AUTOMATIC GARMENT PORTION LOADER

Abstract: Apparatus for loading precut garment portions in an automated production line, said apparatus comprising a conveyor (42) for feeding said garment portions (11) to said production line, means (10 to 40) for delivering garment portions (11) on to said conveyor (42) in a substantially flat condition, means (51) for aligning an edge of a garment portion (11) along a predetermined line (61), relative to said conveyor (42), sensor means (62) f or sensing said edge is or is not aligned and means (64) for rejecting and removing from said conveyor the garment portions which are not so aligned.

Description: The present invention relates to an automated loading device for placing individual garments on an assembly line type conveyor whereon the garment portions are aligned and positioned with respect to a predetermined standard in order to facilitate sewing the garment portion. In the garment producing industry efforts have been made to reduce the production time and labour required to produce each individual garment. For example, automated sewing devices can stitch hems and seams of garments, with the garment portions being placed on an assembly line in accordance with a predetermined standard. In this manner, the machine operators no longer are required simultaneously to align and hem the garment portion with the machine, but rather need only to be able to align the garment portion with the predetermined standard associated with the continuously moving garment portion conveyor. The automated sewing machine then performs the task of sewing along the edge of the garment portion. Of course, the operator must still place the garment portions on the conveyor and must align the garment portions with the standard. It is readily seen that the function of an operator in such an automated system would be monotonous and tedious. DE 3305716 discloses lateral and angular positioning in the plane of the workpiece by means of a rotating disc member engaging the cloth, the disc member being displaced laterally and accurately in the plane of the workpiece. The type of sensing means is not disclosed. DE 1610723 discloses registration of the workpiece by a plurality of rotating beaters which position the workpiece against a stop surface of a template. According to the present invention there is provided apparatus for loading precut garment portions in an automated production line, said apparatus comprising a conveyor for feeding said garment portions to said production line, means for delivering garment portions on to said conveyor in a substantially flat condition and means for aligning an edge of a garment portion along a predetermined line, relative to said conveyor, characterised by sensor means for sensing whether said edge is or is not so aligned and means for rejecting and removing from said conveyor the garment portions which are not so aligned. Such an apparatus can place and align garment portions on a production line conveyor belt, without the necessity of an operator acting as the loader and aligner of the garment portions on the conveyor. The apparatus can operate at a steady and continual pace and can detect and remove misaligned garment portions before they reach the automated sewing machine. The alignment means may comprise an alignment standard having an edge defining said predetermined line, a plurality of alignment members adapted selectively to urge said garment portion towards said predetermined line and said sensor means having an output for selectively controlling each of said alignment members. Preferably said alignment members each comprise a continuous belt positioned for movement transversely in the direction of travel of said conveyor and movable selectively to a first position in spaced relation to a subjacent garment portion and to a second position in contact with said garment portion, to urge said garment portion towards said predetermined line without creating wrinkles or folds therein and a positioning means operatively connected to said belt to position said belt in a vertical plane selectively in accordance with the output of said sensor means. The means for delivering garment portions advantageously comprises means for lifting the single garment portion from a stack of such garment portions and a reciprocating carriage for moving said lifting means selectively between said stack and said conveyor. Desirably means are provided to produce a flow of air across the upper surface of the top garment portion on said stack, such that the upper most layer of said garment portion is at least partially lifted by the flow of said air and a retractable finger is positioned to apply pressure