Analysis Of The Core Technology And Innovative Design Of Industrial Automatic Sewing Machines

So far, China has become the world’s sewing machine production center and production power, but it is still not the most powerful country. My country is taking advantage of the opportunities brought by the favorable period of the world’s sewing machine industry’s great transfer to the development of the sewing machine industry, and re-examines the development strategy of the automatic sewing machine industrial. And especially for the way of thinking of change in product development. For the leading products such as high-speed lockstitch machine and high-speed overlock sewing machine that have achieved mass production, we will strive to shorten the time to gap with Japan and other advanced countries or famous foreign companies in terms of product quality, technical level and product grade, and achieve synchronization.

Bartack Sewing Machine

Let’s have a brief review of the technical trajectory of the development of foreign sewing machines. Taking Japan as an example, in the 1960s, Japanese industrial sewing machines began to change from low speed (medium speed) to high speed. The development of the following 20 years has made the quality and technical level of industrial sewing machines continue to improve, and the varieties have also been enriched and diversified unprecedentedly. Therefore, Japn becoming the world’s largest industrial sewing equipment at that time. The largest export-oriented industrial sewing machine producer.

China just started the high-speed process of industrial sewing machines by introducing foreign technology in the early 1980s, and the time gap was 20 years. In the 1980s, due to the rapid development of electronic technology, Japanese industrial sewing machines comprehensively improved the level of the original machine types by applying electronic technology. And a large mount of automation devices and other high value-added products were developed at the same time. Japanese industrial sewing machines have embarked on the road of a power country of industrial automation amchinery.

In the 1990s, the development and production of automatic thread trimmer sewing machines, especially supporting computers and motors, began to take off. Although China Standard Company introduced this product from Japan’s Mitsubishi Corporation in 1986, it did not include computer and motor production technology at that time. Although many units in the country have experience of developing computers and motors, due to various reasons, the automatic thread trimming lockstitch machine has never been put into normal production. Only after the development of computers and motors is gradually commercialized, can such products be brought into the market with production capacity. Now this model has been produced by many companies and has become an important product produced in my country, with a time gap of 10 years.

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At the beginning of the 21st century, Japan, relying on its long-term accumulated technology, experience and innovation ability in industrial sewing machines, launched a new type of direct-drive oil-free industrial sewing machine with integrated motor and casing in order to maintain its leading position in product technology. Oil-free industrial sewing machine products is another trend of product technology development after high-speed and mechatronics, which will definitely bring industrial sewing machines to a new level. And soon after this product was put on the market, it attracted the attention of my country’s sewing machine manufacturers. At present, many companies have developed and are developing such products, and the time gap has been shortened to less than 5 years. This shortening of the product development start-up time gap, which marks a turning point in technological change, indicates the beginning of a new stage in the development of industrial sewing machines in China.

It also shows that after decades of development, technology introduction, utilization of foreign capital technology, etc., my country’s sewing machine industry has accumulated a certain amount of knowledge and experience in product development technology, and also has relatively strong productivity and technical support, making the sewing machine industry. Many enterprises have the conditions to pay attention to and track the latest trends in the technological development of foreign sewing machine products, and begin to realize the importance of developing high-quality, high-value-added products. They must speed up efforts in this regard to face the new changes in the current product demand structure and industrial sewing machine changes. The acceleration of speed and the globalization of markets and production have brought demands on enterprises to improve their competitiveness.

However, it should be clearly recognized that the shortening of this time gap does not mean that the overall technological gap between my country’s industrial sewing machines and Japan and other advanced countries and foreign famous enterprises is shortening. No matter in the quality of industrial sewing machine products, in the level of application of mechatronics technology or in the development of varieties, there are still obvious gaps. The fundamental reason is that my country has not or rarely mastered the core technology of product development, and its innovation ability is poor. This is an urgent problem faced by my country’s industrial sewing machines from a follow-up to a leap-forward development stage, and it is also the key to my country’s industrial sewing machines from a large production country to a production power.

