 . The projection device 30 includes a projection table 31 on which a material 41 fixed to a material fixing jig 40 is placed, and a projection table fixing section 32 for fixing the material fixing jig 40 . The projection table fixing part 32 is, for example, a jig that fits with the fabric fixing jig 40 to fix the fabric fixing jig 40 .

The fabric fixing jig 40 is a jig for fixing the fabric 41 . In Embodiment 1, the fabric fixing jig 40 is a frame that fixes the outer periphery of the fabric so as to be able to handle fabrics 41 of various shapes. Further, in Embodiment 1, the cloth fixing jig 40 is a jig that holds and fixes the outer peripheral portion of the cloth 41 from the front and back with a magnet. However, the fabric fixing jig 40 may be a jig for fixing the fabric 41 by another method such as hooking the outer peripheral portion of the fabric 41 with a nail to fix it.

***Description of operation***
The operation of the production system 100 according to Embodiment 1 will be described with reference to FIGS. 2 to 6. FIG.
The operation of the production system 100 according to the first embodiment corresponds to the production method according to the first embodiment.

Here, as an example, a production process in which the outer circumference of the fabric 41 is sewn and cut, the part 42 is attached to the fabric 41, and the part 42 is sewn will be described. The production process includes, but is not limited to, various sewing processes and parts attachment processes depending on the product to be produced. In the product production process, the sewing process and the parts mounting process may be alternately repeated.
A specific example of the product produced here is a heat insulating material for space use. Moreover, the part 42 is a hook-and-loop fastener as a specific example.

(Step S1: data generation step)
The data generation device 10 receives design data as an input and generates sewing data 60 and electronic paper pattern data 70 . The design data is, for example, a DXF (Drawing Interchange Format) file generated by CAD (Computer-Aided Design) software or the like. The data generation device 10 may automatically generate the sewing data 60 and the electronic pattern data 70 from the design data using software, or may receive input of the design data from the user and generate the sewing data 60 and the electronic pattern data 70. may be generated.
Then, as shown in FIG. 3, the data generation device 10 transmits the sewing data 60 to the sewing device 20 via the transmission line 50. As shown in FIG. The data generation device 10 also transmits the electronic paper pattern data 70 to the projection device 30 via the transmission line 50 .

The sewing data 60 is data indicating sewing positions. Here, as shown in FIG. 4, sewing data 60 includes fabric sewing data 61 indicating sewing positions on the outer periphery of the fabric 41 , part sewing data 62 indicating sewing positions on parts attached to the fabric, and sewing data 62 indicating sewing positions on the outer periphery of the fabric 41 . cut reference data 63 indicating the cut position of the . It should be noted that the sewing data 60 may not only indicate the sewing positions, but may also include additional information that matches the functions of the sewing device 20 . For example, the sewing data 60 may include additional information as to whether or not the sewing apparatus 20 has a thread cutting detection function, and if so, whether or not to cut the thread. .
The electronic pattern data 70 includes surface data 71 indicating attachment positions of the parts 42 attached to the front side of the fabric 41 and back surface data 72 indicating attachment positions of the parts 42 attached to the back side of the fabric 41 .

(Step S2: Fabric fixing process)
The fabric fixing jig 40 fixes the fabric 41 . In Embodiment 1, the fabric fixing jig 40 is a frame. Therefore, the fabric fixing jig 40 is arranged so as to surround the outer periphery of the fabric 41 by the user, and the fabric 41 is sandwiched and fixed by the fabric fixing jig 40 from the front and back sides of the fabric 41 by magnetic force.
In addition, when a plurality of fabrics 41 are laminated, the laminated fabrics 41 may be stapled by a stapler or the like.

