CA2046979C - Automatic attachment of pre-closed elastic waist bands - Google Patents

Abstract

An apparatus for and method of attaching an elastic band to the body of a garment is provided. The workpieces are monitored and aligned during the attachment process by sensors and guide mechanisms, electrically coupled to a controlling means that facilitates the activities, while a tensioning mechanism maintains the workpieces in a desired configuration. The use of the apparatus and method results in an efficient and automatic process of attachment that eliminates the need for an operator to manually align and guide the workpieces through the sewing instrumentality.

Description

2~979 r~
AUTOMATIC ATTACHMENT OF PRE-CLOSE~
~LASTI~ WAISTBANDS

Fleld of the Invention The present inventlon relates, generally, to an apparatus for and method of sewing, and more particularly, to an apparatus and method related to the automatic attachment of pre-closed clrcular elastlc walstbands to the body portion of a circular garment.

Description of the Prior Art The automation of the sewing operatlon has existed for many years. Over time, machlnes and methods have been developed that allow operators to position pieces of materlal in a specified locatlon where, thereafter, the sewing machlnes would complete the aligning and sewing operation. The entire operation was 8 lmplest when there was one workpiece and the geometry of the material sewn was basic (e.g. straight edges), the conflguration of the sewn material was easy to malntain during the sewing operation (e.g. an even alignment), and the path of the stitching was not complicated (e.g. stralght and flat).
The automation of the aligning and sewing operations i snot as simple when the characteristics of the material to be sewn venture from the basic, e.g. the sewlng of an elastic closed-loop workplece material to a tubular edges of another non-elastlc workpiece. The operator, or the machine, must strive to align the materlals such that, when sewn together, the non-elastic and r 1 Y
!~ T
~ 05085-2 YK~sdw elastlc workpleces are configured with the desired amount of tension in the different materials. If either material i8 not tensioned properly, the resulting combination will have problem areas wher~ the look, feel and final size of the completed garment could be unacceptable.
The co~figuration of the elastlc an~ non-elastic materials is critlcal when the elastic material is being used as a waistband. The elastic material is susceptlble to more notlceable flaw ln lts conflguration wlth the non-elastic materials because the ends of the elastlc materlal must be ~olned to form a loop. If the alignment of the two materlals is not accurate, the elastic loop may not close properly decreasing the quality of the completed garment.
The garments' walstband can be sewn closed wlth more accuracy if the loop ls closed before the band ls sewn to the body of the garment. However, it is burdensome thereafter to attach the pre-closed band to the body of a garment because the time and skill necessary to manoeuvre the materialæ during the sewlng operation decreases the efficiency and speed of the entire process. It is time consumlng for an operator to manually align the materlals, begin to sew, and then have to realign the materlals periodically throughout the sewing operation until the stitching is complete. Thls tedlousness results from the dlfflculty ln positloning any loop materlal, elastic or otherwlse, ln proper alignment with the body of a garment and thereafter sewlng the materlals together in a contlnuous operation, maintaining the alignment such that the entire loop is sewn to the rest of the garment in the desired conflguratlon.
The presently known device or method have been less than 05085-2sY~sdw -ade~uate for sewing pre-closed elastlc bands onto other materials that is efficlent, accurate, ~peedy and automatlc, addresslng the concerns stated above. Such a devlce or method would most deslrably elimlnate the need for manual posltioning of the materlals ln relatlon to each other durlng the sewlng operatlon, and keep both materlals at the proper tenslons, whlle also ellmlnating the need for manual manoeuvring of the aligned workpleces through the sewlng machine.
For e~ample, U.S. Pat. No. 4,~79,447 and U.S. Pat No.
4,827,856, both lssued to Rohrr dlscloses an embodlment that sews the edge of a tubular workplece. Two other patents lssued to Rohr, U.S. Pat. No. 4,512,268 and U.S. Pat. No. 4,467,734, and U.S. Pat. No. 4,473,017, issued to Letard et al., relate to sewlng apparatus that support and tenslon a tubular workplece whlle the workplece passes through a sewlng machlne. The typlcal workplece here is a garment with a hem or other edge that must be sewn in place. U.S. Pat. No. 4,744, 319J also issued to Rohr, discloses a devlce that controls a wor~plece durlng a sewlng operation. The device ls appllcable for sewlng flat (open) materlals - lt feeds materlal ln a substantlally stralght llne.
It is, thereforeJ an ob~ect of the present lnventlon to provlde a new and lmproved apparatus for and method of automatlcally attaching elastic band materlals onto garment bodies to allow the operator to load a second machlne whlle the first machine ls ~oinlng the elastlc band to the body of the 05085-2 YK/sdw 20 46~79 .