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The core technology of Sewing Machine :

The core technology of the product refers to the key technology that is not easily imitated by competitors or has technical secret characteristics (such as unique process, technical know-how, experience parameters, test data, etc.). There are core technologies in sewing machine design, manufacture and assembly. In the process of product development or design, the technical solutions for solving major problems related to product quality and the methods and means for realizing the solutions, that is, the so-called inherent technology of the product, some of which can constitute technical patents and have independent intellectual property rights. Therefore, product inherent technology is an important part of core technology in product development and design. Products can be imitated by means of surveying and mapping, but the core technology cannot be imitated. There is always a “little” gap between industrial sewing machines produced by direct surveying and mapping prototypes in my country and similar products that have been imitated abroad. This gap is not reflected in the technical requirements specified in the product standard, but in the sewing quality of the product, especially the so-called beautiful, uniform, stable, clear, smooth, elastic and other perceptual indicators of the stitches on the sewing material. . Is there a solution or some core technology behind these gaps that we haven’t mastered yet. Listed below are some of the research topics related to the product’s inherent technology during the development and design of industrial sewing machine products.

(1) Analysis of the force of the thread trimming mechanism and the strength of its parts of the automatic thread tension sewing machine

1. Experimental research on the external force acting on the mechanism

2. Analysis of the change of the acting moment of the upper shaft

3. Analysis of the impact moment generated by the lower shaft

(2) Dynamics of feeding mechanism

1. The movement track of the feeding teeth of the feeding mechanism

2. Inertial force acting on the motion pair of the feeding mechanism (no-load and loaded) 3. Analysis of stitch length changes at high and low speeds and improved error countermeasures

4. The force acting on the components of the feeding mechanism and the method for evaluating the strength of the components

(3) Motion analysis of needle and thread take-up mechanism (connecting rod type, sliding rod type)

(4) Sewing machine vibration and countermeasures to reduce vibration

1. The influence of each transmission mechanism of the sewing machine on the vibration force of the whole machine

2. The dynamic external force acting on the shell caused by the needle and thread take-up mechanism

3. Analysis of the moment acting on the main shaft (two cases of no-load and loaded) 4. Measurement of the vibration force on the shaft sleeve

5. Analysis of the influence of each transmission mechanism of the sewing machine on the noise of the whole machine

6. Quantitative analysis of the influence of the shape and position tolerances and fit clearances of the needle mechanism, feeding mechanism and other components on noise 7. Vibration analysis by test method

8. Countermeasures to reduce vibration

(5) Research on the mechanical properties of needles

1. Detection method of needle temperature

2. Measurement of the axial force acting on the needle

(6) Measurement of dynamic tension of suture

(7) Follow-up analysis and structural improvement of pressure bar system under high speed conditions

(8) Analysis of the relationship between the displacement curves of needles, shuttles, feed dogs and the tension of the upper thread and its influence on the quality of the stitches It is related to the technical development of the product itself, the realization of high-speed, automation, specialization, integration, etc., as well as the means and methods of realizing the solution. These constitute the specific content of the core technology of industrial sewing machine products. It can be seen that mastering the core technology of industrial sewing machines must rely on professional knowledge, including professional knowledge in other related fields, like automatic shoe sewing machine, automatic pocket sewing machine, automatic bag sewing machine, automatic zigzag sewing machine and automatic sewing machine for shirts, which are used for whole different products. So it need us to know their products well. Only by deeply analyzing and truly mastering the core technology of the product, can product development and design with independent intellectual property rights be carried out, and through continuous technological accumulation, a product design database, sewing machine organization map, etc. can be gradually established, which lays the foundation for further development of innovative design of industrial sewing machines.

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Of course, the core technology of best sewing machine products is dynamic and developing. With the maturity of the original product technology, the application of new technologies, product upgrades, expansion of functions, changes in the scope of application, especially the creation of new stitch forms and so on. The core technology of industrial sewing machines will also change accordingly. However, many of these common technologies can be used for reference and reference when mastering and analyzing the core technologies of specific products. This is especially true when developing and designing serialized products. This illustrates the importance of technical accumulation and experience.

As an example, try to list the core technologies that a high-speed lockstitch sewing machine should know or master.

(1) Lightweight technology of lock-stitch sewing machine

1. Analysis and test technology of the main vibration source of the casing

2. Lightweight materials and their surface coating technology

3. The influence of the cross-sectional shape of the casing on the vibration

(2) Influencing factors for realizing low tension sewing

(3) Dynamic tension measurement technology of upper thread for lock-stitch stitch machine

