Project: Robot-Assisted Sewing System for the Individual Hemming of Formed Parts
„Robot-Assisted Sewing System for the Individual Hemming of Formed Parts made of Leather and Materials/Textiles within the Field of Automotive and Aircraft Interiors“_x000D_ _x000D_ Documented Procedure of Actual State_x000D_ The hemming of formed parts made of leather or textile added with fleece or foam is actually 100 % made manually by using an industrial standard sewing machine. Alternative to this, a sewing table with a large number of templates, patterns and workpiece holders would be needed. Smallest alterations in size and shape of formed parts require that new workpiece holders must be produced. Current expenditure of workpiece holders amount from EUR 500 up to 7,000 apiece. There is a wide variety of shapes, sizes and material thicknesses of individual models within the field of automotive and aircraft interiors. The variety of models as well as the individuality is on the rise in this field. At the same time the ordering party is targeting accuracy according to commission regulations (EC) of the automotive and aircraft industry to work and operate precisely fitting in downstream operations. In the process is a weak point with a high error rate through the “human” uncertainty factor. In addition, the time factor, in alternation to the other models, plays a significant role and impairs the unit output._x000D_ _x000D_ Objective of the Project_x000D_ The process of this workflow should be automated more comprehensive. The currently high manual steps of feeding during sewing of the form parts (leather, fleece or foam) should be reduced. By implementing robots, the feeding of form parts as well as the exact handling position of the form parts to be sewn are guaranteed by special cameras. The sewing process to be carried out is also robot controlled and monitored by special cameras in an optoelectronic manner with the objective of producing high quality market-relevant products for automotive and aircraft interiors, based on the use of new technological procedures within the sewing segment._x000D_ _x000D_ The following effects should be achieved with this research assignment:_x000D_ ¿ The operation of a robot controlled sewing plant in a three-shift system_x000D_ ¿ Reduction of the high manual feeding operations_x000D_ ¿ Significant reduction of the error rate through the “human” uncertainty factor_x000D_ ¿ Constant quality with low share of scrap_x000D_ ¿ Increase of produced pieces per time unit through a reliable and more efficient process cycle _x000D_ ¿ Elimination of expensive workpiece holders_x000D_ ¿ Significant improvement of the economic ratio within the sewing segment_x000D_ ¿ Products become more competitive_x000D_ _x000D_ Project Consortium_x000D_ The planned project consortium will consist of a small enterprise and two limited companies with different plants. The following companies will be involved: KSL Keilmann Sondermaschinenbau GmbH Germany, Car Trim GmbH Germany and Car Trim K.S. Czech Republic._x000D_ KSL GmbH Germany exclusively developed innovative CNC machining facilities for sewing of airbags, three-dimensional sewing of leathers for upholstery, hot air splicing machines for the automotive industry, filling and hemming machines for the mattress industry. All above mentioned machining facilities are customized unicums. All CNC machining facilities are patented. Because of the company’s operational structure, which is oriented on special engineering, a serial production in the operating program is not designed and not possible._x000D_ _x000D_ Car Trim GmbH Germany offers complete interior equipment systems for the aircraft and automotive industry from development to series production under one roof. The existing vertical range of production in the fields of metalwork, leather production, silk and textile processing as well as foam fabrication, sewing and upholstering guarantees a high level of competence and flexibility. _x000D_ Car Trim K.S. Czech Republic is an industrial supplier company engaged in the automotive industy. The expertise covers the fields of sewing of seat covers, seat belt systems and airbag production and is implemented in the individual segments of production. _x000D_ _x000D_ The consortium agreement will regulate all legal and economic relations between the consortium members.
| Acronym | Autom. Sewing System (Reference Number: 4607) |
| Duration | 01/09/2010 - 31/12/2012 |
| Project Topic | Work cycles within the sewing segment are to be automated by implementing innovative technology. The high proportion of manually operated infeed during the sewing of formed parts is to be reduced. With special cameras, the deployment of robots guarantees feeding and exact processing position. |
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Project Results (after finalisation) |
The joint project E! – 4607 Automatic Sewing System was correctly incorporated into the General European EUROSTARS Program. A scientific and technical project could be successfully implemented across country borders for the first time. New knowledge was gained in the field of industrial sewing technique using robots and the specific vision system in the automotive and aeronautical inner area for the first time. _x000D_With the joint project, the goal setting was achieved in co-operation of Ps Car Trim GmbH Plauen /D and KSL GmbH Lorsch /D, performing the work processes fixing, transport and sowing of formed parts using 2 6-axis KUKA robots in synchronicity without manual operation. _x000D_Acquired secondary experience penetrates into the entire production sewing process and leads additionally to optimising of the scientific and technical overall result._x000D_ |
| Network | Eurostars |
| Call | Eurostars Cut-Off 2 |
Project partner
| Number | Name | Role | Country |
|---|---|---|---|
| 4 | Car Trim GmbH Germany | Partner | Germany |
| 4 | Car Trim K.S. Czech Republic | Partner | Czech Republic |
| 4 | Keilmann Sondermaschinenbau GmbH | Coordinator | Germany |
| 4 | KONRAD Sondermaschinenbau e. K. | Observer | Germany |