Sewing system

A sewing system which includes a detector for detecting an edge of a cloth installed on an installation table, a cloth conveyor for conveying the cloth from the installation table to a sewing machine, and a controller, wherein the cloth conveyor includes a holding member that holds the cloth, and the controller includes a holding position decision portion that determines a holding position of the cloth based on detection data of the detector, and a conveyance control portion that controls the cloth conveyor such that the holding member holds the holding position. In the sewing system according to the above, it is possible to prevent deterioration in productivity of sewn products.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority of Japanese Patent Application No. 2018-108889, filed on Jun. 6, 2018, the content of which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a sewing system.

BACKGROUND ART

A sewing system including a sewing machine is used in a manufacturing process of sewn products. As an example of such a sewing system, a label sewing device disclosed in Japanese Unexamined Patent Application Publication No. 2016-131614 is known.

In order to prevent deterioration in productivity of sewn products, a technology is required which can quickly and accurately feed cloth to a sewing machine.

SUMMARY OF THE INVENTION

An aspect of the present invention is to prevent deterioration in productivity of sewn products.

An aspect of the present invention is a sewing system which includes a detector for detecting an edge of a cloth installed on an installation table, a cloth conveyor for conveying the cloth from the installation table to a sewing machine, and a controller, wherein the cloth conveyor includes a holding member that holds the cloth, and the controller includes a holding position decision portion that determines a holding position of the cloth based on detection data of the detector, and a conveyance control portion that controls the cloth conveyor such that the holding member holds the holding position.

In the sewing system according to an aspect of the present invention, it is possible to prevent deterioration in productivity of sewn products.

DETAILED DESCRIPTION

Hereinafter, an embodiment of the present invention will be described with reference to the drawings, but the present invention is not limited thereto. Configuration elements of the embodiment which will be described hereinafter can be appropriately combined with each other. There is also a case where some configuration elements are not used.

In the following description, an XYZ orthogonal coordinate system is set, and the positional relation of each part will be described with reference to the XYZ orthogonal coordinate system. A direction parallel to an X-axis in a predetermined plane is defined as an X-axis direction, a direction parallel to a Y-axis in the predetermined plane orthogonal to the X-axis is defined as a Y-axis direction, and a direction parallel to the Z-axis orthogonal to the predetermined plane is defined as Z-axis direction. A rotation direction or an inclination direction around the X-axis is defined as a θX direction, the rotation direction or the inclination direction around the Y-axis is a θY direction, and the rotation direction or the inclination direction around the Z-axis is the θZ direction. In the following description, the predetermined plane is appropriately referred to as an XY plane. In the embodiment, the XY plane and the horizontal plane are parallel to each other.

Sewing System

FIG. 1is a plan view schematically illustrating a sewing system1according to the embodiment. The sewing system1stitches cloth to manufacture sewn products. In the embodiment, the sewn product is clothing. The cloth is a concept including at least one of cloth, fabric, nonwoven fabric, and leather. The cloth may be a concept including a label which will be described later. As illustrated inFIG. 1, the sewing system1includes a sewing machine2, a cloth feeder3, and a cloth conveyor4that holds cloth C fed from the cloth feeder3and conveys the cloth C to the sewing machine2.

The cloth conveyor4includes a robot5, and a conveying member6held by the robot5. The robot5is movable on a base member7. In the XY plane, the base member7is disposed between the sewing machine2and the cloth feeder3. The conveying member6holds the cloth C.

The sewing machine2includes a first sewing machine21and a second sewing machine22. The cloth feeder3includes a first cloth feeder31and a second cloth feeder32. The cloth C includes first cloth Ca and second cloth Cb. The first cloth feeder31feeds the first cloth Ca. The second cloth feeder32feeds the second cloth Cb.

The sewing system1manufactures a T-shirt as clothing. The first cloth Ca is a front body part of the T-shirt. The second cloth Cb is a rear body part of the T shirt. In the following description, the first cloth Ca is appropriately referred to as the front body part Ca, and the second cloth Cb is appropriately referred to as the rear body part Cb.

First Sewing Machine

The first sewing machine21is a label sewing machine that stitches up the rear body part Cb and a label L. The label L is a piece of the cloth. Information on clothing, such as size of clothing and type of fiber, or precautionary note on handling, is described on the label L. The label L is fed from a label feeder8to the first sewing machine21via a label conveyor9.

The label feeder8feeds the label L. The label feeder8includes: a label accommodation member84in which a plurality of stacked labels L are accommodated; and a label transfer mechanism85for transferring the label L accommodated in the label accommodation member84to the label conveyor9.

The label L includes a first label L1, a second label L2, and a third label L3. The label feeder8includes: a first label feeder81that feeds the first label L1; a second label feeder82that feeds the second label L2; and a third label feeder83that feeds the third label L3. The first label feeder81, the second label feeder82, and the third label feeder83are disposed in the X-axis direction.

The label conveyor9conveys the label L fed from the label feeder8to the first sewing machine21. The label conveyor9includes: a clamp mechanism91that holds the label L; a guide mechanism92that guides the clamp mechanism91in the X-axis direction; and an actuator93that generates power for moving the clamp mechanism91in the X-axis direction. The clamp mechanism91sequentially receives the first label L1, the second label L2, and the third label L3from each of the first label feeder81, the second label feeder82, and the third label feeder83, and holds the labels. The clamp mechanism91holds the first label L1, the second label L2, and the third label L3in a stacked state. The actuator93generates power for moving the clamp mechanism91that holds the first label L1, the second label L2, and the third label L3in the X-axis direction. The clamp mechanism91is moved to the first sewing machine21while being guided by the guide mechanism92based on the power generated by the actuator93. Accordingly, the first label L1, the second label L2, and the third label L3are conveyed to the first sewing machine21in a stacked state.

The rear body part Cb is conveyed from the second cloth feeder32to the first sewing machine21by the cloth conveyor4. The label L is conveyed from the label feeder8to first sewing machine21by the label conveyor9. The first sewing machine21stitches up the rear body part Cb fed from the second cloth feeder32and the label L fed from the label feeder8. The first sewing machine21stitches the label L to a target part RP of the rear body part Cb.

The first sewing machine21includes: a table211including an installation surface211S on which the rear body part Cb is installed; and a head212that stitches up the rear body part Cb installed on the table211and the label L. The installation surface211S includes an upper surface of the table211. The installation surface211S is substantially parallel to the XY plane. The cloth conveyor4conveys the rear body part Cb to the table211.

The head212includes: a driving mechanism214that moves a needle213in a vertical direction; a first pressing member215that presses the rear body part Cb installed on the table211from above; and a second pressing member216that presses the label L from above. In a state where the rear body part Cb is pressed by the first pressing member215and the label L installed on the rear body part Cb is pressed by the second pressing member216, as the needle213is moved in the vertical direction, the rear body part Cb and the label L are stitched up. In the following description, the position where the stitching is performed by the needle213will be appropriately referred to as a first stitch position PM1. The first stitch position PM1includes a stitch point position where the needle213is lowered.

Second Sewing Machine

The second sewing machine22stitches up the front body part Ca and the rear body part Cb. The second sewing machine22is a shoulder matching sewing machine that stitches up a shoulder part K of the front body part Ca and a shoulder part K of the rear body part Cb.

The front body part Ca is conveyed from the first cloth feeder31to the second sewing machine22by the cloth conveyor4. The rear body part Cb is conveyed from the first sewing machine21to the second sewing machine22by the cloth conveyor4. The rear body part Cb is conveyed from the first sewing machine21to the second sewing machine22in a state where the label L is stitched. The second sewing machine22stitches up the front body part Ca fed from the first cloth feeder31and the rear body part Cb after being fed from the second sewing machine22.

The second sewing machine22includes: a table221including an installation surface221S on which the front body part Ca and the rear body part Cb are installed; and a head222that stitches up the front body part Ca and the rear body part Cb which are installed on the table211. The installation surface221S includes an upper surface of the table221. The installation surface221S is substantially parallel to the XY plane. The cloth conveyor4conveys each of the front body part Ca and the rear body part Cb to the table221.

The head222includes: a driving mechanism224that moves a needle223in the vertical direction; and a pressing member225that presses the front body part Ca and the rear body part Cb which are installed on the table221from above. In a state where the front body part Ca and the rear body part Cb are pressed by the pressing member225, the needle223moves in the vertical direction, and accordingly, the front body part Ca and the rear body part Cb are stitched up. In the following description, the position where the stitching is performed by the needle223will be appropriately referred to as a second stitch position PM2. The second stitch position PM2includes a stitch point position where the needle223is lowered.

The second sewing machine22includes: a cloth pressing conveyor230that conveys the front body part Ca and the rear body part Cb on the table221; a cloth pressing member240that presses and fixes the front body part Ca and the rear body part Cb which are installed on the table221from above; and a cloth position adjustment device250that adjusts the position of the front body part Ca installed on the table221.

The cloth pressing conveyor230includes: a cloth pressing member231that presses the front body part Ca and the rear body part Cb which are installed on the table221from above; a slider233connected to the cloth pressing member231via an arm member232; a guide member234that guides the slider233in the X-axis direction; and an actuator235that generates power for moving the slider233in the X-axis direction.

The cloth pressing member240includes a first cloth pressing member240L and a second cloth pressing member240R. The first cloth pressing member240L and the second cloth pressing member240R are disposed in the X-axis direction. The first cloth pressing member240L is disposed to be closer to the head222side than the second cloth pressing member240R.

The cloth pressing member240is supported on the table221via a supporter241. The supporter241includes an actuator, such as an air cylinder, and supports the cloth pressing member240so as to be movable at least in the Z-axis direction. The supporter241may support the cloth pressing member240to be movable in at least one of the X-axis direction, the Y-axis direction, the θX direction, the θY direction, and the θZ direction. The supporter241includes a first supporter241L that supports the first cloth pressing member240L to be movable and a second supporter241R that supports the second cloth pressing member240R to be movable. The supporter241including the first supporter241L and the second supporter241R can move the first cloth pressing member240L and the second cloth pressing member240R, separately.

FIG. 2is a side sectional view schematically illustrating the cloth position adjustment device250according to the embodiment.FIG. 3is a perspective view in which a part of the cloth position adjustment device250according to the embodiment is broken. The table221of the second sewing machine22includes the installation surface221S on which the cloth C is installed. The installation surface221S includes an upper surface of the table221. The installation surface221S is substantially parallel to the XY plane.

The cloth position adjustment device250adjusts the position of at least a part of the front body part Ca installed on the table221. The cloth position adjustment device250adjusts the position of a part of the front body part Ca in the XY plane.

The cloth position adjustment device250includes: a plate member251that is provided on the installation surface221S of the table221and includes a holding surface251S for holding the front body part Ca; and an actuator252that is provided on the inside of the table221, moves the plate member251in a direction parallel to the installation surface221S, and adjusts the position of the front body part Ca held on the plate member251.

The holding surface251S includes an upper surface of the plate member251. The holding surface251S is substantially parallel to the XY plane. The plate member251includes the holding surface251S, a lower surface251T that faces in a direction opposite to the holding surface251S, and a suction hole253that penetrates the holding surface251S and the lower surface251T. In the direction parallel to the holding surface251S, a plurality of suction holes253are provided on the plate member251with intervals therebetween. The holding surface251S and the installation surface221S are substantially parallel to each other.

The installation surface221S of the table221includes an opening221K. The plate member251is disposed so as to cover the opening221K of the installation surface221S. The installation surface221S is disposed on the periphery of the holding surface251S. An outer edge region of the lower surface251T of the plate member251and a part of the installation surface221S on the periphery of the opening221K face each other.

The cloth position adjustment device250includes a supporting member254that supports the plate member251. At least a part of the supporting member254is fixed to the lower surface251T of the plate member251. The supporting member254is supported by a base member255. The supporting member254and the base member255are installed in an internal space of the table221.

The base member255is fixed to at least a part of the table221in the internal space of the table221. The base member255supports the supporting member254to be movable. The supporting member254is supported by the base member255to be movable in the XY plane. The supporting member254is supported on the base member255via a sliding mechanism including, for example, a ball or a roller. When the supporting member254is movable in the XY plane, the sliding mechanism may not include a ball or a roller. The actuator252generates power for moving the plate member251. The actuator252is disposed between the supporting member254and the base member255, for example. When the supporting member254is movable regarding the base member255, the actuator252may not be disposed between the supporting member254and the base member255. The actuator252moves the plate member251via the supporting member254. By moving the supporting member254, the actuator252moves the plate member251fixed to the supporting member254in the XY plane. The base member255functions as a stator, and the supporting member254functions as a mover. By the operation of the actuator252, the plate member251moves in the XY plane parallel to the installation surface221S.

The supporting member254forms a space VS with the lower surface251T of the plate member251. The space VS between the plate member251and the supporting member254is connected to a vacuum system70including a vacuum pump and a control valve. An opening formed at a part of the supporting member254and a tube member256are connected to each other. The tube member256is flexible. The vacuum system70and the space VS are connected to each other via the tube member256.

When the space VS becomes a negative pressure by the operation of the vacuum system70, at least a part of the gas on the holding surface251S side of the plate member251is suctioned into the space VS via the suction hole253. As illustrated inFIG. 2, as the vacuum system70is operated in a state where the front body part Ca is installed on the holding surface251S, the front body part Ca is suctioned and held on the holding surface251S.

The plate member251suctions and holds at least a part of the front body part Ca on the holding surface251S. In a state where the front body part Ca is suctioned and held on the holding surface251S, the actuator252is operated, and the position of the front body part Ca held on the plate member251is adjusted by the movement of the plate member251. The cloth position adjustment device250adjusts the position of at least a part of the front body part Ca installed on the table221. The cloth position adjustment device250adjusts the position of a part of the front body part Ca in the XY plane.

Cloth Feeder

The first cloth feeder31feeds the front body part Ca. As illustrated inFIG. 1, the first cloth feeder31includes: an accommodator311that accommodates the plurality of front body parts Ca therein; an installation table312on which the front body part Ca is installed; and a first pickup that holds one front body part Ca among the plurality of front body parts Ca accommodated in the accommodator311and installs the front body part Ca on the installation table312. The plurality of front body parts Ca are stacked in the accommodator311. The first pickup holds one front body part Ca disposed at the top among the plurality of stacked front body parts Ca, and conveys the front body part Ca to the installation table312. The first pickup installs one front body part Ca on the installation table312.