garment, thereby increaslng productivlty.
It ls a further ob~ect of the invention to provide a new and improved apparatus for and method of attachlng pre-closed clrcular elastic walstbands to circular underwear, swimwear, etc.
Still another ob~ect of the present inventlon is to provlde a new and improved apparatus for and method of Joining a pre-closed band to another portion of a garment while expanding and tensloning the materlals as necessary for a proper configuratlon of the completed garment.
The foregoing speclfic ob~ects and advantages of the invention are illustrative of those which can be achieved by the present lnventlon and are not intended to be exhaustive or llmlting of the possible advantages whlch can be reallzed.
Thus, these and other ob~ects and advantages of the invention will be apparent from the descrlption hereln or can be learned from practicing the inventlon, both as embodied hereln or as modified in view of any varlations which may be apparent to those s~illed in the art. Accordingly, the present invention resldes in the novel parts, constructions, arrangements, combinations and lmprovements hereln shown and described.

Summary of the Inventlon The above-mentioned and other objectlve of the invention are met by a new and improved apparatus and a method accordlng to the present lnvention. In accordance with an aspect of the present invention, there is provided an apparatus for attaching 05085-2 YK:bw a pre-closed band to a garment workplece comprlslng: means for loading sald pre-closed band at sald apparatus; means for loading sald garment workplece at said apparatus; attaching means for attaching said pre-closed band to sald garment workplece; sald apparatus includlng a tensioning roller for exerting actlve tension and for ad~ustlng the tenslon exerted upon said pre-closed band and sald garment workpiece during attachment to sald garment workplece, said tenslonlng, roller engaglng both sald pre-closed band and sald garment workpiece to actively pull sald pre-closed band and said garment workplece durlng attachment by sald attaching means; an upper roller engaglng sald pre-closed band to keep said garment workplece and sald pre-closed band separated from one another during allgnment; and gulding means for guldlng and allgnlng said pre-closed band and sald garment workpiece through said attachment means.
In another aspect of this inventlon/ there ls provided an apparatus for attaching a pre-closed band to a garment workpiece comprising: means for loading said pre-closed band at said apparatus; means for loadlng sald garment workpiece at said apparatus; control means; attaching means for attaching said pre-closed band to sald garment workpiece; a tensioning roller for exerting active tenslon and for ad~ustlng the tension exerted upon said pre-closed band durlng attachment to sald garment workpiece, sald tensionlng roller engaglng both said pre-closed band and said garment workpiece to actively pull said pre-closed band and sald garment workplece to tenslon said pre-closed band and sald garment workplece durlng attachment of sald - 4a -05085-2 YK:~w 20~ 9~9 .

