Technical Field

The invention relates to the production of bags made of polyethylene (PE) and polypropylene (PP), woven or non-woven fabrics, technical or non-technical fabrics, raw clothing and other different fabrics.

In particular, the invention relates to a garment-sewn automated production system and method for all fabrics which can or cannot be combined by a different combining method, which enables a high reduction of wastes in bag or sack manufacturing.

Present State of the Art

Plastic carrying bags and sacks, plastic pochettes in other words, have been used in many different sectors for many years and are consumed in very high quantities. While the time required for the deterioration of the plastic pochettes with a occupancy of 12-15 minutes per day is 400 to 1000 years at sea, 800 to 1000 years on land. During this deterioration, all the harmful materials contained in it pass into the soil and water. Plastic pochettes must therefore be disposed. During the disposal of plastic pochettes, many harmful gases are released and this situation causes harm to the environment as well as the use of pochettes. In addition, transparent ones of these disposed pochettes absorb the heat by causing greenhouse effect and cause forest fires. Under the influence of light, plastic pochettes turn into more toxic small petro-polymers. This causes many generations to be negatively affected.

In addition to all these, plastic pochettes left to nature cause the animals to try to consume them thinking as food and cause their death due to disruption of the digestive systems and cause the ecological balance to be disrupted. It is also known that especially black plastic pochettes are obtained from garbage and thus are more harmful. Black pochettes are offered to consumers by separating materials such as buckets, pet bottles and medical waste from the garbage and staining them to black to hide their defects. Because of the widespread use of plastic pochettes and their harm to human and environment are known, bags and sacks made of recyclable materials and textile fabrics that protect the environment and support sustainable production are now used. Recycling can mainly be explained by bringing the recyclable wastes out of use to production as raw materials by various methods. By providing recycling, raw material needs can be reduced, harm to nature and human health is prevented and consumption can be balanced. In addition, the use of recyclable materials as raw materials contributes to the limited consumption of consumable energy resources by saving energy. The recycling process is also of great importance for the prevention of environmental pollution.

Today, as an alternative to plastic carrying bags and sacks for supporting recycling, protecting the environment and sustainable production, bags and sacks obtained from non-woven technical fabrics or textile surfaces are used. The use of non-woven technical fabrics such as bags and sacks is becoming increasingly common. Garment sewing products are widely used in the production of bags and sacks made of non-woven technical fabric and the production of this type of products is mostly achieved by manual processes. In this direction, the pieces are cut from the fabric from which the bag will be manufactured according to the desired bag size in the dimensions determined by the molds and these pieces are sewn manually in the garment sewing machines. Then, the handles are also adapted to the bag by hand sewing or by machine with garment sewing. Therefore, a production performed in this way creates a waste of time, increases production costs and can affect the quality standard according to the skill of the person performing the garment sewing process due to the resulting high rate of wastes.

In order to provide production without wastage and to realize faster production by reducing production costs, the automated manufacturing system mentioned in the application No 2016/14354 can be mentioned. This manufacturing system basically refers to a manufacturing system in which fabrics are combined by ultrasonic welding technique. Although the manufacturing system provides an increase in production speeds by minimizing the formation of wastes, it does not have a suitable structure for combining with garment sewing.

As a result, due to the above-mentioned negativities and the inadequacy of the existing solutions on the issue, a development in the related technical field was required. Brief Description of the Invention

The present invention relates to a production system and method with garment sewing and automation of obtaining a carrying bag from woven or non-woven, technical or non technical fabrics, raw clothing or other fabrics made of polypropylene (PP) and polyethylene (PE) that meet the above-mentioned requirements, eliminate all disadvantages and bring some additional advantages.

The primary object of the present invention is to provide a bag manufacturing system and method which enables the production of bag products produced by machine sewing or hand sewing through an automation.

An object of the invention is to provide a production system and method which reduces the production time and costs of bag and sack manufacturing processes.

Another object of the invention is to provide the production of bags with garment sewing from all fabrics which can be combined or not combined by different combining technique.

Another object of the invention is to provide a bag manufacturing system and method using garment sewing.

Another object of the invention is to provide a mass production system and method to produce standard quality products which enables non-standard production to be prevented.

A similar object of the invention to provide a production system and method that provides for improved process stability.

Another similar object of the invention is to provide a production system and method which enables the minimization of wastes during production.

In order to achieve the purposes disclosed above, the invention relates to a production system for the production of bags or sacks of woven or nonwoven, technical or non technical fabrics made of polypropylene (PP) or polyethylene (PE). The present invention according to the invention comprises of an input unit where the fabric roll is placed, an edge folding and sewing station which allows the two sides of the fabric to be folded together with the garment sewing, the handle preparation and fitting station which enables the fitting of the carrying handles adjusted to the desired size to the bag with the garment sewing, the first sensing photocell and the first puller driving mechanism which determines the place to be fitted, the folding unit which makes the folding points clearer, the folding station which ensures the overlap of the two edges of the fabric, the length adjustment station where the length garment sewing point of the bag is adjusted, a sewing station for sewing one side of each of the two bags respectively with a garment sewing, a second puller drive mechanism, cutting station, transfer conveyor, which drives the bags sewn by the garment sewing to the cutting unit, a bellowing station in which the side bellows and the bottom bellows are opened according to the desired bag size in order to give the bag shaped and coming from the cutting unit to which the handles are combined to a triangular structure, triangular cutting and sewing station that cuts the paddles in the form of triangles formed in the lower two corners of the bag to form the bellows, a bellows folding station for folding inwardly from the side and bottom bellows surfaces of the formed bag and an ironing and stacking station through which the bags are conveyed to maintain the form of the resulting bag and reduce the volume during the stacking step.