The second cloth feeder32feeds the rear body part Cb. As illustrated inFIG. 1, the second cloth feeder32includes: an accommodator321that accommodates the plurality of rear body parts Cb therein; an installation table322on which the rear body part Cb is installed; and a second pickup that holds one rear body part Cb among the plurality of rear body parts Cb accommodated in the accommodator321and installs the rear body part Cb on the installation table312. The plurality of rear body parts Cb are stacked in the accommodator321. The second pickup holds one rear body part Cb disposed at the top among the plurality of stacked rear body parts Cb, and conveys the rear body part Cb to the installation table322. The second pickup installs one rear body part Cb on the installation table322.

FIG. 4is a side sectional view schematically illustrating the first cloth feeder31according to the embodiment. As illustrated inFIG. 4, the first cloth feeder31includes the installation table312on which the front body part Ca is installed. One front body part Ca is installed on the installation table312. The installation table312includes: a plate member33; and a supporter34that supports the plate member33.

The plate member33includes: an upper surface33S on which the front body part Ca is installed; a lower surface33T that faces in the direction opposite to the upper surface33S; and a hole37that penetrates the upper surface33S and the lower surface33T. The upper surface33S and the lower surface33T are parallel to each other. In the direction parallel to the upper surface33S, the plurality of holes37are provided on the plate member33with intervals therebetween.

A diameter ϕ of the hole37is smaller than a distance d between the adjacent holes37. The diameter of the hole37is determined to be equal to or less than 2 mm.

The supporter34supports the plate member33such that the upper surface33S and the XY plane are parallel to each other. The supporter34supports the plate member33to be movable in at least one of the θX direction, the θY direction, and the Z-axis direction.

The supporter34includes a base member35and a spring36disposed between the base member35and the plate member33. The upper end portion of the spring36is connected to the plate member33. The lower end portion of the spring36is connected to the base member35. In the XY plane, a plurality of springs36are disposed.

In a case where no external force acts on the plate member33, the upper surface33S of the plate member33and the XY plane are substantially parallel to each other. In a case where an external force acts on the plate member33, the upper surface33S of the plate member33moves in at least one of the θX direction, the θY direction, and the Z-axis direction.

In other words, the supporter34including the spring36has a floating function of supporting the plate member33to be capable of swinging. In a case where no external force acts on the plate member33, the supporter34supports the plate member33such that the upper surface33S of the plate member33and the XY plane are substantially parallel to each other. In a case where an external force acts on the plate member33, the supporter34supports the plate member33such that the upper surface33S of the plate member33moves in at least one of the θX direction, the θY direction, and the Z-axis direction.

The first cloth feeder31includes a detector313that detects an edge of the front body part Ca installed on the plate member33of the installation table312. The detector313detects the position of the edge of the front body part Ca in the XY plane.

The detector313includes an imaging device that acquires an optical image of the front body part Ca as image data. The detector313includes an optical system and an image sensor that receives light that passed through the optical system. The image sensor includes a couple charged device (CCD) image sensor or a complementary metal oxide semiconductor (CMOS) image sensor. The detector313is provided on the installation table312. The detector313acquires the image data of the front body part Ca installed on the installation table312, from above the front body part Ca.

The entire front body part Ca is disposed in an imaging region of the detector313. The imaging region of the detector313includes a field of view region of the optical system of the detector313. The imaging region of the detector313is sufficiently large to fit the entire front body part Ca. The detector313can collectively acquire the image data of the entire front body part Ca.

The second cloth feeder32includes the installation table322on which the rear body part Cb is installed and a detector323that detects an edge of the rear body part Cb installed on the installation table312. The structure of the installation table213of the first cloth feeder31and the structure of the installation table322of the second cloth feeder32are substantially the same as each other. The description of the installation table322will be omitted.

The detector323of the second cloth feeder32detects the edge of the rear body part Cb installed on the plate member33of the installation table322. The detector323detects the position of the edge of the rear body part Cb in the XY plane.

The detector323includes an imaging device that acquires an optical image of the rear body part Cb as image data. The detector323includes an optical system and an image sensor that receives light that passed through the optical system. The image sensor includes a couple charged device (CCD) image sensor or a complementary metal oxide semiconductor (CMOS) image sensor. The detector323is provided on the installation table322. The detector323acquires the image data of the rear body part Cb installed on the installation table322, from above the rear body part Cb.

The entire rear body part Cb is disposed in an imaging region of the detector323. The imaging region of the detector323includes a field of view region of the optical system of the detector323. The imaging region of the detector323is sufficiently large to fit the entire rear body part Cb. The detector323can collectively acquire the image data of the entire rear body part Cb.

Cloth Conveyor

As illustrated inFIG. 1, the cloth conveyor4includes the robot5supported by the base member7to be movable and the conveying member6held by the robot5. The robot5is a horizontal articulated robot (selective compliance assembly robot arm (SCARA)). The robot5includes an arm51that holds the conveying member6. The robot5is movable in four directions of the X-axis direction, the Y-axis direction, the Z-axis direction, and the θZ-axis direction. The conveying member6is movable in four directions of the X-axis direction, the Y-axis direction, the Z-axis direction, and the θZ-axis direction in a state of being held by the arm51of the robot5.

The cloth conveyor4suctions and holds the cloth C from above using the conveying member6. The conveying member6is connected to the vacuum system70, and suctions and holds the cloth C from above.

The robot5is movable on the base member7. The robot5can move the conveying member6to a first feeding position PF1that faces the installation table312of the first cloth feeder31, a second feeding position PF2that faces the installation table322of the second cloth feeder32, a first sewing machine position PH1that faces the table211of the first sewing machine21, and a second sewing machine position PH2that faces the table221of the second sewing machine22, respectively. The first feeding position PF1, the second feeding position PF2, the first sewing machine position PH1and the second sewing machine position PH2are positions different from each other in the XY plane. The conveying member6is movable on the installation table312, on the installation table322, on the table211, and on the table221, respectively.

The cloth conveyor4conveys the front body part Ca from the installation table312to the second sewing machine22. The cloth conveyor4conveys the rear body part Cb from the installation table322to the second sewing machine21. The cloth conveyor4conveys the rear body part Cb from the first sewing machine21to the second sewing machine22.

FIG. 5is a perspective view illustrating the conveying member6according to the embodiment.FIG. 6is a plan view illustrating the conveying member6according to the embodiment.

As illustrated inFIGS. 5 and 6, the conveying member6includes a main body member60, a connecting member71connected to the robot5, and a holding member61and a holding member62that hold the cloth C.

The conveying member6includes a plurality of suction surfaces HS for suctioning and holding the cloth C from above. The suction surface HS includes the lower surface of the conveying member6. The suction surface HS is substantially parallel to the XY plane.

The holding member61suctions and holds the cloth C from above. The holding member62suctions and holds the cloth C from above. The suction surface HS includes a suction surface HS1provided in the holding member61and a suction surface HS2provided in the holding member62.

The suction surface HS includes the lower surface of the holding member6. The suction surface HS1is substantially parallel to the XY plane. In the XY plane, the outer shape of the suction surface HS1is a quadrilateral shape. The suction surface HS2includes the lower surface of the holding member6. The suction surface HS2is substantially parallel to the XY plane. In the XY plane, the outer shape of the suction surface HS2is a circular shape. The suction surface HS1and the suction surface HS2are disposed in the same plane. The suction surface HS1of the holding member61is greater than the suction surface HS2of the holding member62.

The main body member60supports the holding member61and the holding member62. The main body member60is a frame-like member. The main body member60includes a first member60A, a second member60B, a third member60C, and a fourth member60D. Each of the first member60A, the second member60B, the third member60C, and the fourth member60D is a bar-like member. The first member60A and the second member60B are disposed to be substantially parallel to each other. The third member60C and the fourth member60D are disposed to be substantially parallel to each other.

The first member60A is longer than the second member60B. The third member60C is connected to each of one end portion of the first member60A and one end portion of the second member60B. The fourth member60D is connected to each of an intermediate portion of the first member60A and the other end portion of the second member60B. The third member60C is orthogonal to each of the first member60A and the second member60B. The fourth member60D is orthogonal to each of the first member60A and the second member60B.

The main body member60includes a fifth member60E and a sixth member60F. Each of the fifth member60E and the sixth member60F is a bar-like member.

The fifth member60E and the sixth member60F are disposed between the third member60C and the fourth member60D. The third member60C, the fourth member60D, the fifth member60E and the sixth member60F are disposed to be substantially parallel to each other. One end portion of the fifth member60E is connected to the first member60A. The other end portion of the fifth member60E is connected to the second member60B. One end portion of the sixth member60F is connected to the first member60A. The other end portion of the sixth member60F is connected to the second member60B. The fifth member60E is disposed at a position closer to the third member60C than the sixth member60F.

The connecting member71is supported by a plate member72fixed to the fifth member60E and the sixth member60F. The main body member60is connected to the robot5via the connecting member71and the plate member72. The robot5moves the main body member60. The connecting member71is a columnar member. In the longitudinal direction of the fifth member60E and the sixth member60F, the connecting member71is fixed to the center portion of the fifth member60E and the central portion of the sixth member60F.

The holding member61is a box-like member including an internal space. The holding member61includes an upper plate61A, a lower plate61B, and a side plate61C disposed between the upper plate61A and the lower plate61B.

The upper plate61A is connected to a part of the first member60A, a part of the second member60B, the third member60C, the fifth member60E, and the sixth member60F, respectively. The lower plate61B includes the suction surface HS1that can face the cloth C. The suction surface HS1is the lower surface of the lower plate61B. The side plate61C is a frame-like plate member and is connected to each of the upper plate61A and the lower plate61B. The internal space of the holding member61is defined by the upper plate61A, the lower plate61B, and the side plate61C.

The lower plate61B includes a plurality of suction ports. The suction port includes a through-hole that penetrates the suction surface HS1and the upper surface of the lower plate61B. In other words, the lower plate61B is a perforated plate. The through-hole connects the internal space and the external space of the holding member61to each other. A plurality of suction ports are disposed with a certain interval on the lower surface of the lower plate61B.

The conveying member6includes a connector64connected to the vacuum system70. A plurality of connectors64are provided on the upper plate61A. The connector64is connected to the internal space of the holding member61. When the vacuum system70operates, the gas in the internal space of the holding member61is suctioned into the vacuum system70via the connector64. As the vacuum system70operates in a state where the suction surface HS1of the lower plate61B is in contact with the cloth C, the holding member61can suction and hold the cloth C from above on the suction surface HS1.

A plurality of holding members62are provided. Each of the plurality of holding members62includes a suction surface HS2that can face the cloth C.

The holding member62includes a suction port provided on the suction surface HS2. The suction port of the holding member62is connected to the vacuum system70. As the vacuum system70operates in a state where the suction surface HS2of the holding member62is in contact with the cloth C, the holding member62can suction and hold the cloth C from above on the suction surface HS2.

A part of the first member60A protrudes from the fourth member60D. The conveying member6includes a first supporting member65and a second supporting member66that are supported by the fourth member60D. Each of the first supporting member65and the second supporting member66is a bar-like member. The first member60A, the first supporting member65, and the second supporting member66are disposed to be substantially parallel to each other. The main body member60movably supports each of the first supporting member65and the second supporting member66.

The first member60A that protrudes from the fourth member60D supports the plurality of holding members62. The first supporting member65supports the plurality of holding members62. The second supporting member66supports the plurality of holding members62. Three holding members62are provided with intervals in the longitudinal direction of the first member60A. Three holding members62are provided with intervals in the longitudinal direction of the first supporting member65. Three holding members62are provided with intervals in the longitudinal direction of the second supporting member65. In other words, nine holding members62are provided.

As illustrated inFIG. 6, the cloth C including the front body part Ca and the rear body part Cb includes two shoulder parts K, two side parts W, two sleeve parts M, one hem part H, and one neck parts N. The shoulder part K includes a right shoulder part KR and a left shoulder part KL. The side part W includes a right side part WR and a left side part WL. The sleeve part M includes a right sleeve part MR and a left sleeve part ML.

The upper portion of the cloth C including the shoulder part K, the neck part N, and the sleeve part M is suctioned and held by the holding member61. The suction surface HS1of the holding member61is sufficiently large, and it is possible to integrally suction and hold the entire shoulder part K. The conveying member6can stably hold the upper portion of the cloth C while reducing the positional deviation of the shoulder part K using the holding member61.

The lower portion of the cloth C including the side part W and the hem part H is suctioned and held by the holding member62. The weight of the holding member62is sufficiently smaller than the weight of the holding member61. Each of the first member60A, the first supporting member65, and the second supporting member66that hold the holding member62is a bar-like member and is lightweight. Accordingly, weight reduction of the conveying member6is achieved.

The cloth conveyor4includes a rough movement mechanism67that connects the first supporting member65and the main body member60to each other; and a rough movement mechanism68that connects the second supporting member66and the main body member60to each other via at least a part of a fine movement device400.

The rough movement mechanism67is movable regarding the main body member60. The rough movement mechanism67is connected to the first supporting member65. The rough movement mechanism67includes a sliding member67A guided by a guide mechanism69provided in the fourth member60D and a fixing pin67B for fixing the sliding member67A to the fourth member60D. The guide mechanism69guides the sliding member67A in the longitudinal direction of the fourth member60D. The first supporting member65is connected to the sliding member67A. As the sliding member67A moves while being guided by the guide mechanism69, the first supporting member65moves in the longitudinal direction of the fourth member60D together with the sliding member67A.

The fourth member60D includes a plurality of fixing holes. A plurality of fixing holes are provided with intervals in the longitudinal direction of the fourth member60D. The sliding member67A includes an insertion hole into which the fixing pin67B is inserted. By inserting the fixing pin67B into the insertion hole of the sliding member67A and the fixing hole of the fourth member60D, the sliding member67A and the fourth member60D are fixed. When the sliding member67A and the fourth member60D are fixed, the position of the first supporting member65in the longitudinal direction of the fourth member60D is fixed. By removing the fixing pin67B from the insertion hole of the sliding member67A and the fixing hole of the fourth member60D, the fixed state of the sliding member67A and the fourth member60D is released. When the fixed state of the sliding member67A and the fourth member60D is released, the first supporting member65is movable in the longitudinal direction of the fourth member60D while being guided by the guide mechanism69. An operator can position the first supporting member65in the longitudinal direction of the fourth member60D by operating the rough movement mechanism67.

