WO2023073727A1 - Automated system and device for sewing of garments - Google Patents

Abstract

The present disclosure relates to a system and device for automated sewing of garments. The system includes one or more grippers having a mounting base; a holding mechanism located on the mounting base to hold a garment, a driving mechanism and electrically connected to an actuating mechanism. the driving mechanism is coupled to the holding mechanism to move the holding mechanism along said preset path; a processor, operatively coupled to a plurality of sensors and the driving mechanism that causes the system to: receive, a first set of signals from the plurality of sensors sensing one or more edges of the fabric; determine a shape of the fabric to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric determined through the preset path.

Description

TITLE

AUTOMATED SYSTEM AND DEVICE FOR SEWING OF GARMENTS

TECHNICAL FIELD

[0001] The present disclosure relates to an automated sewing system. More importantly, the present disclosure relates to a system that enables sewing of edges of a garment where the sewing takes place automatically once the garment is provided in a gripper of the system.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] In the present scenario some of the important tasks in garment manufacturing are still done manually by workers in the garment industry. Among these tasks many involve the joining of edges of two fabrics for example joining of front and back of a T shirts or shirts at the shoulder seams, sewing the side seams of shirts or T shirts, joining of front and back of a trouser or denims or sportswear etc. Now many similar operations are still performed by workers which are time consuming and do not provide uniform quality.

[0004] The problem in automating these operations is to handle the edge of the fabric. The fabrics used in manufacturing garments are not stiff enough for a conventional gripper can hold and guide it. The present robots cannot hold the fabric and guide it through the sewing machines specifically edge of fabric. Different operations other than sewing edge may have been automated but sewing edges of a garment still poses the challenge, because the edge cannot be held and guided at the same time by any present system. To work with a fabric using a robot is the most challenging task because fabric is not a rigid body. All the conventional robots are designed to work with the rigid bodies. Moreover, there ais no convenient easy and fast machine to load and unload of garments because in the mass production process the waste of couple of seconds in the operation can make a huge difference and [0005] Hence, there is a need for of an automated device that may hold the edge of the fabric and guide it through the sewing machine.

OBJECTS OF THE PRESENT DISCLOSURE

[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0007] An object of the present disclosure is to provide an approach for holding and guiding the fabric or piece of garment through a sewing machine using a robotic system without any human interaction.

[0008] An object of the present disclosure is to provide a gripper that can temporarily grip the edge of fabric at different places in such a way that it keeps the shape of the edge intact.

[0009] An object of the present disclosure is to provide for a gripper that will release the fabric when it reaches a desired point.

SUMMARY

[0010] The present disclosure relates to an automated sewing system. More importantly, the present disclosure relates to a system that enables sewing of edges of a garment where the sewing takes place automatically once the garment is provided in a gripper of the system.

[0011] In an aspect, the present disclosure provides for a system for facilitating automatic sewing of a fabric in a sewing machine. The system may include one or more grippers. A first gripper may include a mounting base; a holding mechanism located on the mounting base. The holding mechanism may be configured to hold an edge of a fabric and positioned to travel along a preset path within the mounting base and within at least part of the sewing machine. The first gripper may further include a driving mechanism and electrically connected to an actuating mechanism, wherein the driving mechanism may be coupled to the holding mechanism to move the holding mechanism along the preset path. The system may further include a processor, operatively coupled to a plurality of sensors and the driving mechanism of the first gripper, wherein the processor executes a set of executable instructions that are stored in a memory, upon execution of which, the processor causes the system to: receive, a first set of signals from the plurality of sensors, wherein the first set of signals pertain to sensing one or more edges of the fabric; determine a shape of the fabric to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric determined through the preset path.

[0012] In an embodiment, the holding mechanism may further include one or more swing arms, at least one fabric presser, and one or more swing arm lifters. [0013] In an embodiment, the one or more swing arms may include a swing arm main body and one or more pin holders. The swing arm main body may rotate along a predefined axis, may remain parallel with the mounting base at one extreme position and may remain perpendicular to the mounting base at rest position.

[0014] In an embodiment, the one or more pin holders may be assembled along the one or more swing arms to retract and contract so that the pins travel along the preset path.

[0015] In an embodiment, the one or more swing arm lifters may be configured to lift the one or more swing arms to a predetermined position.

[0016] In an embodiment, a plurality of pins in the one or more pin holders may be positioned such that they pierce the fabric at the one or more edges of the fabric along the preset path.

[0017] In an embodiment, the one or more grippers may be mounted on a Cartesian robot and articulated robot to guide the base according to the curve or shape of edge through a sewing machine.

[0018] In an embodiment, the fabric presser may be further coupled to a fabric loader and a second gripper, and a gripper changer, wherein the fabric presser further comprises a plurality of pressing arms to press the fabric in a given direction and position.

[0019] In an embodiment, the fabric loader may be configured to load the fabric, wherein the fabric loader may include a plurality of loading arms, and wherein the fabric may be placed first on the plurality of loading arms. The plurality of pressing arms are closed on the plurality of loading arms such that a plurality of magnets on the plurality of loading arms stick to one or more magnets on the plurality of pressing arms such that the fabric is sandwiched between the plurality of magnets and may stay in place until the pins from the one or more pins holders are inserted. The arrangement of the plurality of loading arms and the plurality of pressing arms may be configured to take the shape of edge of fabric.