(Step S3: Perimeter sewing process)
The sewing device 20 sews the fabric 41 fixed to the fabric fixing jig 40 according to the fabric sewing data 61 in a state where the fabric fixing jig 40 is fixed at the sewing table designated position on the sewing table 21 by the sewing table fixing portion 22 . I do.
Specifically, the fabric fixing jig 40 to which the fabric 41 is fixed in step S<b>2 is placed on the sewing table 21 by the user and fixed by the sewing table fixing portion 22 . By being fixed by the sewing table fixing portion 22 , the fabric fixing jig 40 is fixed at the sewing table specified position on the sewing table 21 . Note that the sewing table fixing portion 22 is fixed by the user in advance so that the cloth fixing jig 40 is fixed at the sewing table specified position on the sewing table 21 by fixing the cloth fixing jig 40 with the sewing table fixing portion 22 . 22 is adjusted.
Then, the sewing device 20 sews the outer circumference of the fabric 41 fixed to the fabric fixing jig 40 according to the fabric sewing data 61 while the fabric fixing jig 40 is fixed by the sewing table fixing portion 22 .

(Step S4: Circumference cutting process)
With the sewing table fixing portion 22 fixing the fabric fixing jig 40 at the sewing table designated position on the sewing table 21 , the sewing apparatus 20 cuts the outer circumference of the fabric 41 fixed to the fabric fixing jig 40 in accordance with the cutting reference data 63 . Cut off the part.
Specifically, the fabric fixing jig 40 remains fixed at the designated sewing table position on the sewing table 21 by the sewing table fixing portion 22 in step S3. In this state, the user removes the sewing thread from the sewing needle of the sewing device 20 and replaces the sewing needle with the reference line processing needle. Then, the sewing device 20 processes the cutting position indicated by the cutting guideline data 63 with a needle for cutting guideline processing, thereby processing the cutout guideline on the fabric 41 .

(Step S5: projection processing)
The projection device 30 projects and displays the electronic pattern data onto the fabric 41 fixed to the fabric fixing jig 40 in a state where the fabric fixing jig 40 is fixed at the projection table specified position on the projection table 31 by the projection table fixing portion 32 . do.
Specifically, the user moves the material fixing jig 40 to which the material 41 having the reference line is fixed in step S4 to the projection table 31 and fixes it by the projection table fixing section 32 . By being fixed by the projection table fixing portion 32 , the texture fixing jig 40 is fixed at the projection table specified position on the projection table 31 . Note that the projection table fixing unit 32 is fixed in advance by the user so that the cloth fixing jig 40 is fixed at the projection table designated position on the projection table 31 by fixing the cloth fixing jig 40 by the projection table fixing unit 32 . 32 are adjusted.
Then, the projection device 30 , in a state where the fabric fixing jig 40 is fixed by the projection table fixing portion 32 , applies the electronic template data 70 indicating the pasting positions of the parts 42 to the fabric 41 fixed to the fabric fixing jig 40 . Projected display. Note that when the component 42 is pasted on the front side of the fabric 41 , the projection device 30 projects and displays the surface data 71 . Further, when there is a pasting position of the component 42 on the back side of the cloth 41, the projection device 30 projects and displays the back side data 72. FIG. It should be noted that the magnification of the actual size is calculated in advance, and the projection display is performed at the calculated magnification.
With the electronic paper pattern data 70 projected and displayed on the fabric 41 , the part 42 is pasted on the pasting position of the part 42 indicated by the electronic paper pattern data 70 .

Here, the electronic pattern data 70 is data for highlighting the pasting position of the component 42 . If the fabric 41 is made of a film or the like that is highly reflective, the electronic template data 70 is data in which the background is black and the pasting positions of the parts 42 are painted in green or pink in order to suppress the reflection from the fabric 41 . be. Further, the electronic pattern data 70 is data indicating the frames and diagonal lines of the pasting positions of the parts 42 in consideration of the ease of pasting the parts 42 .
Also, if the base material 41 is made of a material such as a film that easily reflects light, the periphery of the projection table 31 may be surrounded by a blackout curtain or the like. When the projection table 31 is surrounded by a blackout curtain or the like, it is desirable that the illuminance of the projection device 30 is 3000 lm (lumen) or more at a projection distance of about 1 m (meter).