pre-closed band to said garment workpiece by said attaching means; at least one sensor for monitorlng said pre-closed band and sald garment workplece posltlons and slgnalling said positions to sald control means; guidlng means for guiding and aligning said pre-closed band and said garment workpiece through said attachment means ln response to signals for said control means7 and an upper roller engaglng sald pre-closed band to keep said garment workpiece and sald pre-closed band separated from one another durlng allgnment.
Yet in another aspect o~ thls lnventlon, there ls provided a method of attaching a pre-closed band to a garment workpiece lncludlng the steps of: continuously applying actlve tension to sald pre-closed band and said garment workpiece and ad~ustlng the tension exerted upon same by engaglng a tensioning roller to sald pre-closed band to pull sald pre-closed band and said garment workpiece during the attachment operation; sensing said pre-closed band and said garment workpiece positions7 aligning and gulding said pre-closed band and sald garment workpiece in response to said sensed positions while keeping said pre-closed band and said garment workpiece separated durlng allgnment; and attachlng sai~ tensioned and aligned pre-closed band to sald tensioned and aligned garment workpiece.
The preferred method of attachlng the elastic bands to the body of the garments includes sensing when the materlals are ln posltion, tensioning the materials, urging the materials through the sewlng machlne at the same tlme the materials are kept in tension and in thelr deslred - 4b -05085-2 YK:bw A~

. ~ 2046979 alignment, monltoring the allgnment and positlon of the materlals such that correctlons ln ~helr allgnment and posltlon may be made as deemed necessary, and automatically termlnatlng the sewlng process when the stltching ls completed.
In a preferred embodlment, the attachment apparatus lncludes a frame, sensors that can determlne when the elastlc band and the body of the garment are present, a guldlng mechanism that manoeuvres the edge of the garment and malntains the deslred alignment while the materials are attached to each other, a tensloning component that ensures the maintenance of the proper tension in the two materlals durlng the sewlng process, sensors that monlto~ the allgnment and posltlon of the workpieces such that their signal may be used to manoeuvre the workpieces to the desired positions, and a sewing machine that completes the attachment process.
It will be appreciated by those skllled ln the art that the foregolng brief descriptlon and the followlng detailed description are exemplary and explanatory of the invention, but are not intended to be restrictlve thereof or llmltlng of the advantages which can be achleved by the invention. Thus, the accompanying drawlngs, referred to herein and constituting a part hereof, lllustrate preferred embodlments of the lnvention and, together wlth the detailed descriptlon, serve to explaln the prlnciples of the lnvention.

Brlef Description of the Invention The above and other ob~ects, features and advantages of thls invention will be apparent from the following detailed 05085-2:YK/sdw - descrlptlon, especially when taken in con~unction wlth the accompanylng drawlngs, wherein:
FIG. 1 is a perspective view of an attachment apparatus accordlng to the lnvention and its elementæ;
FIG. 2 is a plane view of the elements of the apparatus that initially come lnto contact with an elastic band workpiece;
FIG. 3 ls a plane view of the elements of the apparatus that initially come into contact with a ga~ment body workpiece;
FI~. 4 is a plan view of an attachment apparatus according to the invention wlth elastic band and garment body workpieces;
FIG. 5 is a slde view of an attachment apparatus accordlng to the inventlon;
FIG. 5a is a top view of the top roller throw out seam sensor at the polnt when the start of stitchlng comes lnto contact wlth lt;
FIG. 5b 18 a top view of the conflguration of the garment, elastlc band and stitching when the stltchlng fl~st comes in contact with the end of sew sensing mechanism;
FIG. 5c is a top vlew of the end of sewlng sensing mechanism after the start of stitching has passed;
FIGS. 6a and 6b are portions ~f a tlming chart demonstratlng the sequence of actlvitles in the attachment process; and FIG. 7 is an lnterconnect diagram detailing the input~output of the attachment apparatus control system according to the in~ention.