[0020] In an embodiment, the plurality of loading arms may be provided with an edge locator pin to help a user identify a position of edge on the fabric loader.

[0021] In an embodiment, when at least two grippers are used, the first gripper may be employed for sewing while the second gripper may be loaded with a new piece of fabric.

[0022] In an embodiment, the gripper changer may be configured to swap the first gripper to the second gripper once the function of the first gripper is over and vice versa.

[0023] The sewing machine employed for sewing can be equipped with an auto trimmer configured for automatic trimming of a thread once the sewing is completed.

[0024] A special purpose presser foot can be designed in order to facilitate the easy removal of the pins from the fabrics if needed.

[0025] In an embodiment, the sewing machine may use a shorter bed overlock for sewing and overlooking operations.

[0026] In an embodiment, for two symmetrical edges on the opposite side of the fabric, the one or more swing arms may be mounted on both sides of the mounting base to grip both the edges of the fabric in a single loading operation and wherein each edge may be sewn one after another using a sewing machine or two different sewing machines placed at two sides of the one or more grippers.

[0027] In an embodiment, joining of two edges of different shapes may be done by at least two grippers one above another.

[0028] In an aspect, the present disclosure provides for a device for facilitating automatic sewing of a fabric in a sewing machine. The device may include one or more grippers. A first gripper may include a mounting base; a holding mechanism located on the mounting base. The holding mechanism may be configured to hold an edge of a fabric and positioned to travel along a preset path within the mounting base and within at least part of the sewing machine. The first gripper may further include a driving mechanism and electrically connected to an actuating mechanism, wherein the driving mechanism may be coupled to the holding mechanism to move the holding mechanism along the preset path. The system may further include a processor, operatively coupled to a plurality of sensors and the driving mechanism of the first gripper, wherein the processor executes a set of executable instructions that are stored in a memory, upon execution of which, the processor causes the system to: receive, a first set of signals from the plurality of sensors, wherein the first set of signals pertain to sensing one or more edges of the fabric; determine a shape of the fabric to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric determined through the preset path.

[0029] In an embodiment, the holding mechanism may further include one or more swing arms, at least one fabric presser, and one or more swing arm lifters. [0030] In an embodiment, the one or more swing arms comprise a swing arm main body and one or more pin holders, wherein the swing arm main body rotates along a predefined axis, remains parallel with the mounting base at one extreme position and remains perpendicular to the mounting base at rest position, and wherein the one or more pin holders are assembled along the one or more swing arms to retract and contract so that the pins travel along the preset path. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In the figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0032] FIG. 1A illustrates exemplary network architecture in which or with which proposed automated sewing system can be implemented in accordance with an embodiment of the present disclosure.

[0033] FIG. IB illustrates an exemplary representation of the proposed gripper, in accordance with an embodiment of the present disclosure.

[0034] FIG. 2 illustrates an exemplary architecture of a processor in accordance with an embodiment of the present disclosure.

[0035] FIGs. 3A-3F illustrate exemplary perspective views of an assembly of the proposed device, in accordance with an embodiment of the present disclosure.

[0036] FIGs. 4A-4B illustrate exemplary representations of the whole machine assembly and position in accordance with embodiments of the present disclosure.

[0037] FIGs. 5A-5E illustrate exemplary functional components of the proposed system in accordance to embodiments of the present disclosure.

[0038] FIG. 6 illustrates an exemplary representation of joining of two dissimilar edges of two different fabrics, in accordance with an embodiment of the present disclosure.

[0039] FIGs. 7A and 7B show exemplary representation of an assembly of fabric uncurling device for curling and uncurling, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION [0040] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0041] Embodiments of the present invention may be provided as a computer program product, which may include a machine -readable storage medium tangibly embodying thereon instructions, which may be used to program a computer (or other electronic devices) to perform a process. The machine-readable medium may include, but is not limited to, fixed (hard) drives, magnetic tape, floppy diskettes, optical disks, compact disc read-only memories (CD-ROMs), and magneto-optical disks, semiconductor memories, such as ROMs, PROMs, random access memories (RAMs), programmable read-only memories (PROMs), erasable PROMs (EPROMs), electrically erasable PROMs (EEPROMs), flash memory, magnetic or optical cards, or other type of media/machine-readable medium suitable for storing electronic instructions (e.g., computer programming code, such as software or firmware).

[0042] Various methods described herein may be practiced by combining one or more machine-readable storage media containing the code according to the present invention with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing various embodiments of the present invention may involve one or more computers (or one or more processors within a single computer) and storage systems containing or having network access to computer program coded in accordance with various methods described herein, and the method steps of the invention could be accomplished by modules, routines, subroutines, or subparts of a computer program product.

[0043] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. [0044] The present invention uses the novel approach of using an automated system that enables sewing of edges of a garment where a user only needs to load a piece of the garment in a gripper coupled to the automated system and the sewing takes place automatically.

