A. Device for checking and indicating the rest of underthread sewing yarn of sewing machine
The sewing work can work in a situation where there is no
under-thread by mistake. This leads to defective products and
economic losses. To solve this problem, there is a need for a
device for detecting the remaining amount of under-thread and
transmitting it to an operator. Fig. 3 shows the sensing signal
configuration for system design to detect the residual
under-thread amount and the system configuration diagram to
control it by linking it. The orange block shows the status of the
warning lights, the PLC, the touch screen, and the main brake,
while the blue block indicates each sensor and control signal for
control.
The configuration of under-thread residual
sensing and display system. Each component of the test
apparatus for the detection of the residual thread volume
consists of the lower part of the sewing machine and the display
part. Under-thread residual sensing device was designed and
implemented as primary and secondary sensing parts. The
primary sensing uses a cylinder (CXSM630) for the bobbin and
a SMAT-8M sensor for the FESTO position transmitter.[9] The
system is implemented so that the remaining amount of the
bottom thread can be calculated by the data that the cylinder pin
advances and senses the distance gap.
Secondary detection shows the sensing principle to detect
and warn the bobbin rotation state while reducing the defect
caused by the bobbin not rotating when the bobbin is tangled or
defective in Fig.6. To check the bobbin rotation status, the
Omron NPN type photo sensor (E3Z-LL61) checks the rotation
of the bobbin with four pairs of black and white stickers at 45
degrees on the bobbin.
B. Stitch control device and sewing thread information
detection system concept configuration
In order to make smart factory of sewing factory, it is
necessary to prevent worker’s mistakes and to record and
confirm the current work. Figure 7 shows the position where
the residual under-thread detection device and the stitch
automatic control device are to be attached in the sewing
machine being used in the sewing factory. In order to
automatically adjust the stitches, the information about the
fabric currently being worked on is entered in advance, so that
the number of stitches can be automatically adjusted.
C. Information flow of the sewing machine detected from
sensors for smart sewing process
Fig. 8 shows the flow of information obtained from the
parts(under-thread residual detection device, automatic stitch
control device, monitoring system) developed for the sewing
process smartization. The collected information is displayed in
the monitoring system, and it is transmitted to the POP system,
the PDM system and the final customer-linked system, so that
the sewing process can be made smart.[10-11]
It is a study to apply smart factory to the textile industry in
this research and development. A study on the smartization of
sewing process among several textile streams was
conducted.[12-13] In order to make the sewing machine smart,
we applied the same sewing machine which is used in the
present industrial field and modified the sewing machine.
First, the residual amount of the under-thread was detected to
reduce the worker’s mistake and product defect. Secondly, in
the sewing industry where workers are aging, it is possible to
control the automatic stitch number according to the product
type. Next, monitoring of the overall sewing process requires
further work on the presser foot pressure control, tension
control, POP(point of production) system and all monitoring
data interlocks.
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