The rough movement mechanism68is movable regarding the main body member60. The rough movement mechanism68is connected to the second supporting member66via at least a part of the fine movement device400. The rough movement mechanism68includes a sliding member68A guided by a guide mechanism69provided in the fourth member60D and a fixing pin68B for fixing the sliding member68A to the fourth member60D. The guide mechanism69guides the sliding member68A in the longitudinal direction of the fourth member60D. The second supporting member66is connected to the sliding member68A via at least a part of the fine movement device400. As the sliding member68A moves while being guided by the guide mechanism69, the second supporting member66moves in the longitudinal direction of the fourth member60D together with the sliding member68A.

The sliding member68A includes an insertion hole into which the fixing pin68B is inserted. By inserting the fixing pin68B into the insertion hole of the sliding member68A and the fixing hole of the fourth member60D, the sliding member68A and the fourth member60D are fixed. When the sliding member68A and the fourth member60D are fixed, the position of the second supporting member66in the longitudinal direction of the fourth member60D is fixed. By removing the fixing pin68B from the insertion hole of the sliding member68A and the fixing hole of the fourth member60D, the fixed state of the sliding member68A and the fourth member60D is released. When the fixed state of the sliding member68A and the fourth member60D is released, the second supporting member66is movable in the longitudinal direction of the fourth member60D while being guided by the guide mechanism69. An operator can position the second supporting member66in the longitudinal direction of the fourth member60D by operating the rough movement mechanism68.

As the first supporting member65is moved in the longitudinal direction of the fourth member60D, the position of the holding member62supported by the first supporting member65is adjusted. The holding member62supported by the first supporting member65is movable regarding the main body member60.

As the second supporting member66is moved in the longitudinal direction of the fourth member60D, the position of the holding member62supported by the second supporting member66is adjusted. The holding member62supported by the second supporting member66is movable regarding the main body member60.

The relative position between the holding member62supported by the first member60A and the main body member60is fixed. The relative position between the holding member62supported by the first supporting member65and the main body member60is changeable. The relative position between the holding member62supported by the second supporting member66and the main body member60is changeable. The plurality of holding members62supported by the first member60A move together with the main body member60. The main body member60movably supports the first supporting member65that supports the holding member62and movably supports the second supporting member66that supports the holding member62. For example, as the first supporting member65and the second supporting member66move according to the size of the cloth C, a holding position HP2of the cloth C by the holding member62is adjusted.

FIG. 7is a perspective view illustrating the fine movement device400according to the embodiment. The fine movement device400moves the second supporting member66in the longitudinal direction of the fourth member60D with a resolution higher than that of the rough movement mechanism68. At least a part of the fine movement device400is disposed between the second supporting member66and the sliding member68A. The fine movement device400moves the second supporting member66regarding the sliding member68A.

As illustrated inFIGS. 5, 6, and 7, the fine movement device400includes a power generator401that generates power for moving the second supporting member66regarding the sliding member68A and a power transmission mechanism402that transmits the power generated by the power generator401to the second supporting member66.

The power generator401is supported by the main body member60. The power generator401is supported by the sixth member60. The power generator401is disposed in the vicinity of the connecting member71. In the XY plane, the distance between the connecting member71and the power generator401is shorter than the distance between the connecting member71and the holding member62.

The power generator401includes: a motor401A; a ball screw mechanism401B operated by rotation of the motor401A; and a movable member401C that is movable by the operation of the ball screw mechanism401B.

The power transmission mechanism402includes: a wire member402W that connects the power generator401and the second supporting member66to each other. One end portion of the wire member402W is fixed to the movable member401C. The other end portion of the wire member402W is fixed to the second supporting member66. A bracket66A is fixed to the second supporting member66. The other end portion of the wire member402W is fixed to the bracket66A.

The second supporting member66is connected to the sliding member68A via a sliding mechanism403. By the sliding mechanism403, the second supporting member66can finely move in the longitudinal direction of the fourth member40D regarding the sliding member68A. The sliding mechanism403includes a spring that generates a force for moving the second supporting member66in the +Y direction. The movable distance of the second supporting member66relative to the sliding member68A is approximately 50 mm.

InFIG. 7, as the motor401A is driven, the movable member401C moves in one of the +X direction and the −X direction. When the movable member401C moves in the +X direction and pulls the wire member402W, the second supporting member66moves in the −Y direction regarding the sliding member68A. When the movable member401C moves in the −X direction, the second supporting member66moves in the +Y direction regarding the sliding member68A by the action of the spring of the sliding mechanism403. When the second supporting member66moves in the Y-axis direction regarding the sliding member68A, the holding member62supported by the second supporting member66moves in the Y-axis direction regarding the main body member60. In this manner, the power generator401generates power for moving the holding member62supported by the second supporting member66regarding the main body member60. The power transmission mechanism402transmits the power generated by the power generator401to the holding member62via the second supporting member66.

As illustrated inFIGS. 5 and 6, the cloth conveyor4includes a movable member63that is movable regarding the conveying member6. The movable member63is supported to be movable by the conveying member6. The movable member63is supported to be movable by the third member60C. In the longitudinal direction of the third member60C, the dimension of the movable member63is smaller than the dimension of the third member60C. As indicated by the arrow Ra inFIG. 5, the movable member63is movable in the vertical direction orthogonal to the suction surface HS. The movable member63is movable regarding the suction surface HS of the conveying member6.

The conveying member6includes an actuator73that generates power for moving the movable member63in the vertical direction. The actuator73includes, for example, an air cylinder. The movable member63is movable in the vertical direction by the operation of the actuator73.

FIGS. 8A and 8Bare views schematically illustrating an operation of the movable member63according to the embodiment. As illustrated inFIG. 8A, when the movable member63is disposed in the upper end portion of the movable range of the movable member63in the vertical direction, the lower end portion of the movable member63is disposed above the suction surface HS of the conveying member6. In other words, when the movable member63is disposed in the upper end portion of the movable range, the lower end portion of the movable member63does not protrude downward from the suction surface HS of the conveying member6.

As illustrated inFIG. 8B, in the movable range of the movable member63in the vertical direction, when the movable member63is disposed in the lower end portion of the movable range, the lower end portion of the movable member63is disposed below the suction surface HS of the conveying member6. In other words, when the movable member63is disposed in the lower end portion of the movable range, the lower end portion of the movable member63protrudes downward from the suction surface HS of the conveying member6.

As illustrated inFIG. 8A, when the cloth C is suctioned and held by the suction surface HS, the lower end portion of the movable member63is disposed above the suction surface HS of the conveying member6. As illustrated inFIG. 8B, in a state where the cloth C is suctioned and held on the suction surface HS, the lower end portion of the movable member63disposed below the suction surface HS of the conveying member6can come into contact with the cloth C.

As illustrated inFIG. 5andFIG. 6, the cloth conveyor4includes a gripper500that pinches the cloth C. The gripper500is movable in the Z-axis direction orthogonal to the upper surface of the installation table312and the upper surface of the installation table322on which the cloth C is installed. As described with reference toFIG. 4, the upper surface of the installation table312and the upper surface of the installation table322include the upper surface33S of the plate member33.

FIG. 9is a perspective view illustrating the gripper500according to the embodiment.FIG. 10is a side view illustrating the gripper500according to the embodiment. The gripper500includes: a main body member501; a pair of gripping members502movably supported by the main body member501; and an actuator503that is disposed inside the main body member501, and generates power for moving the gripping member502.

The actuator503can move the gripping member502such that the lower end portions of the pair of gripping members502approach to or are separated from each other.

The cloth conveyor4includes an actuator510that moves the main body member501in the vertical direction. The actuator510includes, for example, an air cylinder, and can move the main body member501in the vertical direction. A stator511of the actuator510is fixed to the sixth member60F. A mover512of the actuator510is connected to the main body member501via a connecting member513. By the operation of the actuator510, as indicated by the arrow Rb inFIG. 10, the gripper500can move in the vertical direction orthogonal to the upper surface of the installation table312and the upper surface of the installation table322. The gripper500is movable regarding the suction surface HS of the conveying member6.

FIGS. 11A and 11Bare side views schematically illustrating an operation of the gripper500according to the embodiment. As illustrated inFIG. 11A, in the movable range of the gripper500in the vertical direction, when the gripper500is disposed in the upper end portion of the movable range, the lower end portion of the gripper500is disposed above the suction surface HS of the conveying member6. In other words, when the gripper500is disposed in the upper end portion of the movable range, the lower end portion of the gripping member502does not protrude downward from the suction surface HS of the conveying member6.

As illustrated inFIG. 11B, in the movable range of the gripper500in the vertical direction, when the gripper500is disposed in the lower end portion of the movable range, the lower end portion of the gripper500is disposed below the suction surface HS of the conveying member6. In other words, when the gripper500is disposed in the lower end portion of the movable range, the lower end portion of the gripping member502protrudes downward from the suction surface HS of the conveying member6.

As illustrated inFIG. 11A, when the cloth C is suctioned and held by the suction surface HS, the lower end portion of the gripping member502is disposed above the suction surface HS of the conveying member6. In a state where the cloth C is not suctioned and held on the suction surface HS, the lower end portion of the gripping member502disposed below the suction surface HS of the conveying member6can come into contact the cloth C. As illustrated inFIG. 11B, the gripper500can pinch a part of the cloth C installed on the upper surface33S of the plate member33using the gripping member502. The cloth conveyor4can convey the cloth C in a state where the cloth C is pinched by the gripper500.

Controller

FIG. 12is a functional block diagram illustrating a controller10of the sewing system1according to the embodiment. The sewing system1includes the controller10. The controller10includes a computer system and controls the sewing system1. The controller10includes an arithmetic processing unit including a processor, such as a central processing unit (CPU) and a storage device including a memory, such as a read only memory (ROM) or a random access memory (RAM) and a storage. The arithmetic processing unit performs arithmetic processing according to a computer program stored in the storage device.

As illustrated inFIG. 12, the controller10is connected to each of the first sewing machine21, the second sewing machine22, the detector313disposed in the first cloth feeder31, the detector323disposed in the second cloth feeder32, and the cloth conveyor4.

The controller10includes: a front body part position data acquisition portion11that acquires position data of the front body part Ca; a rear body part position data acquisition portion12that acquires position data of the rear body part Cb; a first control portion13that outputs a control signal for controlling the first sewing machine21; a second control portion14that outputs a control signal for controlling the second sewing machine22; a holding position decision portion15that determines the holding position of the cloth C by the holding member61and the holding member62; an abnormality decision portion16that determines whether the cloth C installed on the installation table312and the installation table322is abnormal; a conveyance control portion17that outputs a control signal for controlling the cloth conveyor4; a storage portion18; and an input and output portion19.

The front body part position data acquisition portion11acquires the position data of the edge of the front body part Ca based on the detection data of the detector313disposed in the first cloth feeder31. The front body part position data acquisition portion11acquires the position data of the edge of the front body part Ca in the XY plane. The detector313acquires the image data of the front body part Ca installed on the installation table312as the detection data. The detector313acquires the image data including the edge of the entire front body part Ca. The detector313acquires the image data of the front body part Ca together with the image data of a reference mark provided on the installation table312. The reference mark may be provided in the optical system of the detector313. The front body part position data acquisition portion11acquires the image data of the front body part Ca and the image data of the reference mark from the detector313. The front body part position data acquisition portion11performs image processing regarding the image data of the front body part Ca and the image data of the reference mark. The front body part position data acquisition portion11performs image processing regarding the image data of the front body part Ca and the image data of the reference mark, and calculates the relative position between the reference mark and the edge of the front body part Ca. The position data of the reference mark in the XY plane is known data, and is stored in the storage portion18. The front body part position data acquisition portion11calculates the position data of the edge of the front body part Ca in the XY plane, based on the position data of the reference mark stored in the storage portion18and the relative position between the reference mark and the edge of the front body part Ca which are calculated based on the detection data of the detector313.

The rear body part position data acquisition portion12acquires the position data of the edge of the rear body part Cb based on the detection data of the detector323disposed in the second cloth feeder31. The rear body part position data acquisition portion12acquires the position data of the edge of the rear body part Cb in the XY plane. Similar to the detector313, the detector323acquires the image data including the edge of the entire rear body part Cb together with the image data of the reference mark provided on the installation table322. The reference mark may be provided in the optical system of the detector323. The rear body part position data acquisition portion12calculates the position data of the edge of the rear body part Cb in the XY plane, based on the position data of the reference mark stored in the storage portion18and the relative position between the reference mark and the edge of the rear body part Cb which are calculated based on the detection data of the detector323.

The first control portion13controls each of the label feeder8, the label conveyor9, and the head212.

The second control portion14controls each of the supporter241, the cloth position adjustment device250, and the head222.

The holding position decision portion15determines a holding position HP of the front body part Ca installed on the installation table312based on the detection data of the detector313. The holding position decision portion15determines a holding position HP of the rear body part Cb installed on the installation table322based on the detection data of the detector323.

The abnormality decision portion16determines whether the front body part Ca installed on the installation table312is abnormal based on the detection data of the detector313. The reference data related to the front body part Ca is stored in the storage portion18. The reference data related to the front body part Ca indicates correct data indicating a correct value of the dimension of the front body part Ca. The reference data related to the front body part Ca is known data defined in advance, and is stored in the storage portion18. The abnormality decision portion16determines whether the dimension of the front body part Ca installed on the installation table312is abnormal by collating the detection data of the detector313indicating the position of the edge of the front body part Ca installed on the installation table312with the reference data indicating the correct value of the dimension of the front body part Ca stored in the storage portion18.

Similarly, the abnormality decision portion16determines whether the dimension of the rear body part Cb installed on the installation table322is abnormal by collating the detection data of the detector323that detects the rear body part Cb installed on the installation table322with the reference data related to the rear body part Cb stored in the storage portion18.

For example, due to a cutting error or the like, there is a possibility that the front body part Ca having a dimension different from that of the front body part Ca to be originally sewn is accommodated in the accommodator311or installed on the installation table312. The reference data related to the front body part Ca stored in the storage portion18indicates the dimension of the front body part Ca to be originally sewn. The abnormality decision portion16determines whether the front body part Ca installed on the installation table312is abnormal, that is, whether the front body part Ca is the front body part Ca to be originally sewn, by collating the detection data of the detector313with the reference data related to the front body part Ca stored in the storage portion18. Similarly, the abnormality decision portion16determines whether the rear body part Cb installed on the installation table322is abnormal, that is, whether the rear body part Cb is the rear body part Cb to be originally sewn, by collating the detection data of the detector323with the reference data related to the rear body part Cb stored in the storage portion18.

