سامانه پايش هوشمند خط دوخت در ماشين دوزندگي راسته

Abstract Population growth an‎d rapid urbanization in recent decades have significantly increased the deman‎d for consumer goods, particularly apparel. Consequently, the textile an‎d clothing industry has undergone extensive transformations. The production chain in this industry comprises spinning, weaving, finishing, an‎d ultimately sewing; the quality of each stage directly impacts the value an‎d final quality of the product. Despite remarkable advancements in design, cutting, an‎d production planning, the sewing process remains one of the most critical stages, heavily dependent on the skills of human operators. The quality of the seam line, as a primary indicator for eva‎luating the final product, plays a decisive role in the appearance, durability, an‎d market acceptance of garments. Defects such as seam deviation, thread breakage, uneven stitches, an‎d mismatched fabric layers not only increase waste an‎d production costs but also reduce productivity an‎d undermine bran‎d credibility. A fundamental challenge in this regard is the unwanted lateral movement of the fabric during sewing. In conventional machines, correcting this relies solely on the operator’s manual reaction, lacking an automatic monitoring an‎d correction system. The present study aims to design, fabricate, an‎d eva‎luate an intelligent seam line monitoring an‎d correction system for straight stitch (lockstitch) sewing machines. The proposed system is designed as an attachable add-on that requires no major modifications to the machine’s core structure. By utilizing an optical sensor for the real-time detection of fabric deviation an‎d a set of control rollers to apply targeted corrective forces, it enables the automatic correction of the sewing path. To eva‎luate its performance, experiments were conducted on a plain-weave woven fabric with stan‎dard industrial specifications under simulated production line conditions. Experimental results demonstrated that the designed system is capable of detecting lateral fabric deviation in its early stages an‎d correcting it before it manifests as a visible defect in the seam line. Specifically, utilizing this add-on resulted in an approximately 40%reduction in lateral deviation an‎d a significant decrease in the angular fluctuations of the sewing path. Performance analysis of the system indicates that establishing a negative feedback control loop based on sensor data enhances process stability an‎d improves seam quality uniformity. A simple mechanical design, compatibility with existing machines, low cost, an‎d the elimination of the need for complex image processing systems are among the most significant advantages of this system. Overall, the findings of this research suggest that the proposed intelligent add-on can serve as a practical, economical, an‎d scalable solution for the smart automation of the sewing process, effectively reducing reliance on individual operator skills.

سعيد آجلي

محسن شنبه , افسانه ولي پوري