[0045] In an embodiment of the present disclosure, FIG. 1A illustrates an automated sewing system (110) (also referred to as the system (110) hereinafter) while FIG. IB illustrates an exemplary representation of the proposed gripper, in accordance with an embodiment of the present disclosure. The system (110) can include a processing unit (202) or processor equipped with an artificial intelligence engine (214), one or more input devices, one or more output devices, one or more power devices, and one or more communication modules (104) operatively coupled to the processing unit (202). In an exemplary embodiment, the one or more input devices can include a keypad (108), touchpad, and the likes. The keypad (108) can be configured to acquire one or more attributes of the entity or user and other state parameters associated with loading and holding of the garment (also referred to as the fabric). The one or more output devices can include a display unit 106, and the like. The system (110) may be further communicatively coupled to a plurality of sensors (114). The plurality of sensors may be configured to detect and sense one or more edges of the fabric. In a way of example and not as a limitation, the plurality of sensors may include a camera sensor, edge detectors and the like. The display unit (106) can be associated with a computing device (116) to provide a visual signal to the entity or user.

[0046] The system (110) may further include one or more grippers (102). As illustrated in FIG. IB, a first gripper may include a mounting base (152), a holding mechanism (154) located on the mounting base configured to hold an edge of the fabric and positioned to travel along a preset path within the mounting base. The system (110) may further include a driving mechanism (not shown in FIG. IB) located within the mounting base (152) and electrically connected to an actuating mechanism. The driving mechanism may be coupled to the holding mechanism to move the holding mechanism (154) along the preset path.

[0047] The processing unit or the processor (202) may be operatively coupled to the plurality of sensors and the driving mechanism of the first gripper. The processor may cause the system (110) to receive, a first set of signals from the plurality of sensors, wherein the first set of signals pertain to sensing one or more edges of the fabric; determine a shape of the fabric to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric determined through the preset path.

[0048] In an exemplary embodiment, the holding mechanism (154) may further include one or more swing arms, at least one fabric presser, and one or more swing arm lifters. The one or more swing arms may include a swing arm main body and one or more pin holders. The swing arm main body may rotate along a predefined axis, may remain parallel with the mounting base (154) at one extreme position and may remain perpendicular to the mounting base (152) at rest position. The one or more pin holder may be assembled along the one or more swing arms to retract and contract so that the pins travel along the preset path. Alternatively, a plurality of pins in the one or more pin holders may be positioned such that they pierce the fabric at the one or more edges of the fabric along the preset path. A sensor by detecting the edge of fabric can set the position of pin holders such that it pierce the fabric accurately at the edge so the machine by this setting can tolerate or adjust the error in laying of the garment by the worker.

[0049] In an exemplary embodiment, the one or more swing arm lifters may be configured to lift the one or more swing arms to a predetermined position.

[0050] In an exemplary embodiment, the one or more grippers may be mounted on a cartesian robot and articulated robot (120) but not limited to the like to guide the mounting base according to the curve or shape of edge through the sewing machine. [0051] In an embodiment, the edge presser (508) (Ref. FIG. 5) may be further coupled to a fabric loader and a second gripper, and a gripper changer but not limited to the like. The edge presser may further include a plurality of pressing arms to press the fabric in a given direction and position.

[0052] In an embodiment, the fabric loader may be configured to load the fabric, wherein the fabric loader comprise a plurality of loading arms, and wherein the fabric may be placed first on the plurality of loading arms and the plurality of pressing arms may be closed on the plurality of loading arms such that a plurality of magnets on the plurality of loading arms stick to one or more magnets on the plurality of pressing arms such that the fabric is sandwiched between the plurality of magnets and stays in place until the pins from the one or more pins holders are inserted. The arrangement of the plurality of loading arms and the plurality of pressing arms may be configured to take the shape of edge of fabric. The plurality of loading arms may be provided with an edge locator pin to help a user identify a position of edge on the fabric loader.

[0053] In an exemplary embodiment, when at least two grippers are used, the first gripper may be employed for sewing while the second gripper may be loaded with a new piece of fabric. The gripper changer may be configured to swap the first gripper to the second gripper once the function of the first gripper is over and vice versa.

[0054] In an exemplary embodiment, at least two pins may be arranged on the pin holder in such a way that the fabric between the at least two pins are always in the stretched condition. The at least two pins may be arranged such that they are bent inwards towards each other. The distance between the tip of the pins is less than the distance between the base of the pins. For example, initially when the pins are inserted in the fabric the two pierced points may be formed on the fabric. The distance between the pierced points are equal to the distance between the tips of the pin. As the pins travel upwards, the fabric moves away from the tip so the distance between the pins increase and due to this the distance between the pierced points increases and the fabric between the pins becomes stretched. [0055] In an exemplary embodiment, at least the two pins define the range within which the sewing must be carried out. The distance between the pins may stretch the fabric and will not tear the fabric or enlarge the pierced points.

[0056] Alternatively, for those cases where pins may not be desirable to grip the fabric, a plurality of magnets but not limited to the like can be used to grip the edge of fabric temporarily and release the fabric when they reach the sewing machine.

[0057] The sewing machine employed for sewing can be equipped with an auto trimmer configured for automatic trimming of a thread once the sewing is completed. A special purpose presser foot can be designed in order to facilitate the easy removal of the pins from the fabrics if needed.

