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Material feeding. Seams are produced on the fabric with a certain pattern, which is, in the simplest case, a straight line, but may also be a complicated form such as the ones used in embroidery operations. To form these patterns, the material has to be transported-“fed” by a distance that is called the stitch length. Given that industrial machines operate at very high speeds (some of them attaining 10 000 stitches per minute), the dynamics involved is complex and there are very often problems with material deformation and irregular stitch length. Some of these aspects have been addressed in Needle penetration. Considering again the high sewing speeds that occur, problems with needle penetration can arise due to the mechanical and thermal interaction between needle and fabric. Fabric yarns may be torn by the forces acting during needle penetration or they may fuse due to the high needle penetration produced by friction. Systems to monitor needle penetration forces during the process to detect defects and off-line systems to support the choice of needles and fine-tune fabric structures and finishing to avoid these problems, would be of high value to the industry. Read More
Stitch formation/Thread tensions. The interlacing of the threads itself, which constitutes the actual stitch formation, cannot be dissociated from the processes of material feeding and needle penetration. However, there are two variables directly linked to the thread that most intimately represent it: Thread tensions and thread consumption. The relationships between fabrics, machine set-up and stitch formation in lockstitch machines have already been studied in . Methods for defect detection have been developed for overlock machines and presented in . However, an automatic system for setting thread tensions online is still missing. Wang and Ma describe thread tension control in embroidery machines, but the work only tackles the issues associated to the control of the actuator. Setting of the correct references for the controllers to produce a high-quality product in varying conditions is the key issue, and this has to be further tackled Because of the wear of the sewing needles of embroidery machines defects can appear on the embroidery surface of the product. Therefore, it is necessary to schedule the moments of replacing the sewing needles of the embroidery machines based on the anticipation of their failure moments. Within this framework, the purpose of this study is to develop a fuzzy decision system for determining the moment of replacing of the sewing needles of embroidery machines, considering their amplitude of vibrations measured on the three axes of the Cartezian coordinate system.Click Here
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