TECHNICAL FIELD

Embodiments of the present disclosure relate to a sewing machine, more particularly, embodiments relates to the remotely operable sewing machine.

BACKGROUND OF THE DISCLOSURE

Formal Trouser waistband grippers are made with 5 to 10 tapes, based on the styles. Conventionally the waist band grippers are manufactured by attaching these tapes manually by an operator and stitching the attached tapes by the sewing machine. The act of attaching the tapes manually involves 5 to 6 steps based on style and this increase the cost of manufacturing the waist band grippers and reduces the quality of production and consistency. By doing manual construction without any attachment to the sewing machine there is loss in production, increase in manpower, machine, and thread consumption.

Further, the conventional sewing machines are controlled manually and it consumes more operators time. The operator can handle only one machine at the time; hence there was a less production at the shop floor. Since the operator has to stitch the waist band grippers in four to five steps the quality of the waist band grippers was less. In the conventional sewing machines the operator has to feed the tapes to the sewing unit from one end and stretch the stitched tapes from the sewing unit from the other end. This requires more operators to operate the machine which increases the manpower requirement and reduces the quantity of production.

In view of foregoing discussion it is desirable to overcome the problems stated above.

SUMMARY OF THE DISCLOSURE

The shortcomings of the prior art are overcome and additional advantages are provided through the provision of system and method as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered as part of the claimed disclosure.

One non limiting embodiment of the present disclosure discloses a sewing machine. The machine comprises a clutch motor to operate a sewing unit and a tape feeding unit comprising plurality of rolls for feeding tapes to the sewing unit. The sewing machine further comprises a pulling component coupled to a clutch of the clutch motor for regulating speed of said motor. A remote control unit is interfaced to the pulling component for remotely operating the motor. And at least one sensor mounted on each roll of the tape feeding unit for detecting availability of tape in the rolls, wherein said sensors are interfaced with remote control unit to operate the clutch motor based on signals from the sensors.

In one embodiment of the present disclosure, a stretching unit is provided for stretching the stitched band from the sewing unit.

In one embodiment of the present disclosure, a limit switch is provided in between the sewing unit and stretching unit for detecting the band and activating the stretching unit.

In one embodiment of the present disclosure, a winding unit is provided for winding the waist bands after stretching.

In one embodiment of the present disclosure, the remote control unit operates a solenoid valve connected to pulling component for regulating the motor.

In one embodiment of the present disclosure, the pulling component is at least one of pneumatic cylinder, pedal operated by pneumatic cylinder, and rod connected to the pneumatic cylinder.

In one embodiment of the present disclosure, the solenoid valve is interfaced with the pneumatic cylinder, and said pneumatic cylinder regulates the pedal for operating the clutch.

In one embodiment of the present disclosure, the sensors mounted on each roll of the tape feeding unit are optical sensors.

Another embodiment of the present disclosure provides a method of remotely operating a sewing machine. The method fallows acts of actuating a remote control unit by an operator using a remote and detecting availability of tape in each roll of a tape feeding unit using at least one sensor, wherein said sensors are interfaced with remote control unit. Then regulating a pulling component by the remote control unit to operate a clutch motor based on signal from the sensors, wherein the pulling component is coupled to a clutch of the clutch motor.

In one embodiment of the present disclosure, stretching a stitched material when limit switch detects the stitched material between sewing unit and stretching unit.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which: FIG. 1 illustrates a perspective view of sewing machine of the present disclosure.

FIG. 2a illustrates a functional block diagram of a remote control unit in sewing machine of the present disclosure.

FIG. 2b illustrates operational block diagram of a remote control unit in sewing machine of the present disclosure.

FIG. 3 illustrates a stretching unit in sewing machine of the present disclosure.

FIG. 4 illustrates a winding unit in sewing machine of the present disclosure.

FIG. 5 illustrates a tape feeding unit in sewing machine of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific aspect disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

The disclosure is drawn, interalia, to relate to a waist band gripper manufacturing device, more particularly embodiments relates to the remotely operable waist band gripper manufacturing device.

FIG. 1 is an exemplary embodiment which illustrates a perspective view of a sewing machine (100) of the present disclosure. The sewing machine (100) comprises plurality of components but not limited to a sewing unit (207) for stitching the plurality of tapes to form a waist band gripper. A clutch motor (202) mounted below the sewing unit (207) for driving the sewing unit (207). And at least one folder not showed in the figure to feed plurality of tapes to the sewing unit (207). A tape feeding unit (102) comprising plurality of rolls (102a) is provided behind the folder and the said rolls (102a) feed the plurality of tapes to the folder from different directions. The sewing machine (100) further comprises a stretching unit (300) in front of the sewing unit (207) for stretching the waist bands from the sewing unit (207). And the winding unit (400) is provided for winding the waist bands after stretching. In addition to above the sewing machine (100) also comprises a system to remotely operate a clutch motor (202) of sewing machine (100).