[0058] In an embodiment, the sewing machine may use but not limited to a shorter bed overlock for sewing and overlocking operations.

[0059] In an exemplary embodiment, for two symmetrical edges on the opposite side of the fabric, the one or more swing arms may be mounted on both sides of the mounting base to grip both the edges of the fabric in a single loading operation. Each edge may be sewn one after another using a sewing machine or two different sewing machines placed at two sides of the one or more grippers. Alternatively, joining of two edges of different shapes is done by at least two grippers one above another.

[0060] In a way of example and not as a limitation, the edges of certain fabrics may not be straight but may be curled or rolled. The edges of the certain fabrics can be uncurled before the pins are inserted in the certain fabrics. In an exemplary embodiment, at least two different edge loader base assemblies stacked one on another can be implemented to uncurl the upper and lower fabrics independently and then the pins can be inserted to grip the uncurled fabric.

[0061] In an embodiment, the system (110) can be operatively coupled to a communication module (104) and configured to transmit the first set of signals to one or more computing devices, the system (110) and the like. In an exemplary embodiment, the communication module (1040 can include a GSM Module, WIFI Module, WLAN, a Bluetooth, but not limited to the likes. [0062] In an embodiment, the system (110) can include one or more power supply units (112) that can be, but not limited to electrical power supply, one or more batteries, and any other power source.

[0063] In an embodiment, the system (110) can include one or more switching units (118) which can be used to configure the system to start, stop, reset but not limited to the likes.

[0064] In an implementation, the computing devices (116) coupled to the system (110) can be accessed by applications residing on any operating system, including but not limited to, AndroidTM, iOSTM, and the like. Examples of the first and the second computing devices (116) may include, but not limited to, any electrical, electronic, electro-mechanical or an equipment or a combination of one or more of the above devices such as mobile phone, smartphone, virtual reality (VR) devices, augmented reality (AR) devices, pager, laptop, a general-purpose computer, desktop, personal digital assistant, tablet computer, mainframe computer, or any other computing device, wherein the computing device may include one or more in-built or externally coupled accessories including, but not limited to, a visual aid device such as camera, audio aid, a microphone, a keyboard, input devices for receiving input from a user such as touch pad, touch enabled screen, electronic pen and the like. It may be appreciated that the computing devices (116) may not be restricted to the mentioned devices and various other devices may be used. A smart computing device may be one of the appropriate systems for storing data and other private/sensitive information.

[0065] FIG. 2 illustrates an exemplary architecture of the system (110) in accordance with an exemplary embodiment of the present disclosure. The system (110) may include one or more processors (202) that may be configured to receive, a first set of signals from the plurality of sensors, wherein the first set of signals pertain to sensing one or more edges of the fabric; determine a shape of the fabric to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric determined through the preset path. [0066] The one or more processors (202) may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, logic circuitries, and/or any devices that manipulate data based on operational instructions. Among other capabilities, the one or more processor (202) may be configured to fetch and execute computer-readable instructions stored in a memory (204) of the centralized server (112). The memory (202) may store one or more computer-readable instructions or routines, which may be fetched and executed to create or share the data units over a network. The memory (204) may comprise any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory such as EPROM, flash memory, and the like.

[0067] The system (110) may also comprise an interface (206). The interface (206) may comprise a variety of interfaces, for example, interfaces for data input and output devices, referred to as VO devices, storage devices, SCADA, Sensors and the like. The interface (206) may facilitate communication with various devices coupled to it. The interface (206) may also provide a communication pathway for one or more components of the system (110). Examples of such components include, but are not limited to, processing engine (208) and database (210).

[0068] The one or more processors (202) may be implemented as a combination of hardware and programming (for example, programmable instructions) to implement one or more functionalities of the one or more processors (202). In examples described herein, such combinations of hardware and programming may be implemented in several different ways. For example, the programming for the one or more processors (202) may be processor executable instructions stored on a non-transitory machine-readable storage medium and the hardware for the one or more processors (202) may comprise a processing resource (for example, one or more processors), to execute such instructions. In the present examples, the machine-readable storage medium may store instructions that, when executed by the processing resource, implement the one or more processors (202). In such examples, the system (110) may comprise the machine -readable storage medium storing the instructions and the processing resource to execute the instructions, or the machine-readable storage medium may be separate but accessible to the system (110) and the processing resource. In other examples, the one or more processors (202) may be implemented by electronic circuitry.

[0069] In an aspect, the database (210) may be configured to store any data including, but not limited to, at least one of the parameters or the output associated with the automated system (110). In another aspect, the database (210) may comprise data that may be either stored or generated as a result of functionalities implemented by any of the components of the processor (202) or the processing engines (208).

[0070] In an exemplary embodiment, the processing engine (208) may include a signal acquisition engine (212), an Al engine (214) and other engines (216), wherein the other engines (216) may further include, without limitation, input reminder engine, storage engine, or signal generation engine.

[0071] FIGs. 3A-3F illustrate exemplary perspective views of an assembly of the proposed device, in accordance with an embodiment of the present disclosure.