to said stack at an upper edge thereof as said lifting means lifts said single garment from the stack. In a preferred construction a vacuum box assembly is positioned intermediate said stack of said garment portions and said conveyor, such that garment portions transferred from said stack to said conveyor are draped across said vacuum box assembly near the adjacent end of said conveyor, said vacuum box assembly providing a predetermined resistance to said garment portion's movement along said conveyor and an air wand being positioned near the surface of said conveyor, with said air wand directing a predetermined flow of air along the surface of said garment portion to remove overlapping folds therein. The means for delivery may comprise means for sensing the height of said stack of garment portions at a predetermined level and means for raising said stack of grament portions responsive to said sensing means, such that said stack is repeatedly raised to maintain the uppermost garment portion at said predetermined level. In order that the present invention may more readily be understood the following description is given merely by way of example, reference being made to the accompanying drawings: Figure 1 is a diagrammatic side elevation of one embodiment of apparatus according to the invention; Figure 2 is a diagrammatic plan of the apparatus of Figure 1; Figure 3 is a detail view of the delivery mechanism with the delivery table and other parts shown partially in section; Figure 4 is a perspective view of the alignment means; Figure 5 is a detail perspective view of the rejection apparatus; and Figure 6 is a flow chart representation of the operation of the apparatus. Figure 1 shows a stack 10 of garments portions 11, such as sleeves, supported on a tray 12 mounted on a delivery apparatus 13, shown as a turntable. The turntable 13 has a plurality of stations thereon defined by a plurality of vertical passageways 14 (Figure 2), extending upwardly through turntable 13. Each tray 12 has a set of co-operatively position feet 16 (Figure 3), which have downwardly opening recesses 17 formed therein. A set of rods 18 extend upwardly through the passageways 14 and engage the recesses 17 when a tray 12 is in a position for the garment portions 11 to be removed therefrom. The rods 18 are attached to a plate 21, so that they can be simultaneously moved vertically by an actuator 19, such as a worm unit attached to plate 21. Each tray 12 has positioned in a predetermined area thereon a reflective surface 22, such as a piece of retro-reflective or an area painted with retro-reflective paint. When each tray 12 is properly aligned and positioned on the turntable 13 for the garment portions 11 to be removed therefrom, this reflective surface 22 is positioned beneath a photo-electric sensor 23. This may include an infrared (IR) generating and sensing means positioned such that infrared light is only reflected by the surface 22 to the sensors 23 when there are no garment portions 11 on the tray 12. When no garment portion is present, the turntable 13 will be directed to position another tray 12 beneath the photo-electric sensor 23. Adjacent the sensor 23 is positioned a pick-up assembly 24 including a plurality of grippers 25 designed to be raised and lowered by a pneumatic cylinder 26. To facilitate the removal of the garment portions from the stack the grippers 25 are set to grip the fabric at a predetermined height; therefore the stack 10 must be incrementally raised by the actuator 19 each time a garment portion 11 is removed from the stack 10. To accomplish this a photo-electric sensor 27 is mounted at the desired height in conjunction with a flexible metallic finger 28 which carries thereon an upturned vane 29 and which is moved upwardly by the force of garment portions 11 therebeneath, such that the vane 29 blocks an IR beam directed to the sensor 27 from a light source 30, which causes the actuator 19 to stop with the uppermost garment portion 11 at the predetermined height. A hollow metallic plate 31 extends across the top of the stack 12 to a point adjacent the lowest point of travel of the pick-up assembly 24. The hollow plate 31 has a downwardly opening aperture 32 positioned through which a high volume of low pressure air may be directly onto the centre of the upper surface of the uppermost garment portion 11. This creates an airfoil type effect to cause the top layer of fabric of each garment portion 11 to lift and separate from the layer below, to facilitate grasping of the layer by the grippers 25. A pneumatically operated hold finger 33 which reciprocates to and from a position above the uppermost layer of fabric of the stack 10 and