Detailed Description of the Preferred Embodiments Referring to the drawings, a preferred em~odiment of the ,as~
05085-2:YK~sdw - 2~46979 attachment apparatus, according to the present inventlon, is lllustrated ln FIG. 1. In thls particular embodiment, frame 20 supports the attachment apparatus. Control system box 22 is secured to the lower, back portion of frame 20. Inslde control æystem box 22 are the central processing unit (~PU~ that activates and monltors the sewlng and manoeuvring operations.
The motor controls for the various moving components are also located ln control system box 22.
Sewin~ machine 24 is affixed to the top of frame 20. Sewing machine 24 ls electrically connected wlth the approprlate controls in control box 22.
Also electrlcally connected to the appropriate controls in control box 22 are the motors for the manipulatlng cylinder for top roller 28r for rear puller roller 34, and for tenslon roller carrlage 36.
End of sew proxlmlty sensor 58, top roller proximity sensor 56, coarse edge gulder sensor 44 and varlable home and selected position magnetic proximity sensors 72 are mechanlcally connected to the attachment apparatus at varlous locations and are electrlcally connected wlth control box 22. Each sensor produces a signal that is used to control various steps in the attachment process. Roller 25, roller 26 and tenslon roller 30 are also shown.
FIGS. 2 and 3 show a more detalled view of manoeuvring components in reference to the posltlon of elastic band 38 and garment body 40 after the two workpieces have been posltioned in the attachment apparatus, ~ust before the sewlng operatlon has begun. The operator manually loads elastic band 38 first, positioning band 38 against edge stop 54. It will be apparent 05085-2sYKtsdw - to one skllled in the art that the loadlng of elther elastic band 38 or garment body 40, or both may be accompllshed by a mechanical or automated means.
Elastic band 38 ls typlcally a pre-closed clrcular waistband, but may be the band of another plece of a garment (e.g. a collar, a wrist band) and need not be elastlc. The invention, however, ls deslgned to attach elastlc band to garments, a more dlfflcult sewing operatlon.
Elastic band 38 is situated such that it is under presser foot 42 of sewing machine 24 and over roller 25, roller 26, top roller 2B and tension roller 30. Roller 25, roller 26, top roller 28 and tension roller 30 rotate relative to the movement of elastlc band 38. Roller 25, roller 26, top roller 28 and tenslon roller 30 should be constructed of materlals approprlate to manoeuvre elastic band 38 without allowing slippage and without causlng undeslrable wear and tear on elastic band 38 during the sewing operations. The two long rollers (tension roller 30 and roller 26) should preferably have crowned sectlons to keep the elastic band on track. However, roller 25 ls preferably tapered wlth a hlgh frlctlon surface to prevent elastic band 38 from slipping until the tensionlng is completed.
The taper should force elastic band 38 on the wlder portlon of roller 25 ~oward the flxed edge stop 62, and away from the open edge of roller 25.
The portlon of garment body 40 on to which elastlc band 38 will be attached is manually sltuated (in this particular embodiment) over the coarse guider roller 32. Llke the other rollers, coarse gulder roller 32 should be of a material and slze approprlate for manoeuvrlng garment body 40 durlng the sewing 05085-2:YK~sdw operation ln the desired fashion. Moreover, the roller ls preferable smooth wlth low friction so that garment body 40 can move when responding to the edge aligning forces.
Garment body 40 is then routed under presser foot 42, located to cover coarse edge guider sensor 44 and fine edge gulder sensors 50 and then positloned over tension roller 30 and roller 26. Coarse edge gulder sensor 44 may be of such a type as that disclosed in U.S. Pat. No. 4,467,734, issued to Rohr on August 28, 1984. It monitors the alignment and produces a signal that may be used to make rough allgnment ad~ustments. On the other hand, flne edge guider sensor 50 may be of such a type as disclosed in U.S. Pat. No. 4,744,319, issued to Rohr on ~ay 17, 1988. It provldes the slgnal that controls, for lnstance, a flne alignment mechanism incorporated in the sewing head that maintains the edge of garment body 40 in a very precise location during sewing. Fine edge gulder sensor 50 may be, for example, a photo optlc sensor that reflects off an ob~ect above lt.
Although the sequence of positioning the two work-pleces over the rollers and under presser foot 42 may differ, the lnitial configuration, ln thls embodiment, is critical. That is, in the loaded, pre-sewn configuration, elastic band 38 should be under presser foot 42 and over roller 25, roller 26, tension roller 30 and top roller 28 while garment body 40 should be positioned under presser foot 42 and over coarse guider roller 32, roller 26, tension roller 30, fine edge guider sensor 50 and coarse edge guider sensor 44. The remainder of garment body 40, that which is not being attached to elastic band 38, should be t 05085-2 YK:bw ~ 20~6979 allowed to fall between the attachment apparatus and the operator.
End of sew proximity sensor 58 sits in between elastic band 38 and garment body 40 when the workpleces are loaded. ~nd of sew proximity sensor 58 has a flag 78 whlch 18 positioned above flne ed~e gulder sensor 50 until flag 78 ls moved by the stltch ~olning the workpieces (see discusslon of FIGS. 5b and 5c).
Under garment body 40, stepper motor 62 is positloned to move the alignlng feed dog ln response to the signal generated by fine edge guider sensor 50. Stepper motor 62 may be of the type, for example, dlsclosed ln U.S. Pat. No. 4,467,734. Feed dog 46 which helps urge the workpieces from one slde of presser foot 42 to the other may be of the kind, for example, disclosed in U.S. Pat. No.