[0072] FIG. 3A provides a perspective view detailing the mounting base (152), the swing arm (154), the fabric presser (156) and the swing arm lifter (302). In an aspect, the swing arm (154) as shown in FIG. 3B consists of at least two parts, a swing arm main body which can rotate along a predefined axis (154-1) and a pin holder (304). In an example but not a limitation, the pin holder (304) may include at least two pins (306). The swing arm and the pin holder (304) assembled in such a way that the pin holder (304) can be retracted and contracted so that the pins can be set on the desired location i.e. the curve of the edge of fabric to be sewn. The pin can be moved towards or away from the predefined axis (154-1) to achieve the desired location. In an exemplary embodiment, the arrangement of the pin holder (304) and the swing arm (154) is that of a telescopic arm. The swing arms (154) may be assembled on the mounting base (152) in such a way that they are free to rotate along the axis (154-1). The swing arm (154) remains parallel with the mounting base at one of its extreme position and remains perpendicular to the mounting base at rest position. The swing arms (154) may be spring loaded at the axis of rotation so that they come back to their rest position when no external force or obstacle is present.

[0073] In an exemplary embodiment, the swing arm lifter (302) may be used to lift the arms to their extreme position. The mounting base (152) can also be loaded with independent actuator at each swing arm (154) to control the rotation of the swing arm (154), and also an actuating mechanism (interchangeably referred to as the actuator) can be mounted on each swing arm (154) to control the position of the pin holder (304) to adjust it according to the shape of edge.

[0074] In an exemplary embodiment, the shape of the edge can be scanned through a camera and processed by an edge detection program using artificial intelligence. So, when the coordinates of edge are determined by the processing unit, the pins (306) as illustrated in FIG. 3B can be brought to the coordinates by actuating the actuators arranged on the swing arms (154). The position of the pins (306) is of utmost importance. All the pins (306) may be positioned such that they pierce the fabric at the edges of the fabric where stitching will occur. For example, the pins (306) may be a copy of the sewing needles but thinner than the needles. If the sewing operation consists of two needles then the fabric where the pins have pierced it will come under the two sewing needles. If operation consists of one needle only then the sewing needle will be between the two pierced positions.

[0075] In an exemplary embodiment, the fabric after being pierced with the pins, the fabric will move as the pins move so we can control the edge of the fabric by controlling the position of pins and swing arm (154) where the pins (306) are mounted. The swing arms (154) guide these through the sewing machine to complete the operation of sewing edges.

[0076] In an exemplary embodiment, the mounting base (152) can be easily mounted on a Cartesian robot and articulated robot to guide the mounting base according to the curve or shape of edge through a sewing machine. FIG. 3C illustrates the swing arm (154) and the pin holder (304) in extended state while FIG. 3D illustrates the swing arm (154) and the pin holder (304) in the contracted state. FIG. 3E illustrates a fabric gripping base with fabric (work piece) to be sewn. [0077] In an exemplary embodiment, once the swing arms are lifted by the swing arm lifter (302), the swing arms are held in position by the swing arm lifter till the swing arms reach a platform near the sewing machine. The distance between the platform and sewing machine may be set equivalent to the width of the pin holder (304) plus some clearance as shown in FIG. 3B. The swing arms (154) are then placed on the platform and swing arm lifter (302) return to its previous position. As the mounting base (152) moves towards the sewing machine, the swing arms (154) reaches the gap between the platform and the machine one after another. Due to the spring action on the swing arm (154) and no presence of obstacle the swing arm may be retracted from the fabric to its initial or rest position. FIG. 3F illustrates a detailed view of the pins inserted in the fabric to hold the fabric.

[0078] FIGs. 4A-4B illustrates an exemplary representation of the whole machine assembly and position in accordance with embodiments of the present disclosure. FIG 4A shows the proposed assembly of various components of the system. As illustrates, a sewing machine (402) may be but not limited to a cylindrical bed over lock. The swing arm may be located on a platform (406) of the first gripper (412-1). The swing arm may rotated along a axis parallel to axis (408) of the cartesian robot. In an example and not a limitation, a total area of the system may be divided into at least two stations such as a working station (404) and a loading station (418).

[0079] In an exemplary embodiment, the loading station (418) may be a predefined zone where the fabric is loaded in the gripper by a user. This zone may include a second gripper (412-2), a fabric loader and presser (416) and a gripper changer (414).

[0080] In an exemplary embodiment, the fabric loader and presser (416) may be similar to the first gripper, and may include a plurality of loading and pressing arms. The fabric loader and presser may be divided into at least two parts such as an edge loader and edge presser. The edge loader consists of loading arms and the edge presser consists of pressing arms. The loading arms and pressing arms are arranged according to the shape of edge to be sewn. [0081] In an exemplary embodiment, the loading station (418) may at the start of the cycle place the edge loader base (504) away from the second gripper (412-2) at its rest position. The edge loader base (504) may travel towards the second gripper (412-2). The fabric presser (156) on the second gripper (412-2) may be lifted. The first fabric (308-1) may be placed on the mounting base (152) and it is made sure that the edge of the first fabric (308-1) is just touching all the edge locator pins (502-4) of the edge loader arms (502) as shown in FIG. 5D. The second fabric (308-2) may be then placed on the first fabric (308-1) in the similar manner. For example, the objective herein may be two join the first fabric (308-1) and the second fabric (308-2) along the edges which are similar to each other. Then the fabric presser (156) may be lowered and may act as a pressing device for both the fabrics (308-1, 308-2) so that they may not move during any operation. The edge presser base (506) may be then closed on the edge loader base (504) so that magnets (502-1, 502-2) on the edge loader arms (502) may stick to the magnets on the edge presser arm (508). Both the fabrics (308-1, 308-2) may be sandwiched between the two magnets and may stay in place.

