Application of smart system to textile industry: Preliminary design of a smart hanger for garment inspection

Abstract

A smart inspection system, comprising three components, namely a smart hanger, a stitching-workmanship defect classification unit as well as a shade variation detection unit, is introduced for the textile industry. The preliminary design and optimization results of the smart hanger which stretches garments to provide enough tension to facilitate the inspection are presented. The hanger, with a Proportional and Derivative (PD) controller, is modeled as a four-link robot consisting of three revolute joints and one prismatic joint. The design objectives include (1) maximizing the link portions within “effective regions” at the final state, (2) minimizing the force or torque required to finish the stretching process, and (3) minimizing the settling time of the stretching process. In addition to control gains, the lengths of the four links as well as the desired movements of the joints are taken as design variables. The required transient behavior of the hanger is defined by the constraints on settling time and maximum overshoot. In order to prevent the clothes from being damaged by the links during the stretching process, geometrical constraints are imposed on the motions of the links. Optimization results, obtained by using the multi-objective genetic algorithm (MOGA), are presented in the form of Pareto solutions. After analysis, optimal parameters are selected and computer simulations are performed to investigate the transient behavior of the hanger. Satisfactory results are obtained, which provide a good foundation for the on going development of the smart inspection system.