In the sewing machine (100) plurality of tapes are fed from the tape feeding unit (102) to the folder. The folders are selected based on the style of the trouser and the said folders folds the tapes and then feed to the sewing unit (207) for stitching the waist band gripper. The waist bands after stitching in the sewing unit (207) are stretched by the stretching unit (301) to form pucker free finish then the waist band are winded by the winding unit. In the stretching unit (300) a mechanical limit switch is provided for sensing the availability of waist band coming out of sewing unit (207) and to activate the winding unit (401) for winding the waist bands. The mechanical limit switch will be activated based on the pressure applied by the waist band onto it, i.e. the waist band applies more pressure when the sewing unit is OFF and the waist band applies less pressure when the sewing unit is working.

FIG. 2a is an exemplary embodiment which illustrates a functional block diagram of a remote control system in sewing machine (100) of the present disclosure. The remote control system comprises a pulling member coupled to a clutch of the clutch motor (202) for operating the motor (202). In one embodiment the pulling member is a pedal (201) and is operated by a pneumatic cylinder (206) placed below it, and said pneumatic cylinder (206) is interfaced with solenoid valve (205) to regulate the pulling member (201). A remote control unit (203) is operates the solenoid valve (205), and the solenoid valve (205) regulates the pneumatic cylinder (206) to operate the pedal (201). In one embodiment the pneumatic cylinder (206), pedal (201) and solenoid valve (205) act as pulling member. Further, the remote control unit (203) is interfaced with at least one sensor (204) mounted on each roll (101a) of the tape feeding unit (101) for detecting availability of tape in the rolls (101a) and to operate the clutch motor (202) based on signals from the sensors (204). In one aspect of the present disclosure, the sensors (204) are optical sensors and the said optical sensors (204) detect the availability of the tape in each roll (101a) using the optical source. In an exemplary embodiment an optical sensor (204) comprises an infrared ray emitter and receiver unit for sensing the tape. When the infrared ray emitter emits rays, the rays will be reflected back to the receiver unit if the tapes are present, else the optical sensor generates an alarm to notify the operator to feed the tapes to the rolls (101a).

In one aspect of the present disclosure, the pulling member coupled to the clutch of the clutch motor (202) is a pneumatic cylinder, pedal having a pneumatic cylinder below and any connecting member coupled between the clutch and the pneumatic cylinder (206). The pulling member pulls the clutch to operate and regulate the speed of the clutch motor (202), and said clutch motor (202) in turn operates the sewing unit (207).

As shown in FIG. 2b the remote control unit (203) receives signal from radio frequency transmitter through receiver upon pressing the button on the transmitter. The received signal from the transmitter will trigger the flip flop circuit and hold a relay of the solenoid valve (205) permanently. The relay contacts will provide the supply for the sensor circuit. The sensor circuit comprises plurality of optical sensors (204), and said sensors (204) will sense the tape in each roll (101a) of the tape feeding unit and give the input to the circuit. The sensor circuit is interfaced with the remote controller (203), and said controller (203) will give a signal to the solenoid valve (205) to operate the pneumatic cylinder (206) if all the enabled sensors (204) are given the inputs. If all the active sensors (204) sense the tape then the remote control unit (203) will trigger the relay and provide the supply for the machine to start. If any of the active sensors (204) is not working or not sense the fabric then the remote control unit (203) will not give the output and the machine will not run.

FIG. 3 is an exemplary embodiment which illustrates a stretching unit (300) in sewing machine (100). The stretching unit (300) is provided in front of the sewing unit for stretching the stitched waist band gripper from the sewing unit. The stretching unit (300) comprises a pair of rollers (301a and 301b) rotatable in opposite direction for stretching the waist bands. The rollers (301a and 301b) are driven by at least one belt drive, chain drive, and gear drive connected to the clutch motor of the sewing machine (100). The stretching unit (300) further comprises a mechanical limit switch between the sewing unit and the stretching unit (300) to detect the waist band coming out of sewing unit and to activate the winding unit (300) for winding the waist bands. The mechanical limit switch will be activated based on the pressure applied on the waist band by the stretching unit (300). i.e. the waist band experiences more pressure when the sewing unit is OFF as compared when the sewing machine (100) is ON. This is due to the pulling of waist band by the stretching unit (300) i.e. the waist band experiences less pressure when the sewing unit is working. Thus, when the sewing unit is OFF ,the press on the waist band operates the limit switch thus switching OFF the winding unit (300). Further, the stretching unit provides pucker free finish of the waist band.

