Study on Sensing and Monitoring of Sewing Machine for Textile Stream Smart Manufacturing Innovation

The smart factory is a futuristic production paradigm that transforms ICT(Information and communication technology) into a new smart/green/urban production system by integrating the existing traditional industrial production system.[1-2] Industry 4.0 proposed by DFKI, is defined as the 4th industrial revolution based on Internet-of-Things(IoT), cyber-physical systems(CPS), and Internet-of-Services(IoS). [3-6] In the textile industry, the smart factory is a factory based on the CPS that incorporates ICT and IoT technology into the existing production system.[7-8] In order to build a smart factory between textile and apparel streams, the connectivity of the CPS should be strengthened.

This study focuses on the construction of a CPS system to realize a smart factory by deriving three representative processes (fabric, dyeing, sewing) among textile streams. Figure 1 shows the data flow of CPS based inter-stream smart manufacturing system. The rectangle marked with read lines represents the part for detecting and controlling the sewer data for the smart of the sewing process which is the core of this research.

Textile stream smart factory CPS implementation can only be done by linking together the ordering system, design automation system, product information management system, production information integration system and production equipment automation.[6] Fig. 2 shows the interlinkage of high-throughput, high-productivity production systems that minimize plant-to-plant collaboration and prototype production to accommodate small-volume and multi-stream requirements between streams, and can be instantly produced on demand.

It is a study to apply smart factory to the textile industry in this research and development. A study on the smartization of sewing process among several textile streams was conducted.[12-13] In order to make the sewing machine smart, we applied the same sewing machine which is used in the present industrial field and modified the sewing machine. First, the residual amount of the under-thread was detected to reduce the worker’s mistake and product defect. Secondly, in the sewing industry where workers are aging, it is possible to control the automatic stitch number according to the product type. Next, monitoring of the overall sewing process requires further work on the presser foot pressure control, tension control, POP(point of production) system and all monitoring data interlocks.