4,744,319. Rear puller motor 64 is in posltion to rotate rear puller roller 34 when rear puller roller 34 ls lowered onto elastic band 38 and garment body 40 by rear puller llft cyllnder 68. Knife throw out cylinder 70 i8 poised to place the cutting knlfe in its normal operative position after elastic band 38 and garment body 40 are ln place.
FIGS. 4 and 5 show the main components of the attachment operation. ~IG. 4 includes garment body 40 and elastlc band 38 ln order to demonstrate a "loaded" conflguratlon. As garment body 40 ls posltloned over coarse gulder roller 32, flne edge guider sensor 50 and coarse edge gulder 44, sewlng process beglns. Followlng the se~uence programmed by the CPU, presser foot 42 ls lowered to compress elastlc band 38 and garment body 40. Rear puller roller 34 is posltloned by rear puller llft cyllnder 68 such that roller 34 ls ln contact wlth elastlc band 38 and garment body 40. Tenslon roller 30 descends ~r ~ - 10 -05085-2,YK~sdw to its pre-programmed position, movlng with tenslon roller carrlage 36 and monitored by varlable home and selected position magnetic proxlmlty sensors 72 (see FIG. 1), to tension both elastlc band 38 and garment body 40 to a pre-determined extent. Thereafter, sewlng machlne Z4 is started and rear puller 34 and feed dog 46 begin to urge the workpleces through sewing machlne 24. An example of a feed dog mechanism partlcularly applicable to this sewing process is taught in U.S. Pat. No. 4,g67,674 to Rohr et al. whlch ls entltled "Sewlng Machine For Sewlng On A Tape" and lssued November 6, 1990. FIG. 5 shows a slde vlew of the invention and some of its parts dlscussed above, including sewlng machine 24, roller 28, tension roller 30, tenslon roller carrlage 36, coarse guider roller 32, passer foot 42, roller 25 and roller 26.
As the movement of elastic band 38 and garment body 40 beglns, flne edge gulder sensor 50 and coarse edge gulder sensor 44 monitor the allgnment of the workpieces. These sensors send signals to control box 22 which uses the slgnals to determine the necessary manlpulations of the workpieces during the sewing-aligning-realignlng process.
FIG. 5a shows the operatlon of top roller throw out seam proximity sensor 56. As the start of the stitching 52 05085-2 YK:bw between elastlc band 38 and garment body 40 passes spring blased plvotlng le~er 76, stitchlng 52 moves lever 76 ln the dlrectlon of the workpieces' motlon. This movement actlvates top roller throw out seam proxlmity sensor 56 whlch sendæ a si~nal to the CPU. The CPU, in turn, sends a signal whlch causes top roller 28 to retract from beneath elastlc band 38. Althou~h coarse gulder roller 32 is also shut off, rear puller roller 34 and feed dog 46 contlnue to manoeuvre the workpleces through the sewing machlne and to urge the workpiece from one slde of presser foot 42 to the other.
FIGS. 5b and 5c show the operatlon of end of ~ew proxlmity sensor 58 a~ the tlme ~ust be~ore and after start of stitching 52 comes into contact wlth sensor 58. When start of stltchlng 52 pushes end of sew flag 78l end of sew proxlmlty sensor 58 sends a signal to the CPU. The signal ~nitiates the ~PU s stitch countlng process. After a pre-determlned stltch count has been generated, the sewing operatlon ls termlnated and all of the apparatus' mechanlsms and controls return to the inltlal, stand-by con~lguratlon. This return to lnltial settings includes the return of end of sew flag 78 to lts position out of the elastlc band 38 for easler loadlng of elastic band 38 by the use of flag throw out cyllnder 80.
The operator, or a mechanlcal means, may now unload the completed garment, and the apparatus ls ready for the next operatlon cycle.
The tlmlng of the automated actlvltles, in a preferred embodlment, is shown in the tlmlng chart illustrated in FIGS. 6a and 6b. The power up functlons, the systems that come on when the power ls turned on, lnclude a micro-computer that controls 05085-2:YK/sdw ~ 20~6979 an~ monitors the automated activities, and a dlsplay that provides a means for an operator to see the lnitlal settings, to see changes made ln the settings, and to monitor the programmed actlvities.
The automated activities begln when the end of sew sensor and the coarse gulder sensor are covered by the garment body.
The sewing start switch ls pressed. In additlon, the tensioning cyllnder value ls turned on while the stop value is turned of, whlch in combination lowers the tension roller (moving the carriage out and tensioning the workpieces). The tension cyllnder moves the roller downward untll the selected position proxlmity assoclated wlth the positioning sensors indicate that the tension roller is in its pre-determined posltion (which varles depending of the size of the garment).
Several automatlc sewlng functions are also commenced when the tension roller has reached the pre-determlned locatlon. The knife throw out cylinder, the flag throw out cylinder, the final seam proxlmity trlp switch (electrlcally connected to end o~ sew pivoting proximity sensor 58J see FIGS. 5b and 5c), and the venturi are all turned off. The knlfe throw out cyllnder moves the knife into its operable positlon durlng the sewing process.
It retracts the knlfe to a lower position after the sewing process is complete to make it easier to load the next workpieces. The flag throw out cyllnder moves the flag to lts normal position during the sewing process from a location away from the work area where the flag dld not lnhlbit the easy loading of the workpieces. The venturi is a vacuum which sucks the workpiece edge trimmings after the knife has cut the edge of the garment body.