FIG. 4 is an exemplary embodiment which illustrates a winding unit (400) in sewing machine. The winding unit is provided in the sewing machine (100) for winding the stitched waist bands after stretching. The winding unit (400) comprises at least one roller (401) for rolling the stitched waist bands. Further, the winding unit (400) is driven by at least one of clutch motor (202) of the waist band gripper manufacturing device or the separate motor mounted with the winding unit. The winding unit is further controlled by the limit switch.

FIG. 5 is an exemplary embodiment which illustrates a tape feeding unit (101) in sewing machine. The tape feeding unit (101) is mounted behind the sewing unit for feeding plurality of tapes from different directions to the sewing unit for stitching the waist bands. The tape feeding unit (101) comprises plurality of rolls (101a) having the tapes and said rolls (101a) feeds the tapes to the sewing unit. The tape feeding unit (101) further comprises at least one optical sensor (204) mounted on each roll (101a) of the tape feeding unit (101) for detecting availability of tape in the rolls (101a). The optical sensors (204) are interfaced with remote control unit (203) for operating the clutch motor (202) based on signals from the optical sensors (204). Out of plurality of sensors (204) the required sensors (204) can be activated for sensing the availability of tape and the activated sensors (204) give signal to the remote control unit for activating the clutch motor if all optical sensors (204) sense the presence of tapes.

FIG. 6 illustrates a flow chart showing a method of remotely operating the sewing machine. A remote control unit (203) is actuated by the operator using a remote as shown in step 601. The remote control unit (203) checks the availability of tapes in each roll (101a) of a tape feeding unit (101) using at least one sensor (204) mounted on each roll as shown in step 602. If the sensors (204) detect the availability of tape in each roll (101a) then the remote control unit regulates a pulling member to operate a clutch motor (202) as shown in step 603. Else, the remote control unit (203) gives alarm to the operator for filling the tapes to the rollers as shown in step 604.

The sewing machine of the present disclosure has fallowing advantages:

The present disclosure provides a remotely operable sewing machine which can be operated by the single operator, which results in less manpower to operate the machine.

The present disclosure provides a sewing machine which has plurality of sensors in tape feeding unit to sense the availability of tape in each role and to give alarm to the operator if the rolls are empty.

The present disclosure provides a sewing machine which increases the quality and consistency of the waist bands manufactured.

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

We claim:

1. A sewing machine (100) comprises:

a clutch motor (202) to operate a sewing unit;

a tape feeding unit (101) comprising plurality of rolls (101a) for feeding tapes to the sewing unit; and characterized in that;

a pulling component coupled to a clutch of the clutch motor (202) for regulating speed of said motor(202);

a remote control unit (203) interfaced to said pulling component for remotely operating the motor (202); and

at least one sensor (204) mounted on each roll (101a) of the tape feeding unit (101) for detecting availability of tape in the rolls (102a), wherein said sensors (204) are interfaced with remote control unit (203) to operate the clutch motor (202) based on signals from the sensors (204).

2. The sewing machine as claimed in claim 1, wherein a stretching unit (301) is provided for stretching the stitched band from the sewing unit.

3. The sewing machine as claimed in claim 1, wherein a limit switch is provided in between the sewing unit and stretching unit (301) for detecting the band and activating the winding unit (301).

4. The sewing machine as claimed in claim 1, wherein a winding unit (401) is provided for winding the waist bands after stretching.

5. The sewing machine as claimed in claim 1, wherein the remote control unit (203) operates a solenoid valve (205) connected to pulling component for regulating the motor (202).

6. The sewing machine as claimed in claim 1, wherein the pulling component is at least one of pneumatic cylinder, pedal operated by pneumatic cylinder, and rod connected to a pneumatic cylinder.

7. The sewing machine as claimed in claim 5, wherein the solenoid valve (205) is interfaced with the pneumatic cylinder (206), and said pneumatic cylinder (206) regulates the pedal (201) for operating the clutch.

8. The sewing machine as claimed in claim 1, wherein the sensors (204) mounted on each roll of the tape feeding unit (101) are optical sensors.

9. A method of remotely operating a sewing machine, said method comprises acts of;

actuating a remote control unit (203) by an operator using a remote;

detecting availability of tape in each roll (101a) of a tape feeding unit (101) using at least one sensor (204), wherein said sensors (204) are interfaced with remote control unit (203); and

regulating a pulling component by the remote control unit (203) to operate a clutch motor (202) based on signal from the sensors (204), wherein the pulling component (201) is coupled to a clutch of the clutch motor (202).

10. The method as claimed in claim 9, wherein activating a winding unit (401) for winding the stitched material using a limit switch, when said limit switch detects the stitched material.