Moreover, when the parts 42 are pasted on both the front side and the back side of the fabric 41, the projection device 30 projects and displays the surface data 71 with the front side of the fabric 41 facing up. After the component 42 is attached to the front side of the cloth 41, the cloth 41 is turned inside out together with the cloth fixing jig 40 so that the back side of the cloth 41 faces up. The projection device 30 projects and displays the back surface data 72 with the back surface of the fabric 41 facing up. Then, the part 42 is attached to the back side of the fabric 41. - 特許庁
Instead of projecting and displaying the surface data 71 first from the front side and pasting the component 42, the back surface data 72 may be projected and displayed first from the back side and the component 42 may be pasted.

Note that the software used for projection by the projection device 30 does not have to be special software for projection. For example, the software used for projection by the projection device 30 can be realized using the CAD software used to create the design data.

(Step S6: part sewing process)
After the component 42 is attached to the attachment position in step S5, the sewing device 20 sews the fabric according to the component sewing data 62 in a state in which the sewing table fixing section 22 fixes the fabric fixing jig 40 to the sewing table specified position. A part 42 attached to 41 is sewn.
Specifically, the user moves the fabric fixing jig 40 to which the fabric 41 to which the part 42 is stuck in step S5 is moved to the sewing table 21 and fixed by the sewing table fixing portion 22 . By being fixed by the sewing table fixing portion 22 , the fabric fixing jig 40 is fixed at the sewing table specified position on the sewing table 21 . That is, the cloth fixing jig 40 is fixed at the same position as the cloth fixing jig 40 was fixed in step S3. Therefore, the position of the fabric 41 with respect to the sewing device 20 is the same in steps S3 and S6.
Then, the sewing device 20 sews the part 42 attached to the fabric 41 according to the part sewing data 62 while the fabric fixing jig 40 is fixed by the sewing table fixing portion 22 .

After that, the material 41 is cut according to the processing of the reference lines drawn in step S4.

After the processing of step S6, the fabric fixing jig 40 to which the fabric 41 is fixed may be moved to the projection table 31 again, and the electronic pattern data 70 may be projected and displayed by the projector 30. FIG. By including the sewing positions for the parts 42 in the electronic pattern data 70, it is possible to check whether the parts 42 have been properly sewn.

The presetting of the projection device 30 will be described with reference to FIG.
If the projection accuracy of the projection device 30 does not meet the standard, there is a risk that the attachment position of the component 42 will have a larger error than expected. Therefore, as a premise, it is necessary to use a projection apparatus 30 that satisfies the standard for lens distortion per projectable pixel. For example, when the standard accuracy is ±1 mm (millimeter) and projection is performed at a projection distance in which one pixel is 1 mm, the distortion due to the lens must be one pixel or less.

In order to ensure the accuracy of the projected image, the projection device 30 measures the accuracy of the projected image by the following method before executing the process of step S5. In order to guarantee the accuracy of the projected image, it is sufficient to ensure that when the image of the specified size is projected, the actually projected image has the specified size.
Therefore, the projection device 30 projects and displays the grid data 34 indicating the grid on the grid sheet 33 in a state where the grid sheet 33 indicating the grid is placed on the projection table 31 . At least one of the resolution and the projection distance of the projection device 30 is set by the user so that the accuracy is equal to or higher than the reference accuracy. That is, at least one of the resolution and the projection distance is set such that the distortion 35 satisfies the reference accuracy. As a result, an accuracy equal to or higher than the reference accuracy is achieved.

The inspection by the imaging device 80 will be described with reference to FIG.
Before executing the process of step S<b>6 , the projection device 30 may use the imaging device 80 to check whether or not the component 42 is attached to the attachment position of the component 42 .
Specifically, as shown in FIG. 6 , the production system 100 includes an imaging device 80 for imaging a projection surface of a projection table 31 onto which the projection device 30 projects the electronic paper pattern data 70 , and an image obtained by the imaging device 80 . and a judgment device 81 for judging whether or not the component 42 has been pasted to the pasting position based on the data. After the process of step S5, the imaging device 80 images the projection surface of the projection table 31 to obtain imaging data. The determination device 81 compares the photographed data obtained by the photographing device 80 with the pasting position of the component 42 indicated by the electronic template data 70, and judges whether or not the part 42 is pasted at the pasting position. When it is determined that the part 42 is pasted on the pasting position, the user moves the fabric fixing jig 40 to which the fabric 41 is fixed to the sewing table 21, and sticks the fabric 41 according to the part sewing data 62. Part 42 is sewn.