The conveyance control portion17controls the cloth conveyor4based on the position data of the front body part Ca acquired by the front body part position data acquisition portion11. The conveyance control portion17moves the robot5in the XYZ orthogonal coordinate system defined in the sewing system1. A movement amount of the robot5is detected by a movement amount sensor, such as an encoder provided in the robot5. The conveyance control portion17can convey the front body part Ca to a target position in the XY plane by controlling the movement amount of the robot5that holds the front body part Ca via the conveying member6with reference to the position data of the front body part Ca when being installed on the installation table312. Similarly, the conveyance control portion17can convey the rear body part Cb to the target position in the XY plane by controlling the cloth conveyor4based on the position data of the rear body part Cb acquired by the rear body part position data acquisition portion12.

The conveyance control portion17controls the cloth conveyor4such that the holding member61and the holding member62hold the holding position HP of the front body part Ca determined by the holding position decision portion15when the cloth conveyor4holds the front body part Ca installed on the installation table312. The conveyance control portion17controls the robot5and the power generator401of the fine movement device400such that the holding member61holds the holding position HP1of the front body part Ca determined by the holding position decision portion15and the holding member62holds the holding position HP2of the front body part Ca determined by the holding position decision portion15. Similarly, the conveyance control portion17controls the cloth conveyor4such that the holding member61and the holding member62hold the holding position HP of the rear body part Cb determined by the holding position decision portion15when the cloth conveyor4holds the rear body part Cb installed on the installation table322.

Operation

Next, an example of the operation of the sewing system1according to the embodiment will be described.

Conveyance Route of Front Body Part

FIG. 13is a plan view schematically illustrating an operation of the cloth conveyor4that conveys the front body part Ca according to the embodiment. The cloth conveyor4holds the front body part Ca fed from the first cloth feeder31, and conveys the front body part Ca to the second sewing machine22. In the first cloth feeder31, one front body part Ca is installed on the installation table312by the first pickup. The conveyance control portion17controls the cloth conveyor4and moves the cloth conveyor4to the first feeding position PF1that faces the front body part Ca installed on the installation table312.

The cloth conveyor4holds the front body part Ca installed on the installation table312from above. The conveyance control portion17controls the cloth conveyor4such that the holding member61and the holding member62hold the holding position HP of the front body part Ca determined by the holding position decision portion15based on the detection data of the detector313. The conveyance control portion17moves the cloth conveyor4that holds the front body part Ca to the second sewing machine22. In the first cloth feeder31, the cloth conveyor4that holds the front body part Ca conveys the front body part Ca to the second sewing machine22. The cloth conveyor4conveys the front body parts Ca one by one from the installation table312.

The cloth conveyor4adjusts the position of the front body part Ca based on the detection data of the detector313. The conveyance control portion17controls the movement amount of the robot5based on the position data of the front body part Ca acquired by the front body part position data acquisition portion11. As illustrated inFIG. 13, the conveyance control portion17controls the robot5, and moves the conveying member6that holds the front body part Ca to the second sewing machine position PH2that faces the table221of the second sewing machine22.

The cloth conveyor4adjusts the position of the front body part Ca in the second sewing machine22based on the detection data of the detector313. The conveyance control portion17adjusts the position of the cloth conveyor4such that the front body part Ca is disposed at the target position of the front body part Ca defined in the second sewing machine22. After the front body part Ca is disposed at the target position of the front body part Ca defined in the second sewing machine22, the cloth conveyor4releases the suctioned and held state of the front body part Ca by the suction surface HS. Accordingly, the front body part Ca passes the second sewing machine22and is installed on the table221.

Conveyance Route of Rear Body Part

FIG. 14is a plan view schematically illustrating the operation of the cloth conveyor4that conveys the rear body part Cb according to the embodiment. The cloth conveyor4holds the rear body part Cb fed from the second cloth feeder32and conveys the rear body part Cb to the first sewing machine21. In the second cloth feeder32, one rear body part Cb is installed on the installation table322by the second pickup. The conveyance control portion17controls the cloth conveyor4and moves the cloth conveyor4to the second feeding position PF2that faces the rear body part Cb installed on the installation table322.

The cloth conveyor4holds the rear body part Cb installed on the installation table312from above. The conveyance control portion17controls the cloth conveyor4such that the holding member61and the holding member62hold the holding position HP of the rear body part Cb determined by the holding position decision portion15based on the detection data of the detector323. The conveyance control portion17moves the cloth conveyor4that holds the rear body part Cb to the first sewing machine21. In the second cloth feeder32, the cloth conveyor4that holds the rear body part Cb conveys the rear body part Cb to the first sewing machine21. The cloth conveyor4conveys the rear body parts Cb one by one from the installation table322.

The cloth conveyor4adjusts the position of the rear body part Cb based on the detection data of the detector323. The conveyance control portion17controls the movement amount of the robot5based on the position data of the rear body part Cb acquired by the rear body part position data acquisition portion12. As illustrated inFIG. 14, the conveyance control portion17controls the robot5and moves the conveying member6that holds the rear body part Cb to the first sewing machine position PH1that faces the table211of the first sewing machine21.

The cloth conveyor4adjusts the position of the rear body part Cb in the first sewing machine21based on the detection data of the detector323. The conveyance control portion17adjusts the position of the cloth conveyor4such that the rear body part Cb is disposed at the target position of the rear body part Cb defined in the first sewing machine21.

In the embodiment, the cloth conveyor4holds the rear body part Cb in the stitching of the label L by the head212of the first sewing machine21. In other words, in the stitching of the rear body part Cb and the label L in the first sewing machine21, the cloth conveyor4continues to hold the rear body part Cb. The rear body part Cb is stitched with the label L in the first sewing machine21in a state of being held by the cloth conveyor4.

The cloth conveyor4conveys the rear body part Cb to which the stitching with the label L is completed, from the first sewing machine21to the second sewing machine22. As illustrated inFIG. 14, the conveyance control portion17controls the robot5and moves the conveying member6that holds the rear body part Cb to the second sewing machine position PH2that faces the table221of the second sewing machine22.

The cloth conveyor4adjusts the position of the rear body part Cb in the second sewing machine22based on the detection data of the detector323. The conveyance control portion17controls the position of the cloth conveyor4such that the rear body part Cb is disposed at the target position of the rear body part Cb defined in the second sewing machine22. After the rear body part Cb is disposed at the target position of the rear body part Cb defined in the second sewing machine22, the cloth conveyor4releases the suctioned and held state of the rear body part Cb by the suction surface HS. Accordingly, the rear body part Cb passes the second sewing machine22and is installed on the table221.

In this manner, the cloth conveyor4continues to hold the rear body part Cb in conveyance of the rear body part Cb from the second cloth feeder32to the first sewing machine21, stitching of the first sewing machine21, and conveyance of the rear body part Cb from the first sewing machine21to the second sewing machine22.

When conveying the front body part Ca and the rear body part Cb fed from the cloth feeder3to the second sewing machine22using the integrated robot5and the conveying member6, the conveying route of the front body part Ca and the conveying route of the rear body part Cb are different from each other. The front body part Ca is directly conveyed from the first cloth feeder31to the table221of the second sewing machine22. The rear body part Cb is conveyed from the second cloth feeder32to the table221of the second sewing machine22via the first sewing machine21.

Conveying Out Cloth from Cloth Feeder

FIGS. 15A and 15Bare side views schematically illustrating the operation of the cloth conveyor4in the cloth feeder3according to the embodiment.FIG. 15Ais a view schematically illustrating the operation when the detector323detects the rear body part Cb installed on the installation table322of the second cloth feeder32.FIG. 15Bis a view schematically illustrating the operation when the cloth conveyor4conveys out the rear body part Cb from the installation table322of the second cloth feeder32.

When the rear body part Cb is installed on the installation table322, the detector323acquires the image data of the rear body part Cb installed on the installation table322. The imaging region of the detector323is sufficiently large, and the detector323can collectively acquire the image data of the entire rear body part Cb. The image data of the rear body part Cb detected by the detector323is output to the controller10.

The hole37of the plate member33is minute. In the embodiment, the diameter ϕ of the hole37of the plate member33is equal to or less than 2 mm. Therefore, even when the hole37is reflected in the image data of the rear body part Cb acquired by the detector323, the influence on the image processing in the rear body part position data acquisition portion12is reduced.

The rear body part position data acquisition portion12acquires the image data of the rear body part Cb acquired by the detector323. The rear body part position data acquisition portion12calculates the position data of the edge of the rear body part Cb in the XY plane based on the image data of the rear body part Cb acquired by the detector313. The rear body part position data acquisition portion12calculates the position data of the left shoulder part KL of the rear body part Cb, the position data of the right shoulder part KR of the rear body part Cb, the position data of the left side part WL of the rear body part Cb, the position data of the right side part WR of the rear body part Cb, and the position data of the hem part H of the rear body part Cb.

FIG. 16is a view schematically illustrating the image data of the rear body part Cb acquired by the detector323according to the embodiment. As illustrated inFIG. 16, as the position data of the edge of the rear body part Cb, the rear body part position data acquisition portion12calculates the position of an intersection Pa between the left shoulder part KL and the neck part N, the position of an intersection Pb between the right shoulder part KR and the neck part N, the position of an intersection Pc between the left shoulder part KL and the left sleeve part ML, the position of an intersection Pd between the right shoulder part KR and the right sleeve part MR, the position of an intersection Pe between the left sleeve part ML and the left side part WL, the position of an intersection Pf between the right sleeve part MR and the right side part WR, the position of an intersection Pg between the left side part WL and the hem part H, and the position of an intersection Ph between the right side part WR and the hem part H. The rear body part position data acquisition portion12may, for example, calculate the position data of the center of the rear body part Cb based on an intersection between a first virtual line that connects the intersection Pc and the intersection Ph to each other and a second virtual line that connects the intersection Pd and the intersection Pg to each other.

The rear body part position data acquisition portion12calculates dimension data of the rear body part Cb based on the position data of the edge of the rear body part Cb. As the dimension data of the rear body part Cb, the rear body part position data acquisition portion12calculates a dimension La between the intersection Pa and the hem part H, a dimension Lb between the intersection Pb and the hem part H, a dimension Lc between the intersection Pc and the hem part H, a dimension Ld between the intersection Pd and the hem part H, a dimension Le between the intersection Pc and the intersection Pd, a dimension Lf between the intersection Pe and the intersection Pf, and a dimension Lg between the intersection Pg and the intersection Ph. The dimension La, the dimension Lb, the dimension Lc, and the dimension Ld are dimensions in a direction orthogonal to the hem part H. The dimension Le, the dimension Lf, and the dimension Lg are dimensions in a direction parallel to the hem part H.

The abnormality decision portion16determines whether the rear body part Cb installed on the installation table322is abnormal by collating the detection data of the detector323with the reference data related to the rear body part Cb stored in the storage portion18. The reference data related to the rear body part Cb stored in the storage portion18includes a target dimension Lar indicating the correct data related to the dimension La, a target dimension Lbr indicating the correct data related to the dimension Lb, a target dimension Lcr indicating the correct data related to the dimension Lc, a target dimension Ldr indicating the correct data related to the dimension Ld, a target dimension Ler indicating the correct data related to the dimension Le, a target dimension Lfr indicating the correct data related to the dimension Lf, and a target dimension Lgr indicating the correct data related to the dimension Lg. The abnormality decision portion16determines whether a difference ΔLa between the dimension La calculated from the detection data of the detector323and the target dimension Lar is equal to or greater than a predetermined threshold value LR. Similarly, the abnormality decision portion16determines whether each of a difference ΔLb between the dimension Lb and the target dimension Lbr, a difference ΔLc between the dimension Lc and the target dimension Lcr, a difference ΔLd between the dimension Ld and the target dimension Ldr, a difference ΔLe between the dimension Le and the target dimension Ler, a difference ΔLf between the dimension Lf and the target dimension Lfr, and a difference ΔLg between the dimension Lg and the target dimension Lgr is equal to or greater than the threshold value LR. When it is determined that all of the difference ΔLa, the difference ΔLb, the difference ΔLc, the difference ΔLe, the difference ΔLf, and the difference ΔLg are less than the threshold value LR, the abnormality decision portion16determines that the rear body part Cb installed on the installation table322is not abnormal. In a case where it is determined that at least one of the difference ΔLa, the difference ΔLb, the difference ΔLc, the difference ΔLe, the difference ΔLf, and the difference ΔLg is equal to or greater than the threshold value LR, the abnormality decision portion16determines that the rear body part Cb installed on the installation table322is abnormal.

The holding position decision portion15determines the holding position HP of the rear body part Cb determined not to be abnormal based on the detection data of the detector323. The holding position HP is a target position to be held by the holding member61and the holding member62on the cloth C.

FIG. 17is a view schematically illustrating the holding position HP of the rear body part Cb according to the embodiment. The holding position HP1by the holding member61is defined in the upper portion of the cloth C including the shoulder part K, the neck part N, and the sleeve part M.

The holding position HP2by the holding member62includes a holding position HP2rby the holding member62supported by the first member60A, and a holding position HP2lby the holding member62supported by the second supporting member66.

In the following description, the holding member62supported by the first member60A is appropriately referred to as a reference holding member62r, and the holding member62supported by the second supporting member66is appropriately referred to as a non-reference holding member62l.

The reference holding member62rsupported by the first member60A cannot be movable regarding the main body member60. The non-reference holding member62lsupported by the second supporting member66is movable regarding the main body member60. The position of the reference holding member62ris adjusted by the robot5. The position of the non-reference holding member62lis adjusted by the robot5and the fine movement device400.

In the following description, the holding position HP2rby the reference holding member62rsupported by the first member60A is appropriately referred to as a reference holding position HP2r, and the holding position HP2lby the non-reference holding member62lsupported by the second supporting member66is appropriately referred to as a non-reference holding position HP2l.

