SEWING MACHINE SENSING DEVICE DEVELOPMENT FOR SMART FACTORY

Singer Sewing Machine Showroom In Chennai - VS Sewing Machines

SEWING MACHINE SENSING DEVICE DEVELOPMENT FOR SMART FACTORY

Among the processes for making final products using fibers,  the  final  process  can  be  called  a  sewing  process.  The  sewing  process  generally  corresponds  to  the  process  that  requires  the  most  manpower in the production of textile products. The cost of sewing has gradually   increased   due   to   the   recent   rise   in   labor   costs.   The   automation of the sewing process and the smart factory are expected to be  carried  out  along  with  the  fourth  industrial  revolution.  In  order  to  make the sewing factories smart, it is essential to apply smart sensing technology to the sewing machines. Also, sewing Process In order to grasp  real-time  situation,  a  system  to  monitor  the  status  of  each  machine is needed. This study can be regarded as a part of technology development  for  automation  and  unmanned  sewing  process  for  final  CPS(cyber-physical  system)  implementation.  Three  techniques  have  been  developed  in  the  sewing  machine  modification  technology  to  assist the smarting and sewing process of the sewing machine. Three kinds   of   developed   technology   are   a   bobbin   remaining   amount   detecting technique, stitch length control, and monitoring techniques. As  a  result  of  step-by-step  technology  development  to  realize  CPS  finally, it is a partial technology development of automation through some  modification  of  sewing  machine.  https://vssewingmachine.in/ The  developed  technology  is  expected   to   be   used   as   a   technology   for   future   smart   sewing   automation plant construction.
A.Device for checking and indicating the rest of under- thread 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.
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 configurationIn  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.
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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