applies a gentle pressure to the top layer of fabric. The pick-up assembly 24 is supported by a horizontal track 37 which extends above the hollow plate 31, the assembly being moved along the track by a pneumatic actuator 36, such as an Origa band-type pneumatic cylinder. The hollow plate 31 includes a downwardly and forwardly curved portion 31, adjacent which is a vacuum box 38 which has an arcuate perforated surface 39, forming a trough with plate portion 31. As shown in Figure 1, a movable closure member 41 allows the interior of vacuum box 38 to be maintained at a subatmospheric pressure while controlling the flow of air through the perforated surface 39. Adjacent the vacuum box 38 on the opposite side thereof from the plate 31 is an alignment conveyor 42, having a plurality of parallel endless belts 43, interspaced across a horizontal support 44, to carry the garment portion 11 along the conveyor 42. The track 37 extends above the conveyor 42 to allow the pick-up assembly 24 to carry the garment portions 11 partially onto the conveyor 42. An air wand 46 is mounted transversely above the conveyor 42, slightly downstream from the end of the track 37, to direct air onto and along the surface of the conveyor 42 in response to the output of a photo-electric sensor 48 mounted proximal the air wand 46. The sensor 48 senses an IR light beam reflected from a reflector 49, such as a retro-reflective tape, placed on the support 44 proximal the air wand 46. Garment portions 11 carried by the belts 43 interrupt the light path as they cover the reflector 49, thus actuating the air wand 46. Downstream of the air wand 46 is an alignment assembly 51, which utilises a plurality of alignment belts 52 mounted transversely of the conveyor 42 and driven by individual drive pulleys 53 carried on a common shaft 54, having its longitudinal axis aligned parallel to the conveyor 42 and mounted outwardly of the conveyor belts 43 (Figure 4). Each alignment belt 52 has associated therewith a frame 56 which carries thereon a secondary sheave 57 around which the belt 52 travels. Each frame 56 is pivotally mounted for movement about the shaft 54 and has associated therewith a pneumatic actuator 58 which positions the frame 56, and thus its belt 52, selectively adjacent the upper surface of the conveyor 52 or spaced from the upper surface of the conveyor 42. The shaft is driven by suitable means, not shown. Adjacent an edge of the conveyor 42 is an adjustable shelf 59 on which a strip of reflective material is placed. This strip 61 may run parallel to the conveyor 42 and serves as an alignment standard which may be moved relative to the adjacent edge of the conveyor 42. The shelf 59 provides a substantially continuous surface outwardly of the conveyor 42 to support the garment portion 11, adjacent the standard. Each alignment belt 52 has associated with it a photo-electric sensor alignment eye 62 mounted above the strip 61. Each alignment eye 62 controls the associated pneumatic actuator 58 to raise the frame 56 when the light path from strip 59 to the photo sensor is obscured by the edge of a garment portion 11. Downstream of the belts 52 a photo-electric key eye sensor is positioned above a reflective surface 65 formed on the support 44. This key eye 63 senses the leading edge of a garment portion 11, then causes the conveyor belts 43 to stop temporarily and the alignment belts 52 to be lowered to contact the garment portion 11 to urge it laterally and align the lateral edge of the garment portion 11 with the strip 59. Each alignment eye 62 also serves as an input to control a rejection assembly 64 which includes a sweep arm 66, mounted for pivotal movement about a vertical axis, and carrying adhering members, such as carding cloths 67, which engage garment portions 11 to be rejected. The carding cloths 67 are located above a transfer conveyor 70 at a sufficient height to prevent engagement of properly aligned garment portions 11. If any one of the alignment eyes 62 fails to register proper alignment of the garment portions 11, then the rejection assembly is activated. The sweep arm 66 is driven by a pneumatic actuator 68, through an arc and a supporting cam surface 69 causes the arm 66 to descend sufficiently for the carding cloths 67 to engage the garment portion 11. At the end of the arc the carding cloths 67 are positioned outwardly of the conveyor over a hopper 71 into which the garment portion 11 drops by its own weight. A photo-electric control eye 72 may be positioned along the conveyor 42 or 70 to indicate to downstream processing devices that the garment portion 11 is being passed thereto. The input from the various sensors can be advantageously sorted