The holding position HP2by the holding member62is determined to be at a prescribed distance from the edge of the rear body part Cb. The reference holding position HP2ris determined to be at a first prescribed distance Ga from the right side part WR. The non-reference holding position HP2lis determined to be at a second prescribed distance Gb from the left side part WL. The first prescribed distance Ga is, for example, 5 mm. The second prescribed distance Gb is, for example, 5 mm. The first prescribed distance Ga and the second prescribed distance Gb are distances in a direction parallel to the hem part H. In the example illustrated inFIG. 17, the reference holding position HP2rand the non-reference holding position HP2lare separated from each other only by a distance Gs. The distance Gs is a distance in a direction parallel to the hem part H.

In the following description, the right side part WR among the edges of the rear body part Cb is appropriately referred to as a reference edge WR, and the left side part WL is appropriately referred to as a non-reference edge WL.

Three reference holding members62rare provided, and the reference holding positions HP2rare defined at three locations. The first reference holding position HP2rthat is the closest to the hem part H among the reference holding positions HP2rat three locations is determined to be at a third prescribed distance Gc from the hem part H. Three non-reference holding members62lare provided, and the non-reference holding positions HP2lare defined at three locations. The first non-reference holding position HP2lthat is the closest to the hem part H among the non-reference holding positions HP2lat three locations is determined to be at a third prescribed distance Gc from the hem part H. The third prescribed distance Gc is, for example, 5 mm. The third prescribed distance Gc is a distance in a direction orthogonal to the hem part H.

Each of the reference edge WR, the non-reference edge WL, and the hem part H has a shape of a straight line. The reference holding position HP2ris determined to be at a first prescribed distance Ga from the reference edge WR. The non-reference holding position HP2lis determined to be at a second prescribed distance Gb from the non-reference edge WL. The holding position decision portion15determines the reference holding positions HP2rat three positions such that a line that connects the first reference holding position HP2r, the second reference holding position HP2r, and the third reference holding position HP2ris parallel to the reference edge WR.

In the first sewing machine21, the label L is stitched to the target part RP of the rear body part Cb. The reference holding position HP2ris determined to be a part of the periphery of the target part RP on the rear body part Cb. The target part RP is defined between the first reference holding position HP2rthat is the closest to the hem part H among the reference holding positions HP2rat three locations, and the second reference holding position HP2rthat is close to the hem part H next to the first reference holding position HP2r.

The conveyance control portion17controls the cloth conveyor4such that the holding member62holds the holding position HP2. The conveyance control portion17controls the robot5such that the reference holding member62rholds the reference holding position HP2r. In other words, the conveyance control portion17controls the robot5and adjusts the position of the main body member60such that the reference holding member62rand the reference holding position HP2rdefined on the rear body part Cb installed on the installation table322match each other in the XY plane.

The conveyance control portion17controls the power generator401of the fine movement device400such that the non-reference holding member62lholds the non-reference holding position HP2lin a state where the reference holding member62rholds the reference holding position HP2r.

For example, there is a possibility that the dimension of the rear body part Cb in the direction parallel to the hem part H changes for each rear body part Cb due to, for example, expansion and contraction or cutting errors of the rear body part Cb. As described above, the reference holding position HP2ris determined to be at the first prescribed distance Ga from the reference edge WR, and the non-reference holding position HP2lis determined to be at the second prescribed distance Gb from the non-reference edge WL. In a case where the reference holding position HP2rand the non-reference holding position HP2lare determined based on the detection data of the detector323, when the relative position between the reference holding member62rand the non-reference holding member62lis fixed, there is a possibility that the holding member62cannot hold the holding position HP2.

FIG. 18is a view schematically illustrating the holding position HP of the rear body part Cb according to the embodiment. The dimension of the rear body part Cb in the direction parallel to the hem part H illustrated inFIG. 18is greater than the dimension of the rear body part Cb in the direction parallel to the hem part H illustrated inFIG. 17. The abnormality decision portion16determines that there is no abnormality due to, for example, expansion and contraction or cutting errors of the rear body part Cb, but there is a possibility that the dimension of the rear body part Cb in the direction parallel to the hem part H slightly changes. As illustrated inFIG. 18, in a case where the reference holding position HP2ris determined to be at the first described distance Ga from the reference edge WR and the non-reference holding position HP2lis determined to be at the second described distance Gb from the non-reference edge WL, the distance Gs illustrated inFIG. 18between the reference holding position HP2rand the non-reference holding position HP2lis longer than the distance Gs illustrated inFIG. 17between the reference holding position HP2rand the non-reference holding position HP2l.

In each of the rear body part Cb illustrated inFIG. 17and the rear body part Cb illustrated inFIG. 18, the conveyance control portion17controls the power generator401of the fine movement device400and moves the non-reference holding member HP2lin the direction parallel to the hem part H such that the reference holding member62rholds the reference holding position HP2rand the non-reference holding member62lholds the non-reference holding position HP2l. By changing the relative position between the reference holding member62rand the non-reference holding member62l, in a state where the reference holding member62rholds the reference holding position HP2r, the non-reference holding member62lcan hold the non-reference holding position HP2l.

After the holding position HP1and the holding position HP2are determined, the conveyance control portion17controls the robot5and the power generator401of the fine movement device400such that the holding member61holds the holding position HP1, the reference holding member62rholds the reference holding position HP2r, and the non-reference holding member62lholds the non-reference holding position HP2l.

As illustrated inFIG. 15B, the conveyance control portion17moves the cloth conveyor4to the second feeding position PF2that faces the rear body part Cb installed on the plate member33of the installation table322. The supporter34supports the plate member33at a position where the supporter34can face the suction surface HS of the conveying member6of the cloth conveyor4. After the cloth conveyor4is moved to the second feeding position PF2, the conveyance control portion17lowers the cloth conveyor4while performing the suction operation of the suction surface HS. Accordingly, the suction surface HS of the cloth conveyor4and the rear body part Cb installed on the upper surface of the plate member33come into contact with each other, and the rear body part Cb is vacuum-suctioned and held on the suction surface HS of the cloth conveyor4. The cloth conveyor4vacuum-suctions and holds the rear body part Cb installed on the upper surface33S of the plate member33from above. The cloth conveyor4vacuum-suctions and holds and conveys the front body part Ca from above.

The holes37are provided on the plate member33. Accordingly, when the gas is suctioned from the suction hole of the suction surface HS of the cloth conveyor4in a state where the cloth conveyor4and the rear body part Cb installed on the plate member33approach or come into contact with each other, as indicated by an arrow F ofFIG. 15B, the gas in the space on the lower surface33T side of the plate member33flows into the space on the upper surface33S side of the plate member33via the hole37. Accordingly, the vacuum-suctioning and holding of the front body part Ca by the suction surface HS of the cloth conveyor4is stably performed.

The robot5is a horizontally articulated robot, and is movable in four directions of the X-axis direction, the Y-axis direction, the Z-axis direction, and the θZ direction. The suction surface HS of the cloth conveyor4is movable in the X-axis direction, in the Y-axis direction, in the Z-axis direction, and in the θZ direction. The supporter34has a floating function of supporting the plate member33to be capable of swinging. The plate member33is supported by the supporter34to be movable in at least one of the θX direction, the θY direction, and the Z-axis direction.

In other words, regarding the suction surface HS of the cloth conveyor4that is movable only in the XY plane and in the Z-axis direction, the plate member33that supports the front body part Ca can move in the θX direction, in the θY direction, and in the Z-axis direction. Therefore, even when the suction surface HS of the cloth conveyor4and the upper surface33S of the plate member33are not parallel to each other, when the cloth conveyor4is lowered and the suction surface HS of the cloth conveyor4and the front body part Ca installed on the upper surface33S of the plate member33are brought into contact with each other, the plate member33swings such that the suction surface HS of the cloth conveyor4and the upper surface33S of the plate member33are parallel to each other. Accordingly, the suction surface HS of the cloth conveyor4and the upper surface33S of the plate member33can sufficiently come in contact with each other, and the front body part Ca is stably vacuum-suctioned and held on the suction surface HS of the cloth conveyor4.

With reference toFIG. 15, the operation in which the cloth conveyor4conveys out the rear body part Cb from the second cloth feeder32has been described. Since the operation in which the cloth conveyor4conveys out the front body part Ca from the first cloth feeder31is the same as the operation of conveying out the rear body part Cb from the second cloth feeder32, the description thereof will be omitted.

Operation of Cloth Conveyor in First Sewing Machine

FIG. 19is a perspective view schematically illustrating the operation of the cloth conveyor4in the first sewing machine21according to the embodiment.

The first sewing machine21stitches up the rear body part Cb and the label L in cooperation with the cloth conveyor4. As illustrated inFIG. 19, the first sewing machine21includes the table211including the installation surface211S on which the rear body part Cb is installed and the head212that stitches up the rear body part Cb installed on the table211and the label L.

The head212includes: the driving mechanism214that moves the needle213in the vertical direction; the first pressing member215that presses the rear body part Cb installed on the table211from above; and the second pressing member216that presses the label L installed on the rear body part Cb from above.

The cloth conveyor4holds the rear body part Cb in the stitching of the rear body part Cb and the label L by the head212. The conveyance control portion17moves the cloth conveyor4based on the detection data of the detector313such that the label L is stitched to the target part of the rear body part Cb. In the embodiment, the conveyance control portion17adjusts the position of the rear body part Cb held by the cloth conveyor4based on the detection data of the detector313such that the target part PR of the right side part WR of the rear body part Cb is disposed at the first stitch position PM1.

In the embodiment, a position sensor217for detecting the position of the right side part WR of the rear body part Cb is provided in the first sewing machine21. The position sensor217optically detects the position of the right side portion WR by irradiating the edge of the rear body part Cb with the detection light. The conveyance control portion17adjusts the position of the cloth conveyor4that holds the rear body part Cb based on the detection data of the position sensor217such that the target part RP of the right side part WR of the rear body part Cb is disposed at the first stitch position PM1. In other words, in the embodiment, the conveyance control portion17adjusts the relative position between the target part PR of the right side part WR of the rear body part Cb and the first stitch position PM1based on the detection data of the position sensor217.

The head212stitches up the rear body part Cb and the label L while feeding the rear body part Cb and the label L in a sewing direction. The cloth conveyor4moves in the sewing direction while holding the rear body part Cb in synchronization with the stitching of the head212. In the example illustrated inFIG. 19, the sewing direction is the X-axis direction.

The first control portion13controls the first sewing machine21such that the rear body part Cb and the label L are stitched up while being fed in a prescribed sewing direction. The first sewing machine21stitches up the rear body part Cb and the label L by moving the needle213in the vertical direction while feeding the rear body part Cb and the label L in the prescribed sewing direction. The conveyance control portion17moves the cloth conveyor4that holds the rear body part Cb in the prescribed sewing direction in synchronization with the feeding operation in the sewing direction of the rear body part Cb and the label L by the first sewing machine21. The cloth conveyor4moves in the prescribed sewing direction in a state of holding the rear body part Cb in synchronization with the feeding operation in the sewing direction of the rear body part Cb and the label L by the first sewing machine21. Accordingly, the stitching of the rear body part Cb and the label L by the first sewing machine21is performed smoothly.

In the embodiment, the cloth conveyor4presses the rear body part Cb against the table211. The conveyance control portion17is moved in the prescribed sewing direction while pressing the cloth conveyor4against the table211such that a load greater than the weight of the cloth conveyor4acts on the table211.

In the embodiment, the target part RP of the right side part WR of the rear body part Cb stitched with the label L is disposed between one pair of reference holding members62rprovided in the first member60A. The target part RP of the right side part WR stitched with the label L is not covered with the conveying member6. Accordingly, the first pressing member215and the second pressing member216can smoothly press the right side part WR of the rear body part Cb from above. Since the target part RP of the right side part WR sewn with the label L is not covered with the conveying member6, the stitching by the needle213is performed smoothly.

Operation of Cloth Conveyor and Cloth Position Adjustment Device in Second Sewing Machine

Next, an example of the operation of the cloth conveyor4and the cloth position adjustment device250in the second sewing machine22will be described. As described above, in the embodiment, the second sewing machine22is a shoulder matching sewing machine that stitches up the shoulder part K of the front body part Ca and the shoulder part K of the rear body part Cb.

FIG. 20is a view schematically illustrating each of the front body part Ca and the rear body part Cb according to the embodiment. As illustrated inFIG. 20, the front body part Ca includes two shoulder parts K and two side parts W. The rear body part Cb includes two shoulder parts K and two side parts. W. The two shoulder parts K include the left shoulder part KL which is one shoulder part K and the right shoulder part KR which is the other shoulder part K. The two side parts W include the left side part WL which is one side part W and the right side part KR which is the other side portion W. In the second sewing machine22, the stitching of the left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb and the stitching of the right shoulder part KR of the front body part Ca and the right shoulder part KR of the rear body part Cb are performed.

FIG. 21is a view schematically illustrating a state where the front body part Ca and the rear body part Cb overlap each other according to the embodiment. As illustrated inFIG. 21, when the shoulder part K of the front body part Ca and the shoulder part K of the rear body part Cb are stitched up, in the second sewing machine22, the front body part Ca and the rear body part Cb overlap each other. When the front body part Ca and the rear body part Cb overlap each other, there is a possibility that the position of the shoulder part K of the front body part Ca and the position of the shoulder part K of the rear body part Cb do not match each other. For example, as illustrated inFIG. 21, when the front body part Ca and the rear body part Cb overlap each other such that the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other, there is a possibility that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb are deviated from each other. The reason why the position of the shoulder part K of the front body part Ca and the position of the shoulder part K of the rear body part Cb do not match each other is, for example, elongation or cutting displacement of the cloth C.

In a state where the position of the shoulder part K of the front body part Ca and the position of the shoulder part K of the rear body part Cb do not match each other, when the shoulder part K of the front body part Ca and the shoulder part K of the rear body part Cb are not stitched up, defective clothing is manufactured.

The cloth position adjustment device250corrects the deviation between the position of the shoulder part K of the front body part Ca and the position of the shoulder part K of the rear body part Cb. When the front body part Ca and the rear body part Cb overlap each other such that the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other, the cloth position adjustment device250adjusts the position of the right shoulder part KR of the front body part Ca such that a deviation amount G between the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb decreases.