05085-2 sYK~sdw .,~ .

Other automatlc sewing functions commence after the flrst set of automated actlvitles has ~egun. For instance, a pre-determined time after tension roller has been lowered, the belt puller cylinder is turned on while the presser foot llft cylinder ls turned off (i.e. the presser foot is lowered). After another pre-determlned delay, the synchronizer and the sewlng head motor begins to move the sewing needle in the motlon necessary to produce a seam that ~oins the elastic band to the garment body.
~In additlon, miscellaneous outputs produced during the sewing cycle such as those assoclated with the plvoting feed dog photocell, the pivoting feed dog stepper motor, the front feed roller photocell, and the micromoter drlven front gui~ance roller are generated slmultaneous wlth or very soon after the stitching beglns.) In a small interval of time after the stitchlng begins (e.g.
a pro~rammed duratlon e~uivalent to 0 m sec), the belt motor is turned on. After a pre-determined number of stltches (preferably 4 stltches), the front feed roller drive motor ls turned on and the workpieces begln to move.
The sewlng process is now in its programmed operation. This sewing operatlon continues untll the flrst seam proxlmity trlp swltch (electrically connected to top roller throw out seam proximity sensor 56, see FIG. 5a) ls turned off. Thls actlon ls slmultaneous with the terminatlon of the front feed roller photocell (in a covered configuration) output and the micromoter drlven front guldance rollers (in and off conflguratlon) output.
After the trip switch is turned off, the top roller pullout cylinder, which had been on since the power switch was turned on, ls automatically turned off, i.e. the top roller ls retracted.

