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The constant search for methods
that allow the production processes improvement is a driving force for
the development and integration of current technological solutions in
systems which are, currently, still purely human based. It is in this
context that the company “Factoryplay” comes forward with the challenge
to upgrade its current sewing stations by adding a set of mechanization
and automation solutions. This article documents the steps carried out
to provide the current solution with the required technical attributes.
In this paper, the instrumentation and actuation devised solutions, as
well as the method employed to design an embedded PI controller, will be
presented. The PI controller allows the closed-loop control of the
station movement speed as a function of the sewing machine speed. The
practical results obtained, regarding the dynamic response of the sewing
station, are in line with the simulated ones.
As a company that is currently expanding, it requires thereplacement and updating of many of its production paradigmsin order to become more efficient. Namely, regarding the waythe inflatables sewing process occurs.Any inflatable structure is composed of a large numberof tiles made of anti-fire treated sailcloth with a density of620 g/m2. All those pieces are assembled together by meansof double, triple or even quadruple seams. This process iscarried out by human operated industrial sewing machines.A set of sewing stations are aligned along the sides of alarge table where the pieces to be sewn are laid out. Each ofthe stations moves in parallel along the table over a pair ofsteel rails. Each sewing station is operated and propelled by ahuman collaborator. This production method presents severalproblems. One of them is the dependence of the seams spacingwith the speed of the sewing station which, on the other hand,is strongly dependent on the human operator. It is desirablethat the station linear speed to be synchronized with the sewingmachine operation speed. This will lead to a more uniform,and operator independent, seams.In the course of the following sections, the various decisionstaken to circumvent the problem of seam spacing will bedocumented. Additional issues, like the improvement of thesewing station ergonomics, needle issues andseams accuracy , are outside the scope of the currentarticle. Section II describes the mechanical, electrical andinstrumentation solutions that will be transferred to the currentindustrial sewing stations. Section III presents the mathemat-ical model of the actual prototype.
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