Study on Sensing and Monitoring of Sewing Machine for Textile Stream Smart Manufacturing Innovation
He smart factory is a futuristic production paradigm that transforms ICT(Information and communication technology) into a new smart/green/urban production system by integrating the existing traditional industrial production system.[1-2] Industry 4.0 proposed by DFKI, is defined as the 4th industrial revolution based on Internet-of-Things(IoT), cyber-physical systems(CPS), and Internet-of-Services(IoS). [3-6] In the textile industry, the smart factory is a factory based on the CPS that incorporates ICT and IoT technology into the existing production system.[7-8] VS Sewing Machine Dealers In order to build a smart factory between textile and apparel streams, the connectivity of the CPS should be strengthened.
This study focuses on the construction of a CPS system to realize a smart factory by deriving three representative processes (fabric, dyeing, sewing) among textile streams. The data flow of CPS based inter-stream smart manufacturing system. The rectangle marked with read lines represents the part for detecting and controlling the sewer data for the smart of the sewing process which is the core of this research.
Textile stream smart factory CPS implementation can only be done by linking together the ordering system, design automation system, product information management system, production information integration system and production equipment automation. The interlinkage of high-throughput, high-productivity production systems that minimize plant-to-plant collaboration and prototype production to accommodate small-volume and multi-stream requirements between streams, and can be instantly produced on demand.
SEWING MACHINE SENSING DEVICE DEVELOPMENT FOR SMART FACTORY 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. 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.
Software algorithms were designed to implement the logic sequence so that if the under-thread is insufficient, the operation stops immediately.
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. 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. 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. 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.
Detailed data and method of monitoring system at the upper left part of the figure are explained below. C. Information flow of the sewing machine detected from sensors for smart sewing process 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.