Before the front body part Ca is conveyed to the second sewing machine22, the position of the left shoulder part KL of the front body part Ca and the position of the right shoulder part KR of the front body part Ca in the XY plane are detected by the detector313disposed in the first cloth feeder31. Before the rear body part Cb is conveyed to the second sewing machine22, the position of the left shoulder part KL of the rear body part Cb and the position of the right shoulder part KR of the rear body part Cb in the XY plane are detected by the detector323disposed in the second cloth feeder32.

The front body part position data acquisition portion11calculates the position data of the left shoulder part KL of the front body part Ca and the position data of the right shoulder part KR of the front body part Ca in the XY plane based on the image data acquired by the detector313. The rear body part position data acquisition portion12calculates the position data of the left shoulder part KL of the rear body part Cb and the position data of the right shoulder part KR of the rear body part Cb in the XY plane based on the image data acquired by the detector323.

The second control portion14calculates the deviation amount G between the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb when the front body part Ca and the rear body part Cb overlap each other such that the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other, based on the position data of the left shoulder part KL of the front body part Ca and the position data of the right shoulder part KR of the front body part Ca which are calculated by the front body part position data acquisition portion11, and the position data of the left shoulder part KL of the rear body part Cb and the position data of the right shoulder part KR of the rear body part Cb which are calculated by the rear body part position data acquisition portion12. The deviation amount G calculated by the second control portion14is stored in the storage portion18.

FIG. 22is a plan view schematically illustrating the operation of the cloth position adjustment device250in the second sewing machine according to the embodiment.FIG. 22schematically illustrates the front body part Ca conveyed from the first cloth feeder31to the table221of the second sewing machine22by the cloth conveyor4.

Based on the detection data of the detector313, the cloth conveyor4conveys the front body part Ca to the table221such that the front body part Ca is installed at the target position defined in the second sewing machine22. The cloth conveyor4conveys the front body part Ca to the table221such that the left shoulder part KL of the front body part Ca is installed on the installation surface221S of the table221, and the right shoulder part KR of the front body part Ca is installed on the holding surface251S of the plate member251of the cloth position adjustment device250.

After the front body part Ca is installed on the table221, the cloth position adjustment device250performs a suction operation by the suction hole253, and suctions and holds the right shoulder part KR of the front body part Ca by the holding surface251S of the plate member251. Accordingly, in a state where the left shoulder part KL of the front body part Ca is installed on the installation surface221S of the table221, the right shoulder part KR of the front body part Ca is held on the holding surface251S of the plate member251.

The second control portion14controls the actuator252of the cloth position adjustment device250, moves the plate member251in the direction parallel to the installation surface221S, and adjusts the position of the right shoulder part KR of the front body part Ca. The second control portion14moves the plate member251that suctions and holds the right shoulder part KR in the direction parallel to the installation surface221such that the deviation amount G calculated based on the detection data of the detector313and the detection data of the detector323and stored in the storage portion18.

In other words, the second control portion14controls the actuator252and adjusts the movement amount of the plate member251that holds the right shoulder part KR of the front body part Ca such that the deviation amount G between the right shoulder part KR of the front body part Ca installed on the table221and the right shoulder part KR of the rear body part Cb conveyed to the table221later decreases.

Accordingly, as illustrated inFIG. 22, the position of the right shoulder part KR of the front body part Ca is adjusted from the position indicated by a dotted line to the position indicated by a solid line. Even when the right shoulder part KR of the front body part Ca moves due to the movement of the plate member251, the left shoulder part KL of the front body part Ca is substantially stationary by the frictional force with the installation surface221S of the table221. The suction port connected to the vacuum system70may be provided on the installation surface221S of the table221, and the left shoulder part KL of the front body part Ca may be suctioned and held on the installation surface221S of the table221. As the left shoulder part KL of the front body part Ca is suctioned and held by the installation surface221S of the table221, even when the right shoulder part KR of the front body part Ca moves due to the movement of the plate member251, the left shoulder part KL of the front body part Ca suctioned and held by the installation surface221S of the table221is substantially stationary.

In a state where the left shoulder part KL of the front body part Ca is installed on the installation surface221S of the table221, by moving the plate member251that suctions and holds the right shoulder part KR of the front body part Ca in the XY plane, the cloth position adjustment device250can adjust the relative position between the right shoulder part KR of the front body part Ca held by the holding surface251S and the left shoulder part KL of the front body part Ca installed on the installation surface221S in the XY plane.

After the position of the right shoulder part KR of the front body part Ca installed on the table221is adjusted by the cloth position adjustment device250, the rear body part Cb is conveyed to the table221of the second sewing machine22by the cloth conveyor4. Based on the detection data of the detector323, the conveyance control portion17controls the cloth conveyor4such that the rear body part Cb is disposed at the target position defined on the table221, and adjusts the position of the rear body part Cb. The cloth conveyor4adjusts the position of the rear body part Cb relative to the front body part Ca installed on the table221such that the front body part Ca and the rear body part Cb which are installed on the table221of the second sewing machine22overlap each other.

Based on the detection data of the detector313and the detector323, the conveyance control portion17controls the cloth conveyor4such that the left shoulder part KL of the front body part Ca installed on the installation surface221S of the table221and the left shoulder part KL of the rear body part Cb conveyed to the table221by the cloth conveyor4match each other. Accordingly, the rear body part Cb on the front body part Ca installed on the table221is conveyed such that the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other on the installation surface221S of the table221. After the rear body part Cb is conveyed to the table221by the cloth conveyor4, the conveyance control portion17releases the suctioned and held state of the rear body part Cb by the suction surface HS of the conveying member6.

FIG. 23is a plan view schematically illustrating the front body part Ca and the rear body part Cb in the second sewing machine22according to the embodiment. Before the rear body part Cb is conveyed to the table221, the second control portion14controls the actuator252of the cloth position adjustment device250such that the deviation amount G decreases, and adjusts the relative position between the right shoulder part KR of the front body part Ca held by the holding surface251S of the plate member251and the right shoulder part KR of the rear body part Cb conveyed by the cloth conveyor4. The second control portion14controls the actuator252of the cloth position adjustment device250, and moves the plate member251such that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb match each other on the holding surface251S of the plate member251. In other words, by the cloth position adjustment device250, the relative position between the right shoulder part KR and the left shoulder part KL of the front body part Ca installed on the table221is adjusted to match the relative position between the right shoulder part KR and the left shoulder part KL of the rear body part Cb conveyed by the cloth conveyor4. Therefore, by the cloth conveyor4, as the rear body part Cb is conveyed onto the front body part Ca installed on the table221, as illustrated inFIG. 23, on the table221, the front body part Ca and the rear body part Cb overlap each other such that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb match each other and the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other.

FIG. 24is a plan view schematically illustrating the operation of the second sewing machine according to the embodiment. After the front body part Ca and the rear body part Cb overlap each other such that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb match each other and the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other, as illustrated inFIG. 24, the second control portion14fixes the left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb to each other by the first cloth pressing member240L. The left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb are fixed between the first cloth pressing member240L and the table221by being pressed from above by the first cloth pressing member240L.

FIGS. 25 and 26are plan views schematically illustrating the operation of the cloth conveyor4in the second sewing machine22according to the embodiment. After the left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb are fixed to each other by the first cloth pressing member240L, as described with reference toFIG. 8B, the conveyance control portion17lowers the movable member63of the conveying member6such that the lower end portion of the movable member63is disposed below the suction surface HS.

The conveyance control portion17adjusts the position of the cloth conveyor4, and brings the lower end portion of the movable member63into contact with the rear body part Cb. The conveyance control portion17controls the robot5in a state where at least a part of the rear body part Cb and the movable member63are in contact with each other, moves the movable member63that is in contact with at least a part of the rear body part Cb in the XY plane, and adjusts the position of the rear body part Cb and the position of the front body part Ca in the XY plane.

As illustrated inFIG. 25, in the embodiment, the conveyance control portion17moves the cloth conveyor4in the XY plane in a state where the vicinity of the right shoulder part KR of the cloth C and the movable member63are in contact with each other, and adjusts the position of the right shoulder part KR relative to the left shoulder part KL fixed to the first cloth pressing member240L. As illustrated inFIG. 26, the conveyance control portion17adjusts the position of the right shoulder part KR relative to the left shoulder part KL such that the right shoulder part KR and the left shoulder part KL are disposed in a shape of a straight line.

FIG. 27is a plan view schematically illustrating the operation of the second sewing machine22according to the embodiment. After the position of the right shoulder part KR relative to the left shoulder part KL is adjusted, as illustrated inFIG. 27, the second control portion14fixes the right shoulder part KR with the second cloth pressing member240R. Accordingly, a seam line SL of the left shoulder part KL and a seam line SR of the right shoulder part KR are disposed on the same straight line.

Sewing Method

FIG. 28is a flowchart illustrating a sewing method according to the embodiment. One front body part Ca disposed at the top of the plurality of front body parts Ca stacked in the accommodator311of the first cloth feeder31, is conveyed to the installation table312by the first pickup. The front body part Ca installed on the installation table312is detected by the detector313. The front body part position data acquisition portion11acquires the detection data of the detector313(step S10).

The front body part position data acquisition portion11calculates the position data of the edge of the front body part Ca in the XY plane based on the detection data of the detector323(step S20).

As described with reference toFIG. 16, as the position data of the edge of the front body part Ca, the front body part position data acquisition portion11calculates the positions of the intersection Pa, the intersection Pb, the intersection Pc, the intersection Pd, the intersection Pe, the intersection Pf, the intersection Pg, and intersection Ph of the front body part Ca.

The front body part position data acquisition portion11calculates the dimension data of the front body part Ca based on the position data of the edge of the front body part Ca (step S30).

As described with reference toFIG. 16, as the dimension data of the front body part Ca, the front body part position data acquisition portion11calculates the dimension La, the dimension Lb, the dimension Lc, the dimension Ld, the dimension Le, the dimension Lf, and the dimension Lg.

The abnormality decision portion16determines whether the front body part Ca installed on the installation table312is abnormal by collating the dimension data of the front body part Ca with the correct data of the dimension of the front body part Ca stored in the storage portion18(step S40).

In step S40, in a case where it is determined that the front body part Ca is abnormal (step S40: Yes), the conveyance control portion17controls the cloth conveyor4such that the front body part Ca determined to be abnormal is conveyed from the installation table312to an abnormal cloth accommodation member601(step S50).

As illustrated inFIG. 1and the like, the abnormal cloth accommodation member601is disposed at a position adjacent to the installation table312. The conveyance control portion17controls the cloth conveyor4such that the front body part Ca determined to be abnormal is conveyed to the abnormal cloth accommodation member601in a state of being pinched by the gripper500.

As illustrated inFIG. 11, in a case of gripping the front body part Ca installed on the installation table312by the gripper500, the conveyance control portion17controls the actuator510such that the lower end portion of the gripping member502is disposed below the suction surface HS of the conveying member6. The conveyance control portion17controls the actuator503and pinches a part of the front body part Ca determined to be abnormal and installed on the installation table312by the gripping member502. After a part of the front body part Ca is pinched by the gripping member502, the conveyance control portion17controls the robot5such that the front body part Ca pinched by the gripper500is conveyed from the installation table312to the abnormal cloth accommodation member601. After the front body part Ca pinched by the gripper500is disposed above the abnormal cloth accommodation member601, the conveyance control portion17controls the actuator503and releases the gripped state of the front body part Ca by the gripping member502. Accordingly, the front body part Ca determined to be abnormal falls and is accommodated in the abnormal cloth accommodation member601.

After the front body part Ca determined to be abnormal is conveyed to the abnormal cloth accommodation member601, the new front body part Ca accommodated in the accommodator311is installed on the installation table312. The controller10performs the processing from step S10to step S40regarding the front body part Ca installed on the installation table312.

In step S40, in a case where it is determined that the front body part Ca is not abnormal (step S40: No), the conveyance control portion17controls the cloth conveyor4such that the front body part Ca determined not to be abnormal is conveyed from the installation table312to the second sewing machine22.

The holding position decision portion15determines the holding position HP of the front body part Ca based on the detection data of the detector313(step S60).

The holding position HP includes the holding position HP1and the holding position HP2. The holding position HP2includes the reference holding position HP2rand the non-reference holding position HP2l. As described with reference toFIGS. 17 and 18, the holding position decision portion15determines the reference holding position HP2rto be at the first prescribed distance Ga from the reference edge WR, and the non-reference holding position HP2lto be at the second prescribed distance Gb from the non-reference edge WL.

After the holding position HP is determined, the conveyance control portion17controls the robot5and the power generator401of the fine movement device400such that the non-reference holding member62lholds the non-reference holding position HP2lin a state where the reference holding member62rholds the reference holding position HP2r(step S70).

In other words, after moving the cloth conveyor4to the first feeding position PF1above the installation table312, the conveyance control portion17controls the robot5and aligns the reference holding member62rsupported by the main body member60and the reference holding position HP2rdefined in the front body part Ca installed on the installation table312in the XY plane. After the reference holding member62rand the reference holding position HP2rare aligned in the XY plane, in a state where the relative position between the reference holding member62rand the reference holding position HP2ris maintained, the conveyance control portion17controls the power generator401of the fine movement device400and aligns the non-reference holding member62lsupported by the second supporting member66and the non-reference holding position HP2ldefined in the front body part Ca installed on the installation table312in the XY plane. The conveyance control portion17can hold the reference holding position HP2rby the reference holding member62rand hold the non-reference holding position HP2lby the non-reference holding member62lby lowering the cloth conveyor4in a state where the reference holding member62rand the reference holding position HP2rare aligned in the XY plane and the non-reference holding member62land the non-reference holding position HP2lare aligned in the XY plane.

The position data of the front body part Ca includes position data of the circumferential edge part of the front body part Ca including the left shoulder part KL, the right shoulder part KR, the left side part WL, and the right side part WR of the front body part Ca in the XY plane. The position data of the rear body part Cb includes the position data of the circumferential edge part of the rear body part Cb including the left shoulder part KL, the right shoulder part KR, the left side part WL, and the right side part WR of the rear body part Cb in the XY plane. The second control portion14calculates the deviation amount G between the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb when the front body part Ca and the rear body part Cb overlap each other such that the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other, based on the position data of the left shoulder part KL of the front body part Ca, the position data of the right shoulder part KR of the front body part Ca, the position data of the left shoulder part KL of the rear body part Cb, and the position data of the right shoulder part KR of the rear body part Cb which are calculated in step S10. The storage portion18stores the data indicating the calculated deviation amount G.

