System and method for processing material panels

Abstract

A system for processing a material panel is provided including a table supported by a plurality of legs, the table having at least one linear edge. A sewing machine is provided functionally connected to the table at the at least one linear edge. An elongate track is provided mounted along the at least one linear edge. At least one sensor movable along said track is provided for measuring at least a length of the material panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein like reference numerals denote similar elements throughout the views:

FIG. 1 is a front perspective view of a serger flanger system showing a gripper assembly in a forward position according to an aspect of the present invention;

FIG. 2 is front perspective view of a serger flanger system showing a gripper assembly in a midway position according to another aspect of the present invention;

FIG. 3 is front perspective view of a serger flanger system showing a gripper assembly in a rear position according to another aspect of the present invention;

FIG. 4 is front perspective view of a serger flanger system depicting a pivot arm in a partially deployed position according to another aspect of the present invention;

FIG. 5 is front perspective view of a serger flanger system depicting a pivot arm in a fully deployed position according to another aspect of the present invention;

FIG. 6 is a right side perspective view of the serger flanger system of FIG. 3 according to another aspect of the present invention;

FIG. 7 is an enlarged front perspective view of a gripper assembly as shown in area “A” of FIG. 3 according to one embodiment of the present invention;

FIG. 8 is an enlarged front perspective view of a pivot assembly as shown in area “B” of FIG. 3 according to an aspect of the present invention;

FIG. 9 is enlarged view of section “C” of FIG. 6 depicting a retracted edge guide according to an aspect of the present invention;

FIG. 10 is enlarged view of section “C” of FIG. 6 depicting an extended edge guide according to an aspect of the present invention;

FIG. 11 is a top schematic view of a serger flanger system including a loaded panel 1101 according to an aspect of the present invention;

FIG. 12 is a top schematic view of a serger flanger system with the panel 1101 positioned for commencement of a pivot cycle according to an aspect of the present invention;

FIG. 13 a top schematic view of a serger flanger system including panel 1101 upon completion of the pivot cycle according to an aspect of the present invention;

FIG. 14 is a side view of an actuator assembly showing a gripper assembly “D” according to another embodiment of the present invention;

FIG. 15A is an enlarged side view of the gripper assembly of section “D” of FIG. 14;

FIG. 15B is a top view of the gripper assembly of FIG. 15A;

FIG. 15C is a right side view of the gripper assembly of FIG. 15A;

FIG. 16 is a flow chart depicting an exemplary method of processing a material panel according to one aspect of the present invention;

FIG. 17 is a flow chart depicting exemplary method steps of a tension control process according to one aspect of the present invention; and

FIG. 18 is a flow chart depicting exemplary method steps of a measurement system according to one aspect of the present invention.

Claims

1. A system for processing a material panel comprising: a table supported by a plurality of legs, the table having at least one linear edge;a sewing machine functionally connected to the table at said at least one linear edge;an elongate track mounted along said at least one linear edge; andat least one sensor movable along said track for measuring at least a length of the material panel.

2. The system of claim 1, further comprising an operator interface operably connected to at least the sewing machine.

3. The system of claim 2, wherein the operator interface is configured for inputting of desired finished length and width data for the material panel.

3. The system of claim 1, wherein the legs comprise adjustable legs configured to be independently adjustable in height.

4. The system of claim 1, further comprising a movable material edge guide mounted adjacent to the sewing machine along said at least one linear edge.

5. The system of claim 1, further comprising a means for moving the sewing machine relative to said at least one linear edge, based on measurement feedback from said at least one sensor.

6. A system for processing a material panel comprising: a table supported by a plurality of legs, the table having at least one linear edge;a sewing machine functionally connected to the table at said at least one linear edge;an elongate track mounted along said at least one linear edge; anda plurality of sensors mounted at predetermined locations along the track, for providing measurement feedback of at least one edge of the material panel.

7. The system of claim 6, further comprising an operator interface operably connected to at least the sewing machine.

8. The system of claim 6, further comprising a movable material edge guide mounted adjacent to the sewing machine along said at least one linear edge.

9. A system for processing a material panel comprising: a table supported by a plurality of legs, the table having at least one linear edge;a sewing machine functionally connected to the table at said at least one linear edge;an elongate track mounted along said at least one linear edge; andan operator interface operably connected to at least the sewing machine and configured for inputting desired measurement data for the material panel.

10. The system of claim 9, further comprising: a movable material edge guide assembly, mounted adjacent to the sewing machine along said at least one linear edge.

11. The system of claim 9, wherein the legs comprise adjustable legs configured to be independently adjustable in height.

12. A method for processing a material panel comprising the steps of: processing at least one edge of the panel using a tension control process, wherein the step of processing further comprises the steps of:gripping a first end of the panel using a first carriage;moving the first carriage using a second carriage; anddeactivating the second carriage if a tension between the first and second carriages exceeds a predetermined force.

13. The method of claim 12, further comprising the step of connecting the first carriage to the second carriage using a tension device, wherein the predetermined force is determined by a tension device.

14. The method of claim 12, further comprising the step of incorporating human input in real-time during the step of processing.

15. The method of claim 12, wherein the step of processing further comprises: referencing desired panel dimensions;assessing a length of at least a first panel edge in real-time during processing of said panel edge; andadjusting a position of an edge guide according to the desired panel dimensions.

16. The method of claim 15, further comprising the steps of: pivoting the panel to orient a second consecutive edge of the panel flush with the edge guide; andprocessing the second edge of the panel using the tension control process.

17. The method of claim 16, wherein the step of pivoting further comprises activating a pivot arm to turn the panel until a pivot sensor is activated.

18. The method of claim 16, further comprising the step of assessing if all edges of the material panel have been processed.