and co-ordinated through the use of a microprocessor 73, such as a GE Series 1 processor. As can be seen from the flow chart of Figure 6, the sensor 23 indicates whether a garment portion 11 is present on the tray 12. If this tray 12 is missing, a secondary reflective surface 22′ is exposed on the delivery apparatus 13 thereby giving the same result as if the tray 12 were in position. If no garment portion 11 is present the processor 73 directs the delivery apparatus 13 to move to the next tray position, the rods 18 being retracted for this step. This procedure is repeated until a tray 12 carrying garment poritons 11 is positioned beneath the pick-up assembly 24 or until all six tray positions shown in the flow chart have been sampled. If no garment portions 11 are available the apparatus is shut off. If one or more garment portions 11 are sensed then the up-eye 27 indicates whether the stack 10 is at the proper level. If it is too low, the processor 73 will direct the vertical actuator 19 to raise the rods 18 until the stack 10 on this tray 12 presses against the finger 28 and causes the vane 29 to interrupt the optical path to the eye 27 and indicate that the top garment portion 11 is at the proper height. A high volume, low pressure air stream is continuously directed out of aperture 32, spreads over the surface of the top garment portion 11 and lifts the top garment portion. The hold finger 33 descends and applies pressure to the edge of the stack 10 while the pick-up assembly 24 descends and grips near an edge of the top garment portion, intermediate hollow plate 31 and hold finger 33. The pick-up assembly 24 carrying the garment portion 11 is moved vertically by the actuator 26 and horizontally by the arm 36, thereby pulling the garment portion 11 from beneath the plate 31 and hold finger 33 and across the top of the plate 31. The hold finger 33 is then retracted. As the pick-up assembly 24 moves horizontally, it actuates a magnetic sensor 35 to open the closure member 41 on vacuum box 38, so that air is drawn through the perforated surface 39. Since the garment portion 11 is gripped only at one end, the free end is draped over the vacuum box 38 as the pick-up 24 moves forwardly and is subjected to a slight resistance due to the vacuum. This has a smoothing effect on the material and reduces the tendency of the garment portion 11 to fold or gather on itself. When the pick-up assembly 24 reaches its end of travel a magnetic sensor 40 sends a signal to the processor 73 which directs the pick-up assembly 24 to release the garment portion 11 onto the conveyor 42. The return of the pick-up assembly 24 to its "home" position, is sensed by a magnetic sensor 40′ and the closure member 41 closes the perforated surface 39 and the belts 43 draw the garment portion further onto the conveyor from the vacuum box 38. If folds in the material had occurred during release from the pick-up assembly 24, the sensor 48 signals the processor 73 when the leading edge of the garment portion 11 has passed under the air wand 46, which is caused to deliver a short burst of air along the garment portion 11 surface to remove any folds. A downstream baffle 45 is provided to prevent this air from impinging on a downstream garment portion. The garment portion 11 passes beneath the alignment belts 52 until its leading edge is sensed by the key eye 63. The processor 73 then stops the conveyor 42 for a predetermined time interval and lowers the continuously driven alignment belts 52, which each engage and laterally move on the conveyor 42 the garment portion 11 to align its edge over the strip 61. A resulting signal from the associated alignment eye 62 causes the pneumatic actuator 58 to lift the frame 56 and to disengage the belt 52 from the garment portion 11. If all of the alignment belts 52 are raised during the interval, the microprocessor 73 determines the garment portion 11 to be properly aligned and passes it for further processing. If any alignment belt 52 has not been raised at the end of the time interval, the procesor 73 determines that the garment portion 11 is not properly aligned and the conveyor 42, a predetermined time later, delivers the garments to the transfer conveyor 70 beneath the carding cloths 67 which engage and remove the garment portion 11, from the conveyor 70. Clearly a number of other forms of rejection assembly may be used. It will be appreciated that the various assemblies described may function simultaneously such that one garment portion may be aligned while another is positioned by the pick-up assembly 24 so that a continuous operation of the apparatus may be facilitated as indicated by the dashed return line in Figure 6.