After the conveyance control portion17suctions and holds one front body part Ca installed on the installation table312on the suction surface HS of the cloth conveyor4, the conveyance control portion17controls the robot5and conveys the front body part Ca held by the cloth conveyor4from the installation table312to the second sewing machine22(step S80).

The conveyance control portion17moves the cloth conveyor4that holds the front body part Ca to the second sewing machine position PH2. The conveyance control portion17adjusts the position of the front body part Ca held by the cloth conveyor4at the second sewing machine position PH2such that the front body part Ca is conveyed to the target position defined on the table221of the second sewing machine22.

In the embodiment, the conveyance control portion17conveys the front body part Ca to the table221by the cloth conveyor4such that the left shoulder part KL of the front body part Ca is installed on the installation surface221S of the table221and the right shoulder part KR of the front body part Ca is installed on the holding surface251S of the plate member251provided on the table221.

The conveyance control portion17releases the suctioned and held state of the front body part Ca by the suction surface Hs of the cloth conveyor4after conveying the front body part Ca to the table221of the second sewing machine22by the cloth conveyor4and adjusting the position of the front body part Ca. Accordingly, the front body part Ca passes the table221of the second sewing machine22. After the front body part Ca passes from the cloth conveyor4to the table221of the second sewing machine22, the conveyance control portion17moves the cloth conveyor4to the second feeding position PF2.

The second control portion14controls the cloth position adjustment device250and adjusts the position of the right shoulder part KR of the front body part Ca installed on the table221(step S90).

As described with reference toFIG. 22, the right shoulder part KR of the front body part Ca is suctioned and held on the plate member251. The left shoulder part KL of the front body part Ca is installed on the installation surface221S of the table221. The second control portion14controls the actuator252of the cloth position adjustment device250, moves the plate member251in the direction parallel to the installation surface221S, and moves the plate member251that suctions and holds the right shoulder part KR in the direction parallel to the installation surface221S such that the deviation amount G stored in the storage portion18decreases.

In the second cloth feeder32, one rear body part Cb disposed at the top of the plurality of rear body parts Cb stacked in the accommodator321of the second cloth feeder32, is conveyed to the installation table322by the second pickup. The rear body part Cb installed on the installation table322is detected by the detector323. The rear body part position data acquisition portion12acquires the detection data of the detector323(step S100).

The rear body part position data acquisition portion12calculates the position data of the edge of the rear body part Cb in the XY plane based on the detection data of the detector323(step S110).

As described with reference toFIG. 16, as the position data of the edge of the rear body part Cb, the rear body part position data acquisition portion12calculates the positions of the intersection Pa, the intersection Pb, the intersection Pc, the intersection Pd, the intersection Pe, the intersection Pf, the intersection Pg, and intersection Ph of the rear body part Cb.

The rear body part position data acquisition portion12calculates the dimension data of the rear body part Cb based on the position data of the edge of the rear body part Cb (step S120).

As described with reference toFIG. 16, as the dimension data of the rear body part Cb, the rear body part position data acquisition portion12calculates the dimension La, the dimension Lb, the dimension Lc, the dimension Ld, the dimension Le, the dimension Lf, and the dimension Lg.

The abnormality decision portion16determines whether the rear body part Cb installed on the installation table322is abnormal by collating the dimension data of the rear body part Cb with the correct data of the dimension of the rear body part Cb stored in the storage portion18(step S130).

In step S130, in a case where it is determined that the rear body part Cb is abnormal (step S130: Yes), the conveyance control portion17controls the cloth conveyor4such that the rear body part Cb determined to be abnormal is conveyed from the installation table322to an abnormal cloth accommodation member602(step S140).

As illustrated inFIG. 1and the like, the abnormal cloth accommodation member602is disposed at a position adjacent to the installation table322. The conveyance control portion17controls the cloth conveyor4such that the rear body part Cb determined to be abnormal is conveyed to the abnormal cloth accommodation member602in a state of being pinched by the gripper500.

As illustrated inFIG. 11, in a case of gripping the rear body part Cb installed on the installation table322by the gripper500, the conveyance control portion17controls the actuator510such that the lower end portion of the gripping member502is disposed below the suction surface HS of the conveying member6. The conveyance control portion17controls the actuator503and pinches a part of the rear body part Cb determined to be abnormal and installed on the installation table322by the gripping member502. After a part of the rear body part Cb is pinched by the gripping member502, the conveyance control portion17controls the robot5such that the rear body part Cb pinched by the gripper500is conveyed from the installation table322to the abnormal cloth accommodation member602. After the rear body part Cb pinched by the gripper500is disposed above the abnormal cloth accommodation member602, the conveyance control portion17controls the actuator503and releases the gripped state of the rear body part Cb by the gripping member502. Accordingly, the rear body part Cb determined to be abnormal falls and is accommodated in the abnormal cloth accommodation member602.

After the rear body part Cb determined to be abnormal is conveyed to the abnormal cloth accommodation member602, the new rear body part Cb accommodated in the accommodator321is installed on the installation table322. The controller10performs the processing from step S100to step S130regarding the rear body part Cb installed on the installation table322.

In step S40, in a case where it is determined that the rear body part Cb is not abnormal (step S13: No), the conveyance control portion17controls the cloth conveyor4such that the rear body part Cb determined not to be abnormal is conveyed from the installation table322to the first sewing machine21.

The holding position decision portion15determines the holding position HP of the rear body part Cb based on the detection data of the detector323(step S150).

The holding position HP includes the holding position HP1and the holding position HP2. The holding position HP2includes the reference holding position HP2rand the non-reference holding position HP2l. As described with reference toFIGS. 17 and 18, the holding position decision portion15determines the reference holding position HP2rto be at the first prescribed distance Ga from the reference edge WR, and the non-reference holding position HP2lto be at the second prescribed distance Gb from the non-reference edge WL. On the rear body part Cb, the reference holding position HP2ris determined to be a part on the periphery of the target part RP to which the label L is stitched.

After the holding position HP is determined, the conveyance control portion17controls the robot5and the power generator401of the fine movement device400such that the non-reference holding member62lholds the non-reference holding position HP2lin a state where the reference holding member62rholds the reference holding position HP2r(step S160).

In other words, after moving the cloth conveyor4to the second feeding position PF2above the installation table322, the conveyance control portion17controls the robot5and aligns the reference holding member62rsupported by the main body member60and the reference holding position HP2rdefined in the rear body part Cb installed on the installation table312in the XY plane. After the reference holding member62rand the reference holding position HP2rare aligned in the XY plane, in a state where the relative position between the reference holding member62rand the reference holding position HP2ris maintained, the conveyance control portion17controls the power generator401of the fine movement device400and aligns the non-reference holding member62lsupported by the second supporting member66and the non-reference holding position HP2ldefined in the rear body part Cb installed on the installation table322in the XY plane. The conveyance control portion17can hold the reference holding position HP2rby the reference holding member62rand hold the non-reference holding position Hp2lby the non-reference holding member62lby lowering the cloth conveyor4in a state where the reference holding member62rand the reference holding position HP2rare aligned in the XY plane and the non-reference holding member62land the non-reference holding position HP2lare aligned in the XY plane.

After the conveyance control portion17suctions and holds one rear body part Cb installed on the installation table322on the suction surface HS of the cloth conveyor4, the conveyance control portion17controls the robot5and conveys the rear body part Cb held by the cloth conveyor4from the installation table322to the first sewing machine21(step S170).

The processing of conveying the rear body part Cb from the installation table322to the first sewing machine21is performed in parallel with at least a part of the processing of adjusting the position of the right shoulder part KR of the front body part Ca by the cloth position adjustment device250.

The conveyance control portion17moves the cloth conveyor4that holds the rear body part Cb to the first sewing machine position PH1. The conveyance control portion17adjusts the position of the rear body part Cb held by the cloth conveyor4at the first sewing machine position PH1such that the rear body part Cb is conveyed to the target position defined on the table221of the first sewing machine21.

As described with reference toFIG. 19, the conveyance control portion17adjusts the position of the rear body part Cb held by the cloth conveyor4such that the target part PR of the right side part WR of the rear body part Cb is disposed at the first stitch position PM1. Based on the detection data of the position sensor217, the conveyance control portion17finely adjusts the relative position between the rear body part Cb held by the cloth conveyor4and the first stitch position PM1, at the first sewing machine position PH1.

The first control portion13controls the first sewing machine21, and stitches up the rear body part Cb suctioned and held by the suction surface HS of the cloth conveyor4and the label L fed from the label feeder8(step S180).

The head212stitches up the rear body part Cb and the label L while feeding the rear body part Cb and the label L in the sewing direction. The conveyance control portion17moves the cloth conveyor4that holds the rear body part Cb in the sewing direction in synchronization with the stitching of the rear body part Cb and the label L by the head212of the first sewing machine21. The conveyance control portion17moves the cloth conveyor4in the sewing direction while pressing the rear body part Cb against the table211with the cloth conveyor4.

After the stitching of the rear body part Cb and the label L in the first sewing machine21is completed, the conveyance control portion17controls the cloth conveyor4, and conveys the rear body part Cb from the first sewing machine21to the second sewing machine22(step S190).

The conveyance control portion17moves the cloth conveyor4that holds the rear body part Cb to the second sewing machine position PH2. The conveyance control portion17adjusts the position of the rear body part Cb held by the cloth conveyor4at the second sewing machine position PH2such that the rear body part Cb is conveyed to the target position defined on the table221of the second sewing machine22. The conveyance control portion17controls the rear cloth conveyor4and adjusts the position of the rear body part Cb relative to the front body part Ca installed on the table221of the second sewing machine22.

The conveyance control portion17adjusts the position of the cloth conveyor4such that the front body part Ca installed on the table221and the rear body part Cb held by the cloth conveyor4overlap each other on the table221. Before the rear body part Cb is conveyed to the table221by the cloth conveyor4, in step S90, the position of the right shoulder part KR of the front body part Ca is adjusted. Therefore, as the conveyance control portion17controls the cloth conveyor4such that the left shoulder part KL of the front body part Ca installed on the installation surface221S of the table221and the left shoulder part KL of the rear body part Cb conveyed to the table221by the cloth conveyor4match each other, as described with reference toFIG. 23, on the table221, the front body part Ca and the rear body part Cb can overlap each other such that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb match each other and the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other.

The conveyance control portion17controls the cloth conveyor4, and releases the suctioned and held state of the rear body part Cb by the suction surface Hs of the cloth conveyor4after conveying the rear body part Cb held by the cloth conveyor4to the table221of the second sewing machine22and adjusting the position of the rear body part Cb. Accordingly, the rear body part Cb passes the table221of the second sewing machine22and overlaps the front body part Ca. The front body part Ca and the rear body part Cb overlap each other such that the position of the right shoulder part KR of the front body part Ca and the position of the right shoulder part KR of the rear body part Cb match each other and the position of the left shoulder part KL of the front body part Ca and the position of the left shoulder part KL of the rear body part Cb match each other.

After the front body part Ca and the rear body part Cb are installed on the table221of the second sewing machine22and the suctioned and held state of the rear body part Cb is released by the cloth conveyor4, as described with reference toFIG. 24, the second control portion14fixes the left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb to each other by the first cloth pressing member240L (step S200).

After the left shoulder part KL of the front body part Ca and the left shoulder part KL of the rear body part Cb are fixed to each other by the first cloth pressing member240L, as described with reference toFIG. 8B, the conveyance control portion17lowers the movable member63of the conveying member6such that the lower end portion of the movable member63is disposed below the suction surface HS.

The conveyance control portion17adjusts the position of the cloth conveyor4, and brings the lower end portion of the movable member63into contact with the rear body part Cb separated from the suction surface HS of the cloth conveyor4. In a state where the movable member63and the rear body part Cb are in contact with each other, the conveyance control portion17controls the robot5, moves the movable member63in the XY plane, adjusts the positions of the rear body part Cb and the front body part Ca.

As described with reference toFIG. 25, the conveyance control portion17moves the cloth conveyor4in the XY plane in a state where the vicinity of the right shoulder part KR of the cloth C and the movable member63are in contact with each other, and adjusts the position of the right shoulder part KR relative to the left shoulder part KL fixed to the first cloth pressing member240L.

As described with reference toFIG. 26, the conveyance control portion17adjusts the position of the right shoulder part KR relative to the left shoulder part KL such that the right shoulder part KR and the left shoulder part KL are disposed in a shape of a straight line. As described with reference toFIG. 27, the conveyance control portion17adjusts the position of the right shoulder part KR relative to the left shoulder part KL such that the seam line SL of the left shoulder part KL and the seam line SR of the right shoulder part KR are disposed on the same straight line (step S210).

By adjusting the position of the right shoulder part KR relative to the left shoulder part KL such that the right shoulder part KR and the left shoulder part KL are disposed in a shape of a straight line, there is a possibility that wrinkles are generated at least at a part of the cloth C between the right shoulder part KR and the left shoulder part KL. The conveyance control portion17can smooth the wrinkles by moving the robot5in the XY plane in a state where the movable member63and the cloth C are in contact with each other.

After the position of the right shoulder part KR is adjusted by the movable member63of the cloth conveyor4, as described with reference toFIG. 27, the second control portion14fixes the right shoulder part KR of the front body part Ca and the right shoulder part KR of the rear body part Cb by the second cloth pressing member240R (step S70).

After the front body part Ca and the rear body part Cb are fixed to each other by the first cloth pressing member240L and the second cloth pressing member240R, the second control portion14controls the cloth pressing conveyor230, and holds the front body part Ca and the rear body part Cb by the cloth pressing conveyor230. The second control portion14controls the head222, and stitches up the front body part Ca and the rear body part Cb along the seam line SL and the seam line SR (step S230). The front body part Ca and the rear body part Cb are stitched up by the head222while being moved in the sewing direction parallel to the X-axis direction.

Effects

As described above, according to the embodiment, the sewing system1includes the cloth conveyor4that holds the cloth C fed from the cloth feeder3and conveys the cloth C to the sewing machine2. By providing the cloth conveyor4including the robot5, the cloth C is fed to the sewing machine2quickly and accurately. Therefore, deterioration in productivity of clothing is prevented.