It should be noted that the inspection may be performed using not only the imaging device 80 but also other sensors.

*** Effect of Embodiment 1 ***
As described above, in the production system 100 according to the first embodiment, the sewing device 20 that sews the cloth 41 fixed to the cloth fixing jig 40 and the cloth 41 fixed to the cloth fixing jig 40 are electronically sewn. and a projection device 30 for projecting and displaying the paper pattern data 70 . Since both the sewing device 20 and the projection device 30 are provided, manual sewing, printing, management and removal of the paper pattern, and copying from the paper pattern to the fabric 41 are not required.

Further, in the production system 100 according to the first embodiment, the fabric fixing jig 40 to which the fabric 41 is fixed is fixed by the sewing table fixing portion 22 in the sewing device 20 and by the projection table fixing portion 32 in the projection device 30 . do. Therefore, once the sewing table fixing portion 20 and the projection table fixing portion 30 are aligned, the fabric fixing jig 40 to which the fabric 41 is fixed can be simply removed when switching between sewing and attaching the parts 42 . It is possible to adjust the position by simply moving the
For example, in the first embodiment, the fabric 41 is moved from the sewing device 20 to the projection device 30 after the processing from step S3 to step S4 is completed, and the fabric 41 is transferred from the projection device 30 to the sewing device 20 after the processing of step S5 is completed. 41 is moved. As described above, even when the fabric 41 is repeatedly moved between the sewing device 20 and the projection device 30, the fabric 41 fixed to the fabric fixing jig 40 is moved, Only by fixing with the base fixing part 32, it is possible to adjust the position.

In addition, when a product requiring sewing is manually manufactured using a sewing machine, conventionally, the position where the part 42 is attached is marked with a needle hole or the like on the fabric on which the pattern paper is superimposed, and the pattern paper is sewn. After removing it, the parts 42 were attached to the fabric according to the marks. Therefore, there is a high risk of erroneous attachment of the part 42, and it takes time to attach the part 42.例文帳に追加
However, in the production system 100 according to the first embodiment, the component 42 is pasted at the pasting position indicated by projecting and displaying the electronic pattern data 70 by the projection device 30 . Therefore, it is possible to attach the component 42 in a short period of time without causing a mistake in attaching the component 42 .

Further, when a product requiring sewing is manually manufactured using a sewing machine, conventionally, the positional and dimensional accuracy of the finished product has been judged by palpation from the pattern paper. Therefore, detailed accuracy inspection could not be performed. In addition, it takes a long time to perform the inspection because each patient is palpated one by one.
However, in the production system 100 according to the first embodiment, by projecting and displaying the electronic paper pattern data 70 on the completed cloth 41 by the projection device 30 after step S6, it is possible to easily determine the accuracy of the positional dimensions. In addition, it is possible to inspect the position and dimension in a short time.

Also, when the automatic sewing devices described in Patent Documents 1 to 5 are simply introduced, if the data to be input to the automatic sewing device is incorrect, there is a possibility that the user will proceed with the work without noticing the mistake.
However, since the production system 100 according to the first embodiment includes both the sewing device 20 and the projection device 30, the sewing data 60, which is the input data to the sewing device 20, and the electronic pattern paper, which is the input data to the projection device 30. If the data 70 is inconsistent, it can be easily noticed. Therefore, it is difficult to proceed with the work without noticing an error in the input data.