.~
05085-Z:YK/sdw !~,, 2 0 4 6 9 7 9 (The first seam proxlmlty trip switch turns back on sometime after the top roller pullout cylinder has been turned off f returning the swltch to lts initial position.) Later, the flnal seam proxlmity trlp swltch ~electrlcally connected to end of sew pivotlng proxlmity sensor 58, see FIGS.
5a and 5b) ls turned on and off. When the switch is turned on, the stitch countlng routine commences, the plvoting feed dog photocell ~egins to output a constant covered signal, and the pivoting feed dog stepper motor begins to output a counter-clockwlse (CCW) slgnal.
The stitch bunching cyllnder is turned on at the same timethat the belt puller cyllnder is turned off a pre-determined number of stitches (e.g. 5 stitches) after the final seam proxlmity trlp switch has been turned on. After another pre-determined number of stltches (e.g. 12 stitches), the sewing head motor, the front feed roller driver motor and the belt puller motor are turned off, thereby terminating the stitchlng activity.
After the stitching has stopped, (1) the tension roller is ralsed, (2) the selected position proximity are in the uncovered mode, (3) the knife throw out cylinder is turned on, (4) the flag throw out cylinder is turned on, ~5) the final seam proximity trip swltch is turned on for the second time during this cycle, (~) the stitch bunching cylinder is turned off, (7) the venturi is turned on, (8) the presser foot lift cylinder is turned on (raising the presser foot), (9~ the pivoting feed dog photocell returns to its initial uncovered output mode, (10) the pivoting feed dog stepper motor returns to its initial clockwlse ~CW) mode, and (11) the front feed roller photocell returns to its initlal uncovered mode.

05085-2:YK/sdw When the tenslon roller carriage has returned to the lnitial positlon (the carriage has moved home and the tensioning cyllnder stop valve has been turned on), the top roller pullout cyllnder i8 turned off ~returnlng the top roller to the loadlng posltlon).
At such time, all of the system components and slgnals have been returned to thelr initlal status, the operator may remove the cornpleted ~arment and load the apparatus ln preparatlon for the next sewlng (attachment) operation.
The inputs and outputs of control box ~2 (see FIGS. 1 and 5) are shown ln FIG. 7. The lnputs to control box 22 lnclude inputs into the CPU such as sensor readlngs from position sensors, e.g. the feed dog sensor ~fine edge gulder sensor 48, see FIGS. 2 and 3) and the materlal present sensor ~e.g. coarse edge gulder sensor 44, see FIGS. 1, 2 and 3). Inputs also come from a slgnal from the synchronlzer (ln control box 22, see FIGS.
1 and 5), end o~ sew proximlty sensor 58 (see FIGS. 5b and Sc) and top roller proxlmity sensor 56 (see FIG. 5a). In addltion, the CPU receives a 220 volt, 60 hz signal (3 degree phase shlft), along wlt~ lnformatlon from the machlne operator s key pad box.
The output from the CPU come dlrectly from the CPU or indlrectly via way of a D.C. motor driver board or stepper motor drlver boards. The direct output goes to components that control such ltems as, for example, presser foot 42 (see FIGS. 2 and 3), the feet do~ sensor flag ~flne edge guider sensor 50), the knlfe (by manlpulating knlfe throw out cylinder 70, ~ee FIGS. 2 and 3), tension roller 30 (manipulated by tenslon roller carriage 36, see FIGS. 1, 4 and 5), the sewlng machlne motor (part of sewlng machlne 24, see FIGS. 1, 2, 3, 4 and 5), rear puller llft cyllnder 68 (see FI&S. 2, 3 and 4), and top roller 28 05085-2:YK/sdw ; . (manipulated by cyllnder 66, see FIGS. 1 and 5). The output from the stepper motor goes to rear roller motor 64 (see FIGS. 2, 3 and 4) and feed dog motor 74 (see FIGS. 2 and 3~ while D.C.
motors goes edge aligner motor and edge guider motor (which combined make up the stepper motor 62, see FIGS. 2 and 3~.
Although illustratlve preferred embodiments have thus been described herein ln detail, lt should be noted and will be appreclated by those skllled ln the art that numerous variatlons may be made wlthln the scope of thls lnvention wlthout departing from the principle of the invention and without sacriflcing lts chlef advantages. For example, the workpiece materials may be placed in thelr lnltlal posltlon in the apparatus by a mechanlcal means lnstead of the manual means presented ln thls disclosure.
The terms and expressions have been used as terms of descriptlon and not terms of llmitation. There is no intentlon to use the terms or expresslons to exclude any equlvalents of features shown and descrlbed or portions thereof and the inventlon should be defined in accordance wlth the clalms whlch follow.