According to the embodiment, the holding position HP1and the holding position HP2of the cloth C are determined based on the detection data of the edge of the cloth C, and the cloth conveyor4is controlled such that the holding member61holds the holding position HP1and the holding member62holds the holding position HP2. Accordingly, the cloth conveyor4can hold the appropriate holding position HP of the cloth C. By detecting the position data of the edge of the entire cloth C, for example, even when the processing of teaching the holding position HP to the cloth conveyor4is not performed before the sewing processing, the cloth C can be fed to the sewing machine2quickly and accurately.

According to the embodiment, the holding position HP2is determined to be at a prescribed distance from the edge of the cloth C. For example, in a case where the holding position HP2is set to a position where the distance from the edge is long on the cloth C, or the holding position HP2is set to a center portion of the cloth C, the cloth conveyor4conveys the cloth C in a state where a part of the cloth C on the outer side of the holding position HP2held by the holding member62hangs down. When the part that hangs down in the cloth C is large, there is a possibility that the part comes into contact with a member on the periphery during the conveyance of the cloth C or the holding by the holding member62becomes unstable. When the holding position HP2is extremely close to or extremely far from the edge of the cloth C, there is a high possibility that a holding failure (suction error) of the cloth C by the holding member62occurs. By determining the holding position HP2to be at a prescribed distance from the edge at which the holding member62can stably hold the cloth C, the cloth conveyor4can stably convey the cloth C.

In the embodiment, the reference holding position HP2ris determined to be at the first prescribed distance Ga from the reference edge WR. The reference holding position HP2ris held by the reference holding member62rof which the relative position to the main body member60is fixed. The non-reference holding position HP2lis held by the reference holding member62rof which the relative position to the main body member60is fixed. By controlling the robot5, the conveyance control portion17can align the non-reference holding position HP2land the reference holding member62rwith high accuracy.

The reference holding position HP2ris determined to be a part on the periphery of the target part RP to which the label L is stitched on the rear body part Cb. Since the non-reference holding position HP2land the reference holding member62rare aligned with high accuracy, when the cloth conveyor4conveys the rear body part Cb to the first sewing machine21, the conveyance control portion17can control the robot5and align the first stitch position PM1and the target part RP in the first sewing machine21with high accuracy. Accordingly, it is possible to stitch the label L to a correct position of the rear body part Cb.

The non-reference holding position HP2lis defined to be at the second prescribed distance Gb from the non-reference edge WL. The non-reference holding position HP2lis held by the non-reference holding member62lthat can change the relative position between the main body member60and the reference holding member62r. Accordingly, even when the dimension of the cloth C changes due to the expansion and contraction or cutting errors of the cloth C, the non-reference holding member62lmoves regarding the reference holding member62r, and accordingly, in a state where the reference holding member62rholds the reference holding position HP2r, it is possible to hold the non-reference holding position HP2lat the second prescribed distance Gb from the non-reference edge WL. Since the fine movement device400for finely moving the non-reference holding member62lregarding the main body member60is provided, the position of the non-reference holding member62lcan be accurately aligned regarding the non-reference holding position HP2l.

In the embodiment, in the XY plane, the distance between the connecting member71and the power generator401is shorter than the distance between the connecting member71and the holding member62. In other words, the power generator401of the fine movement device400is disposed in the vicinity of the connecting member71connected to the robot5. Accordingly, even when the weight of the power generator401is large, the moment that acts on the main body member60is reduced. Therefore, the main body member60can move in a state of being held by the robot5with an excellent weight balance. The robot5can move the main body member60having an excellent weight balance with high position accuracy.

Even when the power generator401and the second supporting member66are separated from each other, the power generated by the power generator401is transmitted to the second supporting member66that supports the non-reference holding member62lvia the power transmission mechanism402.

The reference edge WR has a shape of a straight line and the holding position decision portion15defines the plurality of reference holding positions HP2rsuch that a line that connects the first reference holding position62rand the second reference holding position62rto each other becomes parallel to the reference edge WR. In a case where the target part RP to which the label L is stitched is defined between the first reference holding position62rand the second reference holding position62r, as the line that connects the first reference holding position62rand the second reference holding position62rto each other is parallel to the reference edge WR, in the first sewing machine21, in a state where each of the two reference holding positions HP2ris held by the reference holding member62r, the label L can be smoothly stitched to the target part RP. In the conveyance of the cloth C, the cloth C does not hang down.

In the embodiment, it is possible to easily determine whether there is an abnormality in the cloth C by collating the detection data of the edge of the cloth C with the reference data. By conveying the cloth C determined to be abnormal to the abnormal cloth accommodation members601and602, it is possible to prevent continuation of the sewing processing of the abnormal cloth C. Accordingly, deterioration in efficiency of the sewing processing is prevented.

In a state of being pinched by the gripper500, the cloth C determined to be abnormal is conveyed to the abnormal cloth accommodation members601and602. There is a high possibility that the holding member61and the holding member62do not suction and hold the abnormal cloth C. Even in a case of the abnormal cloth C, by pinching a part of the cloth C, the gripper500can smoothly convey the cloth C to the abnormal cloth accommodation members601and602.

In the embodiment, the cloth conveyor4holds the cloth C from above. Accordingly, the cloth conveyor4can move above each of the first feeding position PF1, the second feeding position PF2, the first sewing machine position PH1, and the second sewing machine position PH2, and quickly convey the cloth C by holding the cloth C from above or releasing the held state.

In the embodiment, the first sewing machine21includes the table211and the head212that stitches the rear body part Cb installed on the table211, and the cloth conveyor4conveys the rear body part Cb to the table211. Accordingly, the first sewing machine21can quickly perform the stitching up of the rear body part Cb conveyed to the table211and the label L. The second sewing machine22includes the table211and the head212that stitches up the front body part Ca and the rear body part Cb which are installed on the table221, and the cloth conveyor4conveys the front body part Ca and the rear body part Cb to the table211. Accordingly, the second sewing machine22can quickly perform the stitching of the front body part Cb and the rear body part Cb which are conveyed to the table212.

In the embodiment, the cloth conveyor4holds the rear body part Cb in the stitching of the head212. For example, when the held state of the rear body part Cb by the cloth conveyor4is released before the stitching in the head212, there is a possibility that it is necessary to additionally provide a position adjustment mechanism for adjusting the relative position between the first stitch position PM1and the rear body part Cb. There is a possibility that it is necessary to ensure the time required for the position adjustment by the position adjustment mechanism. As a result, there is a possibility that the equipment costs increase or productivity of clothing deteriorates. In the embodiment, the rear body part Cb is stitched with the label L in the first sewing machine21in a state of being held by the cloth conveyor4. Therefore, the increase in equipment costs and deterioration in productivity are prevented.

In the embodiment, the head212stitches the rear body part Cb while feeding the rear body part Cb in the sewing direction, and the cloth conveyor4holds and moves the rear body part Cb in the sewing direction in synchronization with the stitching by the head212. Accordingly, the sewing in the head212is performed smoothly.

In the embodiment, the cloth conveyor4presses the rear body part Cb against the table211. Accordingly, the stitching in the first sewing machine21is performed smoothly.

In the embodiment, the cloth conveyor4conveys the rear body part Cb against the second sewing machine22from the first sewing machine21. Accordingly, even in a case where clothing is manufactured through the plurality of processes by the plurality of sewing machines2, the cloth C is fed to each of the plurality of sewing machines2quickly and accurately. Therefore, the deterioration in productivity of clothing is prevented.

In the embodiment, the cloth conveyor4continues to hold the rear body part Cb in the conveyance of the rear body part Cb from the first cloth feeder31to the first sewing machine21, the stitching of the rear body part Cb by the first sewing machine21, and the conveyance of the rear body part Cb from the first sewing machine21to the second sewing machine22. When the cloth conveyor4frequently repeats the holding and releasing and the holding of the rear body part Cb, it is necessary for the cloth conveyor4to ensure the time required for releasing the held state of the rear body part Cb and time required for holding the rear body part Cb. Every time the holding and releasing and the holding of the rear body part Cb are repeatedly performed, it is necessary to perform the position adjustment of the rear body part Cb by the separately provided position adjustment mechanism. As a result, there is a possibility that the equipment costs increase and productivity of clothing deteriorates. In the embodiment, since the cloth conveyor4continues to hold the rear body part Cb, it is possible to eliminate the time required for the cloth conveyor4to release the held state of the rear body part Cb and the time required for the cloth conveyor4to hold the rear body part Cb. Therefore, deterioration in productivity of clothing is prevented.

In the embodiment, the cloth conveyor4adjusts the position of the cloth C in a state where the cloth C is held in each of the first sewing machine21and the second sewing machine22. Accordingly, in each of the first sewing machine21and the second sewing machine22, the cloth C is accurately conveyed to the target position.

In the embodiment, the cloth conveyor4includes a movable member63which is a contact member that can come into contact with the cloth C, and by moving the cloth conveyor4in a state where at least a part of the cloth C and the lower end portion of the movable member63are in contact with each other, the position of the cloth C is adjusted. Accordingly, it is possible to adjust the position of the cloth C with high accuracy by using high positioning accuracy of the cloth conveyor4including the robot5.

In the embodiment, the detector313that detects the position of the front body part Ca and the detector323that detects the position of the rear body part Cb are provided, and the cloth conveyor4adjusts the position of the front body part Ca and the position of the rear body part Cb based on the detection data of the detector313and the detection data of the detector323. Accordingly, the cloth conveyor4can convey the cloth C to the target position with high accuracy in a coordinate system defined in the sewing system1.

In the embodiment, the detector313is disposed in the first cloth feeder31, and the detector323is disposed in the second cloth feeder32. Since the position of the front body part Ca is detected in the first cloth feeder31that serves as a starting point of the conveyance of the front body part Ca, the cloth conveyor4can adjust the position of front body part Ca with high accuracy based on the detection data of the detector313from the first cloth feeder31that serves as a starting point of the conveyance of the front body part Ca to the second sewing machine22that serves as an end point of the conveyance. Similarly, since the position of the rear body part Cb is detected in the second cloth feeder32that serves as a starting point of the conveyance of the rear body part Cb, the cloth conveyor4can adjust the position of the rear body part Cb with high accuracy based on the detection data of the detector323from the second cloth feeder32that serves as a starting point of the conveyance of the rear body part Cb to the second sewing machine22that serves as an end point of the conveyance.

In the embodiment, the adjustment of the position of the cloth C by the cloth conveyor4includes the adjustment of the position of the cloth C regarding the target position defined by the first sewing machine21, and the adjustment of the position of the cloth C regarding the target position defined by the second sewing machine22. By the cloth conveyor4, since the cloth C is disposed with high accuracy at the target position defined by the sewing machine2, the target part of the cloth C is sewn excellently. Therefore, manufacturing defects of clothing are prevented.

In the embodiment, the second sewing machine22includes the first cloth pressing member240L that fixes the left shoulder part KL of the cloth C, and the adjustment of the position of the cloth C by the cloth conveyor4includes the adjustment of the position of the right shoulder part KR of the cloth C regarding the left shoulder part KL. Accordingly, as described with reference toFIGS. 18 and 19, the seam line SL and the seam line SR can be accurately disposed on the same straight line using the cloth conveyor4.

In the embodiment, the cloth conveyor4includes the conveying member6including the suction surface HS for suctioning and holding the cloth C from above, and the movable member63supported to be movable by the conveying member6. After the left shoulder part KL of the cloth C is released from the suctioned and held state of the conveying member6, the left shoulder part KL is fixed to the first cloth pressing member240L, the cloth conveyor4moves in the XY plane in a state where the cloth C separated from the suction surface HS and the lower end portion of the movable member63are in contact with each other, and adjusts the position of the right shoulder part KR of the cloth C. Accordingly, the relative position between the left shoulder part KL and the right shoulder part KR in the XY plane is smoothly adjusted.

In the embodiment, the adjustment of the position of the cloth C by the cloth conveyor4includes the adjustment of the position of the rear body part Cb regarding the front body part Ca installed on the table221of the second sewing machine22. Accordingly, on the table221of the second sewing machine22, the rear body part Cb can accurately overlap the front body part Ca.

In the embodiment, after conveying the front body part Ca from the first cloth feeder31to the second sewing machine22and adjusting the position of the front body part Ca, the cloth conveyor4conveys the rear body part Cb from the second cloth feeder32to the second sewing machine22and adjusts the position of the rear body part Cb regarding the front body part Ca installed in the second sewing machine22. In the embodiment, the front body part Ca and the rear body part Cb are sequentially conveyed to the second sewing machine22by the cloth conveyor4including the integrated robot5and the conveying member6, and the position of the front body part Ca and the position of the rear body part Cb can be accurately adjusted.

In the embodiment, the first cloth feeder31includes the installation table312on which the front body part Ca is installed, and the cloth conveyor4conveys the front body parts Ca one by one from the installation table312. The second cloth feeder32includes the installation table322on which the rear body part Cb is installed, and the cloth conveyor4conveys the rear body parts Cb one by one from the installation table322. Accordingly, in the sewing machine2, since the front body parts Ca and the rear body parts Cb are stitched one by one, manufacturing defects of clothing are prevented.

Another Embodiment

In the above-described embodiment, the imaging region of the detector313has a sufficient size to fit the entire front body part Ca installed on the installation table312. In other words, one detector313can collectively acquire the image data of the entire front body part Ca. In the first cloth feeder31, the plurality of detectors313for acquiring the image data of the front body part Ca installed on the installation table312may be provided. For example, the first detector313may acquire the image data of the upper portion of the front body part Ca including the shoulder part K, the neck part N, and the sleeve part M out of the front body part Ca installed on the installation table312, and the second detector313may acquire the image data of the lower portion of the front body part Ca including the side part W and the hem part H. After acquiring the image data of a plurality of different parts of the front body part Ca by each of the plurality of detectors313, the image data of the entire front body part Ca may be acquired by combining the image data of the plurality of parts. The same is also applied to the detector323for acquiring the image data of the rear body part Cb installed on the installation table322.

In the above-described embodiment, the sewing system1manufactures a T-shirt as clothing. Clothing manufactured by the sewing system1is not limited to a T-shirt, and may be, for example, a long-sleeved shirt or pants.

In the above-described embodiment, the sewing system1manufactures clothing as a sewn product. The sewn product manufactured by the sewing system1is not limited to clothing, and may be a component manufactured by sewing a plurality of cloths, such as pouches, bags, and shoes. The sewn product manufactured by the sewing system1is not limited to a finished product, and may be an intermediate product or a part product.