1. The design objectives
Achieve high-precision and high-efficiency quilting operations to meet the quilting needs of different materials, different thicknesses and different patterns.
It has an intelligent control system, which can easily edit patterns, set parameters and monitor operations.
Ensure that the equipment runs stably and reliably, with a low failure rate and long service life, and at the same time is easy to maintain and maintain.
The design is ergonomic, easy and comfortable to operate, and reduces the labor intensity of the operator.
2. Mechanical structure design
● Racks
It is welded with high-strength steel, and has undergone aging treatment to eliminate welding stress and ensure that the frame has sufficient rigidity and stability, and will not produce obvious vibration and deformation during high-speed quilting.
The design of reasonable dimensions should not only ensure that the size of the quilting work area meets the processing requirements of common quilts, mattresses and other products, but also consider the overall floor area and space layout of the equipment, so as to facilitate the placement in the production workshop.
● Quilting machine head
The high-precision quilting needle bar mechanism is selected, and the needle bar movement adopts advanced cam or connecting rod transmission mode to ensure that the up and down movement of the quilting needle is accurate and stable, and the needle distance can be accurately adjusted in a wide range, such as the minimum needle length can reach 0.5mm, and the maximum needle distance can reach more than 10mm, so as to adapt to different quilting patterns and process requirements.
Equipped with an automatic thread trimming device, after the quilting completes a thread segment or pattern unit, the suture can be cut quickly and neatly, improving work efficiency and ensuring the quality of quilting.
The design of the bobbin mechanism that can be changed quickly makes it easy for the operator to change the bobbin in time when the stitching needs of different colors or materials, reducing downtime.
● Feeding mechanism
The feeding in the X and Y directions is driven by high-precision ball screws and linear guide rails, and driven by servo motors to achieve precise position control and high-speed and stable feeding movements. The feeding speed can be adjusted in a wide range according to different quilting patterns and process requirements, and the maximum feeding speed can reach several meters per minute.
The surface of the feeding platform adopts special treatment, which has good friction and wear resistance, which can not only ensure that the cloth does not slip or shift during the feeding process, but also reduce the damage to the cloth. At the same time, the feeding platform should have convenient loading and unloading functions, such as designing a lifting or sliding auxiliary plate to facilitate the operator to place and remove large quilted workpieces.
● Thread-picking mechanism
The optimally designed take-up rod and pick-up spring ensure a stable and suitable thread tension during the quilting process, avoiding problems such as jumpers, broken threads or uneven stitches. The thread tension can be adjusted manually or automatically depending on the thread material and thickness.
A well-designed thread passage reduces the friction resistance and the risk of entanglement during the movement of the suture, and ensures the smooth progress of the quilting operation.
Computer control system design
Hardware design
Motherboard and microprocessor selection: Choose a high-performance, stable microprocessor, such as an ARM architecture or an industrial-grade x86 processor. The motherboard should have enough interfaces to connect various external devices, such as motor drivers, sensors, etc.
Motor drive module: Computerized quilting machine usually has multiple motors, including spindle motor, feeding motor and pick-up motor, etc. The motor drive module needs to be able to precisely control the speed, steering and torque of the motor. For example, with servo motor drives, high-precision speed control and position control can be realized.
Sensor interface: In order to achieve automatic and high-precision quilting, various sensors such as needle position sensors, fabric edge sensors, etc. need to be installed. The motherboard should reserve the interfaces for these sensors and have corresponding signal processing circuits.
Software design
Operating system selection: You can choose an embedded real-time operating system (RTOS) such as FreeRTOS or μC/OS-II to ensure the real-time and stability of the system. The operating system needs to be able to effectively manage hardware resources and enable multitasking.
Pattern design software: This is the core part of the computerized quilting machine software. Users can design or import a variety of complex quilting patterns through the software. The software needs to be able to translate the pattern data into machine-readable commands that control the movement of the needle bar and the feeding mechanism. For example, the software can break down a flower pattern into a series of pin positions and feed distances, and generate a sequence of control instructions through mathematical algorithms.
Human-Computer Interface (HMI) design: The interface should be concise, intuitive, and easy for users to operate. The user can set quilting parameters such as speed, pattern selection, stitch length, etc. via the touch screen or buttons. At the same time, the interface should be able to display the operating status of the machine, such as the current needle position, the remaining quilting length, etc.
Designed for safety protection
The emergency stop button is installed to facilitate the operator to stop the machine immediately in case of emergency. Emergency stop buttons are usually in a striking red color and are distributed in easily accessible locations to the machine.
The moving parts of the machine, such as the needle bar, feeding teeth, etc., should be equipped with protective devices to prevent accidental contact injuries to the operator. Guards can be transparent plastic covers or metal grilles.
Appearance design
Considering the industrial aesthetics and practicality, the appearance of the computerized quilting machine should be simple and elegant. The shell is generally made of metal or engineering plastic, and the surface is painted or frosted to improve the texture.
The layout of the computerized quilting machine should be reasonable, which is convenient for users to operate and maintain. For example, the operator panel should be placed in a position that is easy for the operator to observe and operate, and the service ports of each component should be easy to open and service.
+8619892598261
+8619892598261