~,, 05085-2:YK~sdw

Claims (9)

1. An apparatus for attaching a pre-closed band to a garment workpiece comprising:
means for loading said pre-closed band at said apparatus;
means for loading said garment workpiece at said apparatus;
attaching means for attaching said pre-closed band to said garment workpiece;
said apparatus including a tensioning roller for exerting active tension and for adjusting the tension exerted upon said pre-closed band and said garment workpiece during attachment to said garment workpiece, said tensioning, roller engaging both said pre-closed band and said garment workpiece to actively pull said pre-closed band and said garment workpiece during attachment by said attaching means;
an upper roller engaging said pre-closed band to keep said garment workpiece and said pre-closed band separated from one another during alignment; and guiding means for guiding and aligning said pre-closed band and said garment workpiece through said attachment means.

2. An apparatus according to claim 1 including a sensor means for sensing an edge of said garment workpiece.

3. An apparatus according to claim 2 wherein said sensor means comprises a coarse edge guider sensor and a fine edge guider sensor.

4. An apparatus according to claim 2 wherein said guiding means including a feed dog mechanism for maneuvering said pre-closed band and said garment workpiece through said attaching means and for maintaining said edge of said garment workpiece in proper alignment.

5. An apparatus according to claim 1 wherein said guiding means includes at least one roller configured to transport and align said pre-closed band and said garment workpiece.

6. An apparatus according to claim 2 wherein said attaching means is a sewing machine.

7. An apparatus for attaching a pre-closed band to a garment workpiece comprising:
means for loading said pre-closed band at said apparatus;
means for loading said garment workpiece at said apparatus;
control means;
attaching means for attaching said pre-closed band to said garment workpiece;
a tensioning roller for exerting active tension and for adjusting the tension exerted upon said pre-closed band during attachment to said garment workpiece, said tensioning roller engaging both said pre-closed band and said garment workpiece to actively pull said pre-closed band and said garment workpiece to tension said pre-closed band and said garment workpiece during attachment of said pre-closed band to said garment workpiece by said attaching means;

at least one sensor for monitoring said pre-closed band and said garment workpiece positions and signalling said positions to said control means;
guiding means for guiding and aligning said pre-closed band and said garment workpiece through said attachment means in response to signals for said control means; and an upper roller engaging said pre-closed band to keep said garment workpiece and said pre-closed band separated from one another during alignment.

8. An apparatus according to claim 7 wherein said attaching means is a sewing machine.

9. A method of attaching a pre-closed band to a garment workpiece including the steps of continuously applying active tension to said pre-closed band and said garment workpiece and adjusting the tension exerted upon same by engaging a tensioning roller to said pre-closed band to pull said pre-closed band and said garment workpiece during the attachment operation;
sensing said pre-closed band and said garment workpiece positions;
aligning and guiding said pre-closed band and said garment workpiece in response to said sensed positions while keeping said pre-closed band and said garment workpiece separated during alignment; and attaching said tensioned and aligned pre-closed band to said tensioned and aligned garment workpiece.