Abstract:
In the apparel industry, fabric loaders feed the fabric rolls to spreading
machines. Those fabric loaders are optimized only for roll-form fabrics.
Textile manufacturers relax the fabric rolls for most types of fabrics, from
pure cotton to silk and wool into fabric bales to remove built-in fabric
tensions. These relaxed bale-form fabrics are manually loaded into the
spreading machines. This process takes considerable time and labor and
affects the efficiency of the fabric spreading process. The main aim of this
research is to design and implement an automated fabric loader that can
efficiently load and unload roll-form and bale-form fabrics to the spreading
machine. The potential advantages of designing an automated fabric loader
include reducing manual intervention, improving workplace safety, and
eliminating labor shortages. It also increases product quality as less fabric is
damaged due to manual loading, decreasing lead times and manufacturing
costs. The initial step of this research involves a CAD design. Next, a robust,
lightweight frame will be designed to support the entire system. The loader
will be equipped with two specialized feeding systems: one for roll-form
fabrics and another for bale-form fabrics allowing for seamless transition
with various fabric types. An integrated electronic control system with
sensors will detect fabric types, dimensions, and positions, ensuring precise
handling and minimizing damage. A built-in conveyor transports fabric from
the loader to the spreading machine. Additionally, an interface will be added
to the system to set parameters, monitor the loading process, and
troubleshoot any issues quickly, enhancing user experience and operational
efficiency. The proposed automated fabric loader represents a significant
advancement in the apparel industry enhancing overall production
throughout in textile manufacturing.