(4) Rotary shuttle design technology of lock-stitch stitching machine

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The industrial sewing machine industry has formulated stitch type standards. The basic mechanism types of industrial sewing equipments that realize various stitches are relatively mature after long-term use, and the mechanism types tend to be finalized. The improvement of product quality, the development of varieties, the improvement of technical level, and the replacement of new products are more reflected in the continuous improvement on the basis of the original products. The application of mechatronics technology provides more space for the gradual and continuous change and innovation of products, but it must also add automation, integration or systematic functions based on the original products. It is unlikely to completely change the basic mechanism type of the current industrial new automatic sewing machine. Even if the cam mechanism is replaced by electronic control technology like a periodic sewing machine, it is only a change in the control method to achieve the purpose of simplifying the mechanism. , the basic functional structure type of buttonhole machine and tacking machine. According to the characteristics of industrial sewing machines, the use of reverse design as the basic method of product innovation design is an effective method that is suitable for the current level of Chinese sewing machine product development.

Reverse design is also an innovative design. It must conduct a comprehensive, in-depth and systematic analysis of the existing advanced products by applying various scientific testing methods to understand and master the product’s structural characteristics, mechanism principles, functions, and quality levels. and relevant design parameters, and at the same time, make an evaluation on the basis of digestion and absorption of new technologies, new processes, and new materials used in the products. Make judgments on various problems to be improved in the product itself found in the analysis, as well as the requirements and potential requirements for product quality feedback from users and the market, and use this as the entry point for innovative design to develop innovative products. Therefore, reverse design is a pioneering, practical and comprehensive product innovation design method.

(1) Market demand

Any sewing machine product development comes from market demand. Its guiding ideology is that it contributes the most to the development strategy of the enterprise and has the highest development success rate. Recognize the marketability, economy and high quality of products and make choices to meet market needs at different levels.

(2) Prototype selection

Select basic products as prototypes to facilitate the development of serialized products in the future; pay attention to the advanced nature of prototypes; choose famous brand products; pay attention to user requirements for product quality and potential quality requirements; pay attention to the establishment of product data (sample) libraries.

(3) Prototype evaluation items

(different industrial sewing machines, the evaluation items are different) sewability evaluation: broken thread, broken needle, skipped stitch, floating thread, skewed stitch, neatly arranged stitch, thread tension, high and low speed thread Evaluation of functions such as track uniformity, seam slippage, wrinkling, vibration, noise, torque, etc.:

  • Functional parameters and reliability
  • Durability Evaluation: Durability of Key Components
  • Adjustment Performance Evaluation: Adjustability, Stability, Adjustment Range and Ease of Operation Safety Evaluation: Operational Safety
  • Rationality evaluation of sewing process design parameters: motion cycle diagram, motion diagram of functional mechanism executive components, etc. Assembly evaluation: positioning benchmark, assembly clearance, etc.
  • Evaluation of new materials, new processes and new technologies: analysis of characteristics
  • Appearance design evaluation and others (including parts structure and size)
  • Product differentiation evaluation: characteristic analysis

(4) Evaluation method

Compare with existing products or other advanced products collected, internal control standards of foreign advanced enterprises, etc. The conclusions drawn are used as technical indicators and evaluation basis for innovative product design.

(5) Examples of innovative solutions

  1. Innovative design of feeding methods:bottom feeding, needle feeding, upper and lower feeding, differential feeding, upper and lower feeding with variable amount of upper feeding, new structure of independent movement of upper and lower feeding, integrated feeding, roller feeding, etc.
  2. Thread take-up mechanism Innovative design:cam thread take-up, connecting rod thread take-up, sliding bar thread take-up, rotating disc thread take-up, etc.;
  3. Innovative design of needle mechanism:center crank slider mechanism, rocker slider mechanism, connecting rod mechanism, needle bar The swing is changed from the fulcrum mode to the translation mode, etc.
  4. Design of the upper and lower shaft transmission modes:connecting rod mode, gear mode, synchronous belt mode, etc. and the innovation of the feeding mechanism.

(6) Innovative solutions

After the sample evaluation, confirm the improvement project, clarify the goals and technical requirements that the improvement project should achieve, and use the product data (sample) database, design database, organization map, and related professional knowledge and experience to complete the specific design plan, and improve the part. Make real objects for verification, and sometimes need to be revised repeatedly, and finally complete the optimal solution.

The above is just a brief introduction to the reverse design process.

Of course, innovative design is improved and fundamental. As long as we establish innovative design concepts, study hard, have the courage to explore, and constantly sum up experience, our innovation level and innovation ability will definitely be improved. This will effectively promote breakthroughs in my country’s sewing machine industry and accelerate my country’s pace of becoming the world’s largest sewing machine production power!

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