Parameter Monitoring and Control in industrial sewing machines

Parameter Monitoring and Control in industrial sewing machines

The end of the 20th century has brought important new trends in fashion design, marketing tools and consumer attitudes that have reshaped the demands on the textile and apparel industry. The main consequences to apparel manufacturing have been a constant increase of individual production orders, product and materials variety and much smaller order quantities. This fact posed new requirements on the production systems and equipment: both have to be flexible and reliable. In the case of the equipment, this means that quicker set-up times are required whenever material changes and that quality assurance has to be much more efficient. Managing this situation with the traditional empirical machine set-up and process planning methods is difficult. https://vssewingmachine.in/ Better control and predictability of the processes are required. Additionally, in the new and thriving segment of technical textiles, defects may represent failure of product functions, also demanding new methods that provide a more holistic and knowledge-based management and control of the processes.

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The developed measurement system is based on a Singer 882 overedge machine configured to produce the three-thread stitch type 504. Several sensors measuring the relevant process parameters have been applied to the machine. The sensors’ signals are conditioned by custom-developed hardware and are then connected to a data acquisition board plugged to the PC. A software package developed in LabView acquires, stores, displays and analyses the signals [[1],[3]]. The test rig measures sewing process variables related to three different sub-functions of the machine: Needle penetration, fabric feeding and thread interlacing or stitch formation.

To assess the fabric feeding behavior, a piezoelectric sensor was applied to the presser-foot bar as shown in Fig. 2. This sensor measures the dynamic forces on the presser-foot bar and the spring. Additionally, an LVDT has been incorporated to indicate vertical displacement of the presser-foot.

Stitch formation is described by the thread pulling forces and thread consumptions. Fig. 3 shows the set-up of the sensors. Thread forces are sensed by semiconductor strain gages applied to the base of a metallic beam. To measure thread consumption, digital encoders have been equipped with wheels where the sewing threads are wound. The pulses produced by the passing thread are then counted during seam formation.

The software, developed in the LabView programming environment, is the most important component of the system. It provides extensive functionalities to support the study of the sewing variables.[[1]] The first of these are the signal acquisition functions that allow the user to quickly perform a seam or a set of seams, display and store them. Included are also very effective graphing functions, with multiple zoom and pan capabilities on the graphs, allowing a detailed analysis of the signals. Finally, and most relevantly, the software provides an extensive set of analysis functions. These include a complete set of functions specifically designed to process each individual sewing parameter, computing, displaying and testing the results against pre-defined limits. Additionally, some general-purpose tools like FFT-processing, digital filtering, peak detection, and other functions are available. In the current state of development, it is possible to perform a seam and immediately obtain complete results concerning the evaluation of machine operation in its different aspects.

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