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Cutting embroidered fabrics for the clothing industry is a complex task that has traditionally been carried out by hand in an otherwise highly automated manufacturing environment. A demonstrator machine has been produced that cuts embroidered fabric using a CO2 laser guided by a high speed computer-vision system. Cutting speeds of up to 300mm/s have been achieved for regular shaped patterns.
The process of laser cloth cutting has no tool wear, does not cause fraying and also reduces the formation of dust. The focussed laser spot allows cutting widths as low as 0.1mm producing an extremely clean edge to the cut. Laser powers up to 100W are required depending upon the cutting speed and the material being cut. For each type of fabric it has been necessary to research the systems operating parameters, in order to specify a working range over which a good quality cut can be obtained. The fabrics successfully evaluated are nylon, polyester, viscose, cotton and poly-cotton.
A major obstacle in the production of high quality cuts, was the problem of accurately detecting and following the embroidered seams at high speeds. These seems are typically very small and may be raised only 2 or 3mm from the base material. The sensing method was a vision system with a structured light technique using a low intensity (10mW) laser stripe, which was projected on to the fabric at right angles to the seam. This technique allowed the seam profile to be viewed by a CCD camera operating at 1000Hz.The cutting laser was mounted on a 3 axis belt driven cartesian gantry actuator suspended over a flat cutting table. A rotary wrist was used in order to maintain the sensor geometry while cutting around corners. This rotation ensured that the axis of the projected laser line always remains normal to the seam direction.
Extensive trials with the machine have achieved cutting speeds of up to 300mm/s on simple repetitive seam shapes. These cuts accurately follow the seam shape to within less than 0.5mm and exhibit a regular high quality cut. The demonstrator machine represents a significant improvement on traditional manual cutting. By automating the process it has been shown that cutting speeds can be significantly increased, delivering significant financial savings and increasing the variety of shapes that can be cost-effectively produced. The demonstrator machine is now ready for engineering as a prototype machine in preparation for its introduction in to industry.
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