Claims: 1. Apparatus for loading precut garment portions in an automated production line, said apparatus comprising a conveyor (42) for feeding said garment portions (11) to said production line, means (10, 12 to 40) for delivering garment portions (11) on to said conveyor (42) in a substantially flat condition and means (51) for aligning an edge of a garment portion (11) along a predetermined line (61), relative to said conveyor (42), characterised by sensor means (62) for sensing whether said edge is or is not so aligned and means (64) for rejecting and removing from said conveyor the garment portions which are not so aligned. 2. Apparatus according to claim 1, characterised in that said alignment means (51) comprise an alignment standard (59) having an edge (61) defining said predetermined line, a plurality of alignment members (52) adapted selectively to urge said garment portion (11) towards said predetermined line (61) and in that said sensor means (62) have an output for selectively controlling each of said alignment members (52). 3. Apparatus according to claim 2, characterised in that said alignment members (51) each comprise a continuous belt (52) positioned for movement transversely in the direction of travel of said conveyor (42) and movable selectively to a first position in spaced relation to a subjacent garment portion and to a second position in contact with said garment portion, to urge said garment portion towards said predetermined line without creating wrinkles or folds therein and a positioning means (54 to 58) operatively connected to said belt to position said belt in a vertical plane selectively in accordance with the output of said sensor means. 4. Apparatus according to claim 2 or 3, characterised in that said alignment standard (59) is made from reflective material and in that said sensor means (62) comprises a plurality of photo-electric sensors each associated with selective alignment members (51) and positioned relative to said alignment standard (59), such that the properly aligned garment portion (11) blocks light reflected by said alignment standard. 5. Apparatus according to any preceding claim, characterised in that the rejection means (64) comprises a sweep arm (66) mounted for selective pivotal motion about a vertical axis between a rest postion above said conveyor (42) and a rejection position outwardly of the conveyor, means (68) for pivoting said arm about said vertical axis and adhering means (67) mounted on said arm for engaging a misaligned garment and removing it with said arm to said rejection position. 6. Apparatus according to any preceding claim, characterised in that said means for delivering garment portions (11) to said conveyor (42) comprise means (24) for lifting the single garment portion (11) from a stack (10) of such garment portions and a reciprocating carriage (35,36) for moving said lifting means (24) selectively between said stack (10) and said conveyor (42). 7. Apparatus according to claim 6, characterised in that means (30 to 32) are provided to produce a flow of air across the upper surface of the top garment portion (11) on said stack (10), such that the upper most layer of said garment portion is at least partially lifted by the flow of said air and a retractable finger (33) is positioned to apply pressure to said stack at an upper edge thereof as said lifting means lifts said single garment from the stack. 8. Apparatus according to claim 6 or 7, characterised in that a vacuum box assembly (38) is positioned intermediate said stack (10) of said garment portions and said conveyor (42), such that garment portions (11) transfered from said stack to said conveyor are draped across said vacuum box assembly near the adjacent end of said conveyor, in that said vacuum box assembly (38) provides a predetermined resistance to said garment portion's movement along said conveyor and in that an air wand (46) is positioned near the surface of said conveyor (42), with said air wand directing a predetermined flow of air along the surface of said garment portion (11) to remove overlapping folds therein. 9. Apparatus according to claim 8, characterised in that a sensor ((48) for indicating the presence of a garment on said conveyor is positioned downstream of said air wand (46) and in that said air wand is responsive to said sensor (48), such that said flow of air is directed towards said garment only after the leading edge thereof passes beneath said air wand. 10. Apparatus according to claim 6, 7, 8 or 9, characterised in that said means for delivering comprises means (27 to 29) for sensing the height of said stack of garment portions (11) at a predetermined level and means (16 to 18) for raising said stack of garment portions responsive to said sensing means (27 to 29), such that said stack is repeatedly raised to maintain the uppermost garment portion at said predetermined level. 11. Apparatus according to claim 10, characterised in that a plurality of platens (12) are provided so that each can support thereon a stack (10) of garment portions and in that means (13) for sequentially delivering said platens are provided to raise said stack of garments. 12. Apparatus according to any preceding claim, characterised in that means (22,23) are provided for sensing the absence of garments on said delivery means.

Inventors: ADAMSON, FLETCHER D., CALDWELL, JAMES MERRELL
Applicants: RUSSELL CORPORATION
Application year: 1986
Main classification: A41H43
IPC codes: B65H3, B65H9, B65G47, B65H29, D05B33, A41H43, B65G59