Adaptive Control of an Industrial Sewing Machines

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Adaptive Control of an Industrial Sewing Machines

This study describes some possibilities of setting up an adaptive control method for an electromagnetically actuated presser-foot in an industrial high-speed sewing machine. The control of fabrics feeding in sewing machines is difficult not only because of the complexity of relations between the intervening variables (material properties, sewing speed), but also because in many operations a varying number of material plies are crossed. This implies that the reference for the controller has to be adapted dynamically. Several methods, using PID and/or fuzzy logic control, have been tried and are described in this paper. A preliminary sewing test is able to provide data to tune the controller variables. With these adaptation techniques, the machine would be able to automatically adapt its feeding system according to the material being sewn.VS Sewing Machines

Adaptive Control of an Industrial Sewing Machines

Gaining quantitative knowledge over the industrial process of joining flexible materials by sewing has become a major concern in the industrial manufacture of high-quality sewn products. Controlling the process is not only important in the traditional garment industry(where high-quality, flexibility and low set-up times have become even more important), but especially in the manufacture of technical textiles, in order to assure the correct function of the final product.One important aspect of a sewing machine is the fabric feeding system. The objective of the study herein reported is addressed to the feeding system of an industrial overlock sewing machine for the design and development of closed-loop controllers. This is a resultof research work carried out by the authors and other team members in this area [1-4], to which researchersfrom three different departments at the School of Engineering have contributed.This paper represents a further contribution towards the development of a new generation of sewing equipment integrating control systems designed to reduce set-up times, improve machine performance and increase flexibility in the production of high-quality sewn products.For some decades now, the problem of sewing technology and its defects have been the basis for a regular research work. This research has been primarily undertaken in the universities and in 1961, Dorkin and Chamberlain [5], analyzed and discussed the relation of seam pucker (the effect of undulation of the fabric along the seam line) and its occurrence with the behavior of the feeding system. From this point on, many studies have been carried out regarding the following four major aspects:• The study of seams quality [5, 6];• The study of damage in sewing needles [7];• The analysis of sewing threads tensions and its consumptions, related with the production of balanced seams [8-16] and its behavior during the sewing operation [17, 18], and• The study of needle penetration and fabrics feeding system dynamics [8, 10, 14, 15, 19-41]. All these studies, and others not herein mentioned, have contributed essentially to a better scientific understanding of the sewing processes, performance and behavior of materials used, in order, on one hand, to solve the problems related with the process itself and, on the other hand, to improve sewing machines and to enable the control of the sewing process. Some interesting solutions have been found and an active actuation system for the presser-foot, called “autodamp” [37], using an electromagnetic actuator with a “maglev” presser-foot controller was proposed [38]. An industry solution was also developed and implemented, using a linear motor to dynamically vary the pre-tension of the spring that exerts force on the presser-foot. This system, proposed and adopted by the German company PFAFF, is named SRP, the English acronym for “Speed-Responsive Presser-foot”.In 1992 however, based on a joint research effort between several researchers of the Department of Textile Engineering, at the University of Minho, and two researchers from the North Carolina State University (in the United States), a new research area has been undertaken, supported on a mechatronic research framework. Some of the findings and other achievements accomplished by the University of Minho team, which currently gathers several senior researchers from three different departments of the School of Engineering (Textile, Mechanical and Industrial Electronics), are summarized in the next topics.https://www.vssewingmachine.in/

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