[0082] In an exemplary embodiment, the swing lifter arm (302) may be then rotated which raises all the swing arms (154), the pin holders (304) and the pins (306) to the desired positions. For example, the pins (306) pierce both the fabric near the edge where the seam is desired. Once the pins are inserted in the fabric the edge presser arms (506) with the edge presser base (508) are opened. The edge loader base (504) may then travel back to its original position.

[0083] In a way of example and not as a limitation, the edges of certain fabrics may not be straight but may be curled or rolled. The edges of the certain fabrics can be uncurled before the pins are inserted in the certain fabrics. In an exemplary embodiment, at least two different edge loader base assemblies stacked one on another can be implemented to uncurl the upper and lower fabrics independently and then the pins can be inserted to grip the uncurled fabric.

[0084] In an exemplary embodiment, the gripper changer (414) may swap the position of the first gripper (412-1) (interchangeably referred to as the primary gripper (412-1) ) and the second gripper (412-2) (interchangeably referred to as the secondary grippers (412-2) ) with each other.

[0085] In an exemplary embodiment, the fabrics (308-1 and 308-2) to be sewn, with the secondary gripper may be loaded on the Cartesian CNC robot carriage but not limited to it and the finished fabric with the primary gripper returns to the loading station which may be removed by the user and a new fabric may be placed on it.

[0086] In an exemplary embodiment, the working station (404) may include a zone where the actual sewing of the fabric takes place. There is very little to no intervention of human in this zone. The working station (404) may include Sewing machine (402), the sewing machine is a cylinder bed overlock with shortest possible bed, a platform (406) for swing arm (154) where the swing arm (154) may be rested when the edge lifter arm may be released.

[0087] In a way of example and not a limitation, a cartesian CNC robot machine with Y axis (408) along the travel of the fabric through the sewing machine and X axis (410) perpendicular to Y axis (408), the first gripper (412-1) which consists of the preloaded fabric to be sewn.

[0088] In an exemplary embodiment, the task of working station (404) may start when the gripper changer (414) swaps the first gripper (412-1) with the second gripper (412-2) on the carriage of the cartesian CNC robot.

[0089] Due to this swapping now secondary gripper becomes the primary gripper and wise versa, the fabrics which were loaded on the secondary gripper in loading station arrives at the working station and are ready to be sewn. The CNC machine then moves the carriage to the platform (406) where the swing arm (154) come over the platform. (406). The swing lifter arm (302) may be lowered and all the swing arms (154) rest over the platform (406) due to spring action.

[0090] In an exemplary embodiment, a set of geodes regarding the curve or shape of the edge is already fed into the actuating mechanism comprising of a controller. A presser foot may be lifted and the carriage travels along the y-axis. When the start of the edge arrives below the presser foot on the sewing machine (402), the presser foot may be lowered and the sewing cycle starts. As the sewing takes place the CNC adjusts the position of the camage according to the curve. While controlling the carriage the position of swing arms (154), the pins (306) and the edge of the fabric (308) may be controlled. The objective of the CNC is to control the position of swing arms (154) along the X axis while the carriage travels on the Y axis with the speed of sewing. So when the swing arm (154) comes nearest to the sewing machine (402) the position of the pins (306) should be exactly in the middle of the presser foot of the sewing machine. All the swing arms (154) while traveling along the Y axis comes at the middle of the presser foot when they are nearest to the sewing machine and they will trace the shape of edge.

[0091] FIG. 4B illustrates a 3D view of the machine assembly.

[0092] FIGs. 5A-5E illustrate exemplary functional components of the proposed system in accordance to embodiments of the present disclosure. FIG. 5A illustrates the fabric loader and presser according to embodiments of the present disclosure. The fabric loader and presser (416) may include an edge loader base (504), an edge loader arms (502), an edge presser base (508), one or more edge presser arms (506), loading platform (510). The edge loader base (504) may be mounted on the loading platform (510).