***Other Configurations***
<Modification 1>
Embodiment 1 has been described on the premise that the processes from step S1 to step S6 in FIG. 2 are continuously performed. However, in the case of producing a plurality of the same product, the process of step S1 is executed once, then the processes of steps S2 to S4 are repeated for the number of production, and then the process of step S5 is repeated for the number of production, After that, the process of step S6 may be repeated for the production number.
For example, when producing three identical products, one sewing data 60 and one electronic paper pattern data 70 are generated in step S1. After that, steps S2 to S4 are repeated three times to produce three fabrics 41 on which the outer circumference is sewn and the reference lines are processed. At this time, three fabric fixing jigs 40 are installed, and each fabric 41 is fixed to each fabric fixing jig 40 . Thereafter, step S5 is repeated three times, and parts 42 are attached to each fabric 41. FIG. After that, step S6 is repeated three times, and the parts 42 attached to each fabric 41 are sewn.
This makes it possible to improve work efficiency.

<Modification 2>
In Embodiment 1, sewing device 20 performs only sewing and processing of reference lines. However, a cutting tool may be attached to the sewing device 20 and the cutting process may be performed according to the reference line after step S6. Alternatively, another processing tool such as a punch may be attached to the sewing device 20 to process the cloth 41 or the part 42 .

REFERENCE SIGNS LIST 100 production system, 10 data generation device, 20 sewing device, 21 sewing table, 22 sewing table fixing unit, 30 projection device, 31 projection table, 32 projection table fixing unit, 33 grid sheet, 34 grid data, 35 distortion, 40 cloth Fixing jig 41 cloth 42 part 50 transmission line 60 sewing data 61 cloth sewing data 62 part sewing data 63 cutting reference data 70 electronic paper pattern data 71 surface data 72 back surface data 80 photographing device 81 decision device.

Claims (6)

a fabric fixing jig for fixing the fabric;
Electronic paper pattern data indicating the pasting positions of parts is projected and displayed on the fabric fixed to the fabric fixing jig in a state where the fabric fixing jig is fixed to the projection table designated position on the projection table by the projection table fixing section. a projection device that
In a state in which the fabric fixing jig is fixed at the sewing table designated position on the sewing table by the sewing table fixing portion, the fabric fixing jig is fixed to the fabric fixing jig in accordance with the part sewing data indicating the sewing position for the part attached to the fabric. a sewing device that sews the parts attached to the fabric;
production system with The sewing device performs sewing on the fabric according to fabric sewing data indicating a sewing position on the fabric in a state where the fabric fixing jig is fixed at the sewing table specified position by the sewing table fixing portion,
The projection device projects and displays the electronic paper pattern data indicating the attachment position of the part on the fabric sewn by the sewing device,
The sewing device attaches the part to the attaching position, and then fixes the fabric fixing jig to the designated position on the sewing table by the sewing table fixing section. 2. The production system according to claim 1, wherein sewing is performed on the parts attached to the fabric. The production system further includes:
a photographing device for photographing a projection plane;
a judgment device for judging whether or not the component is pasted at the pasting position based on photographed data obtained by photographing by the photographing device;
3. The production system according to claim 1, wherein the sewing device sews the part attached to the fabric after the determining device determines that the part has been attached to the attachment position. The projection device projects and displays the grid data indicating the grid on the grid sheet in a state where the grid sheet indicating the grid is installed on the projection table, and adjusts the resolution and the projection distance so that the accuracy is equal to or higher than the reference accuracy. 4. The production system according to any one of claims 1 to 3, wherein the electronic pattern data is projected and displayed on the fabric after at least one of the above is set. 5. The production system according to any one of claims 1 to 4, wherein the production system is a system for producing heat insulating material for space use. With the projection device fixing the fabric fixing jig to the specified position of the projection table on the projection table by the projection table fixing part , the parts are pasted on the fabric fixed to the fabric fixing jig. Projects and displays the electronic pattern data showing
The sewing device, in a state where the fabric fixing jig is fixed at the sewing table designated position on the sewing table by the sewing table fixing portion, adjusts the fabric fixing jig according to part sewing data indicating the sewing position for the part attached to the fabric. a production method in which the parts attached to the fabric fixed to the fabric are sewn .

Images