[0093] In an example and not a limitation, the edge loader base (504) can travel along the direction of arrow shown in FIG. 5A, which is towards and away from the second gripper (412-2). The edge loader arms (502) which are equal to the number of the swing arms (154) on the first gripper may be mounted on the edge loader base (504). The edge presser base (508) may be hinged to the edge loader base (504) as shown in FIG. 5A and the edge presser arms (506) similar in number to the edge loader arms (502) may be mounted on the edge presser base (508). FIG. 5B illustrates the edge loader arm and the edge presser arm. The structure of edge loader arm (502) and the edge presser arm (506) may include at least two magnets (502-1, 502-2). The magnets on the edge loader arms (502) may stick to the magnets on the edge presser arms (506). The fabric may be placed first on the edge loader arm (502) and then the edge presser arm (506) may be closed on the edge loader arm (502) such that the magnets (502-1, 502-2) on the edge loader arms stick to the magnets on the edge presser arms. The fabric may be sandwiched between the two magnets and stays in place until the pins (306) are inserted in an area (502-3). [0094] In a way of example and not as a limitation, the difference between the edge loader arms (502) and the edge presser arms (506) is that, the edge loader arms (502) may be provided with an edge locator pin (502-4) as shown in FIG.5B. The edge locator pin (502-4) helps the user to identify the position of edge on the loader. The user only needs to place the fabric in such a way that it touches the edge locator pin (502-4) on each edge loader arm. Because of the edge locator pin (502- 4), the pins (306) may be inserted at the desired place on the edge of fabric at each loader arm position.

[0095] In an exemplary embodiment, the gripper changer (414) may be very similar to the automatic tool changers used in the CNC lathes or milling centres.

[0096] FIG. 5C illustrates exemplary representations of one or more fabrics placed between the edge loader arms and the edge presser arms. The one or more fabrics (308-1, 308-2) may be held by the one or more grippers.

[0097] FIG. 5D illustrates an exemplary representation of the function of the edge locator pin (502-4) while FIG. 5E illustrates an exemplary representation of the swing arm (154) exit location. As illustrated, when the swing arms (154) arrives between a gap (310-1) of sewing machine (402) and the platform (406) there is no resistance for the swing arm (154) any more so it travels back to its rest position releasing the fabric. The swing arm (154) does not play any role in further sewing of the fabric and it stays at its rest position till it is raised by lifter in loading station (418). As the process of sewing continues all the swing arms (154) leaves the fabric one by one when they arrive in the gap (310-1).

[0098] In an exemplary, the operation of sewing may be completed after the automatic trimming of the thread takes place.

[0099] Alternatively, a typical presser foot (522) can also be designed in order to facilitate the easy removal of the pins from fabrics if needed but existing foots can also do the job.

[0100] In an exemplary embodiment, in a way of example and not as a limitation, all the processes, machines, and equipments may be controlled by servo motors and a specially designed micro controller in a closed loop control system. The primary gripper may be controlled by a Cartesian CNC robot, an articulated 6 axis robotic arm but not limited to the like.

[0101] FIG. 6 illustrates an exemplary representation of joining of two dissimilar edges of two different fabrics, in accordance with an embodiment of the present disclosure. In an exemplary embodiment, in case of joining two edges of different shapes the same concept can be used just by having two primary grippers one above the another, that are driven by two different X axis controlled independently by two different actuators with single Y axis. The two fabrics with different shapes will also have different loading stations and secondary grippers.

[0102] FIGs. 7 A and 7B show exemplary representation of an assembly of fabric uncurling device (700) for curling and uncurling. As illustrated, the fabric uncurling device (700) that may include the edge loader base, the lower edge presser (506-A) base, the upper edge presser (506-B) base, the lower edge loader (502-A) arms mounted on the edge loader base, the lower edge presser (506-A) arms, the upper edge loader (502-B) arms both mounted on the lower edge presser (506-A) base, and the upper edge presser (506-B) arms mounted on the upper edge presser (506-B) base. Initially the lower edge presser (506-A) base and upper edge presser (506-B) base are in open position, the lower fabric is placed on the lower edge loader (502-A) arms by aligning the fabrics with the locator pins. The lower edge presser (506-A) base is then closed on the edge loader base. The lower fabric is sandwiched between lower edge loader (502-A) arms and lower edge presser (506-

A) arms. The upper edge loader (502-B) arms are mounted above the lower edge presser (506-A) base. The upper fabric is then placed on upper edge loader (502-B) arms and the upper edge presser (506-B) base is closed. The upper fabric is sandwiched between upper edge loader (502-B) arms and upper edge presser (506-

B) arms. While loading the fabrics the curled edge of the fabric is not directly placed beneath the magnets on loading and pressing arms, when the arms closes on each other they grip the fabric at a certain distance from the curled edges. The curled edge remains between the locator pins and magnets. [0103] The fabric presser on the secondary griper is lowered and the edge loader base along with the lower and upper edge presser (506-B) base moves away from the secondary gripper. Due to this motion of edge loader base and pressure of the fabric presser on both the fabrics the uncurling of both the fabrics takes place simultaneously. The lower and upper edge loader (502-B) arms are equipped with the sensors which sense the presence and absence of fabric, these sensor are used to detect the uncurling of the fabric due to their positioning on the arms such that they sense the absence of fabric which infers the uncurled edge.

[0104] The pins may be inserted after this in both the fabrics, the lower edge presser base and the upper edge presser base are then opened and further operations are carried out.

[0105] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE

[0106] Some of the advantages of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0107] The present disclosure provides for an approach for holding and guiding the fabric or piece of garment through a sewing machine using a robotic system without any human interaction.

[0108] The present disclosure provides for a gripper that can temporarily grip the edge of fabric at different places in such a way that it keeps the shape of the edge intact.

[0109] The present disclosure provides for a gripper that will release the fabric when it reaches a desired point.

Claims

CLAIMS:

1. A system (110) for facilitating automatic sewing of a fabric (308) in a sewing machine (402), characterized in that said system comprising: one or more grippers (102), wherein a first gripper

(412-1) consisting of:a mounting base (152); a holding mechanism (154) located on the mounting base, said holding mechanism configured to hold an edge of a fabric (308) and positioned to travel along a preset path within the mounting base and within at least part of the sewing machine (402); a driving mechanism and electrically connected to an actuating mechanism, wherein said driving mechanism is coupled to said holding mechanism to move said holding mechanism (154) along said preset path; a processor (202), operatively coupled to a plurality of sensors (114) and the driving mechanism of the first gripper (412-1), wherein the processor executes a set of executable instructions that are stored in a memory (204), upon execution of which, the processor causesthe system to: receive, a first set of signals from the plurality of sensors (114), wherein the first set of signals pertain to sensing one or more edges of the fabric (308); determine a shape of the fabric (308) to be sewn based on the one or more edges of the fabric sensed; and activate said driving mechanism to guide the holding mechanism along the shape of the fabric (308) determined through the preset path. The system as claimed in claim 1, wherein the holding mechanism (154) consisting of one or more swing arms (154), at least one fabric presser (156), and one or more swing arm lifters (302). The system as claimed in claim 2, wherein the one or more swing arms (154) comprise a swing arm main body and one or more pin holders (304), wherein the swing arm main body rotates along a predefined axis (154-1), remains parallel with the mounting base (152) at one extreme position and remains perpendicular to the mounting base at rest position. The system as claimed in claim 2, wherein the one or more pin holders (304) are assembled along the one or more swing arms (154) to retract and contract so that the pin holder (304) along with pins (306) travels along the preset path to take its required position such that pins

(306) pierce the fabric (308) at the edge only. The system as claimed in claim 2, wherein the one or more swing arm lifters (302) are configured to lift the one or more swing arms (154) to a predetermined position. The system as claimed in claim 2, wherein a plurality of pins (306) in the one or more pin holders (304) are positioned such that they pierce the fabric (308) at the one or more edges ofthe fabric along the preset path. The system as claimed in claim 2, the one or more grippers (102) is mounted on a Cartesian robot and articulated robot (120) to guide the base (152) according to the curve or shape of edge through a sewing machine (402). The system as claimed in claim 2, wherein the edge presser (508) is coupled to a Fabric Loader

(416) and a second gripper (412-2), and a gripper changer, wherein the edge presser (508)consisting of a plurality of pressing arms (506) to press the fabric (308) in a given direction and position. The system as claimed in claim 8, wherein the fabric loader is configured to load the fabric (308), wherein the fabric loader comprise a plurality of loading arms (502), and wherein the fabric is placed first on the plurality of loading arms (502) and the plurality of pressing arms

(506) are closed on the plurality of loading arms (502) such that a plurality of magnets on the plurality of loading arms (502) stick to one or more magnets on the plurality of pressing arms

(506) such that the fabric (308) is sandwiched between the plurality of magnets and stays in place until the pins from the one or more pins holders are inserted, wherein the arrangement of the plurality of loading arms (502) and the plurality of pressing arms (506) are configured to take the shape of edge of fabric. The system as claimed in claim 8, wherein the plurality of loading arms (502) are provided with an edge locator pin (502-4) to help a user identify a position of edge on the fabric loader. The system as claimed in claim 8, wherein when at least two grippers are used, the first gripper

(412-1) is employed for sewing while the second gripper (412-2) is loaded with a new piece of fabric (308), wherein the gripper changer is configured to swap the first gripper (412-1) to the second gripper (412-2) once the function of the first gripper (412-1) is over and vice versa. The system as claimed in claim 8, wherein a presser foot (522) coupled to the sewing machine

(402) facilitate easy removal of the pins from the fabrics if needed, wherein at least two pins are arranged on the pin holder (304) in such a way that the fabric (308) between said at least two pins are always stretched, wherein said at least two pins are arranged such that they are bent inwards towards each other such that the distance between the tip of the at least two pins is less than the distance between the base of the at least two pins. The system as claimed in claim 12, wherein a plurality of magnets are used to grip the edge of the fabric (308) temporarily when the pins associated with the pin holder (304) cannot be used to hold the edge of the fabric, wherein the plurality of magnets release the fabric when the fabric reaches the sewing machine (402). The system as claimed in claim 1, wherein one or more edges of a fabric (308) is uncurled before the pins are inserted in the fabric by at least two edge loader base (504) assemblies stacked one on another that uncurls the upper and lower fabrics independently before the pins are inserted to grip the uncurled fabric. The system as claimed in claim 1, the sewing machine (402) uses a shorter bed overlock for sewing and overlocking operations like cylinder bed overlock. The system as claimed in claim 1, for two symmetrical edges on the opposite side of the fabric (308), the one or more swing arms (154) are mounted on both sides of the mounting base (154) to grip both the edges of the fabric (308) in a single loading operation and wherein each edge is sewn one after another using a sewing machine (402) or two different sewing machinesplaced at two sides of the one or more grippers (102). The system as claimed in claim 16, joining of two edges of different shapes is done by at least two grippers one above another.

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