The structural and characteristic features and all advantages of the invention will become more apparent from the following figures and the detailed description made with reference to these figures, and therefore the evaluation should be made considering these figures and detailed description.

Figures to Help Understand the Invention

Figure 1 is a general schematic view of the production system according to the invention.

Figure 2 is a detailed view of the production system according to the invention.

Figure 3 is another detailed view of the production system according to the invention.

The drawings do not necessarily have to be scaled and details which are not necessary to understand the present invention may be omitted. Over and above this, elements which are at least substantially identical or at least with substantially identical functions are designated by the same number.

Description of References 10 Production System

1 1 Input Unit

1 1 1 Roll Loading Station

1 12 Brake Mechanism

12 Edge Folding and Sewing Station

13 Handle Preparation and Fitting Station

14 First Puller Drive Mechanism

141 First Sensor Photocell

142 First Carrier Mechanism

15 Forming Unit

151 Pleating Unit

152 Folding Station

153 Second Sensor Photocell

154 Second Carrier Mechanism

16 Length Sewing Station

17 Second Puller Drive Mechanism

18 Length Cutting Unit

19 T ransfer Conveyor

20 Bellowing Station

21 Triangle Cutting and Sewing Station

22 Bellow Folding Station

23 Ironing and Stacking Station

Detailed Description of the Invention

In this detailed description, the bellow fabric bag production system (10) and method with the garment sewing of the present invention are explained only for a better understanding of the subject and with no limiting effect.

Referring to Fig. 1 , the automation production system (10), which is schematically illustrated basically comprises of an input unit (1 1 ), an edge folding and sewing station

(12) provided continuation of said input unit (1 1 ), a handle preparation and fitting station

(13) provided behind said edge folding and sewing station (12), the first sensor photocell (141 ) and the first puller driving mechanism (14) located in the continuation of said handle preparation and fitting station (13), a forming unit (15) behind the first puller driving mechanism (14) and in the continuation of said forming unit (15) respectively a length sewing station (16), a second puller drive mechanism (17), a length cutting unit (18), a transfer conveyor (19), a bellowing station (20), a triangular cutting and sewing station (21 ), a bellow folding station (22), and an ironing and stacking station (23).

The said input unit (1 1 ) comprises a roll loading station (1 1 1 ) and a brake mechanism (1 12) provided in the continuation of said roll loading station (1 1 1 ). The First Puller Drive Mechanism (14) comprises a first sensor photocell (141 ) and a first carrier mechanism (142) provided in the continuation of said first sensor photocell (141 ). The forming unit (15) comprises a pleating unit (151 ), a folding station (152), a second sensor photocell (153) and a second carrier mechanism (154). A length adjuster unit is also provided within said length sewing station (16).

In the production system (10) according to the invention, the production of the bag or sack is initiated by placing the fabric that forming the bag in roll in the loading unit (1 1 1 ) in the input unit (1 1 ). The fabric in the fabric roll may also be woven or non-woven technical or non-technical fabrics, preferably made of polypropylene (PP) or polyethylene (PE). The fabric loaded in the roll loading station (1 1 1 ) is then directed to the edge folding and sewing station (12) by means of the brake mechanisms (1 12). The brake mechanisms (1 12) adjust the tension of the fabric to ensure that it is always fed at the same tension before entering the combining process with the garment sewing. At the edge folding and sewing station (12) there are sewing heads which perform the garment sewing. At the edge folding and sewing station (12), the edges of the fabric to be fitted to the handle are folded and combined with the garment sewing. In other words, the mouth sewing of the bag or sack with garment sewing is performed. The purpose of this is to ensure that the edges to be handled are secured. After the edge folding and sewing operations, it is provided to fit a handle on the folded edge. The first sensor photocell (141 ) is used to determine the position of the handles before the handles are fitted. Handle fitting is made with garment sewing with the sewing heads in the handle preparation and fitting station

(13). The garment sewing is applied at this stage can be in the form of straight seam or cross seam. Handles can be fitted in desired lengths. Fitting of the handles is carried out when the fabric forming the bag is in the open state. After the handles are fitted to the folded edges by garment stitching, the fabric is pulled by the first puller drive mechanism

(14) and transmitted to the forming unit (15). The fabric which comes to the forming unit (15) is folded and the handles of which are fitted to the folded edges are first taken to the pleating unit (151 ) and folding traces are provided from the bag in accordance with the desired model (bellows etc.). Then, at the folding station (152), the two sides of the bag forming the mouth part are folded so as to overlap/to the brim. In the folding process performed at the folding station (152), the second sensor photocell (153) is used to bring the fabrics to the brim. Following the completion of the mouth folding process, the bag is guided to the length sewing station (16) by the rollers in the second carrier mechanism (154).

In the length sewing station (16), first of all, the position of the side garment sewing of the bag is set in the length adjuster unit (161 ). Then length sewing is done. Length sewing process is provided with sewing heads that perform garment sewing. The length of the bag is the distance from the mouth to the bottom, which means height of the bag. The bag, whose length sewing is also completed, proceeds to the length cutting unit (18) by means of the rollers in the second puller drive mechanism (17), where the cutting process of the bag is performed. Obtained bag is transferred to the transfer conveyor (19). The transfer conveyor (19) ensures that the bag exiting from the length cutting unit (18) is centered on said bellowing station (20). For this purpose, the transfer conveyor (19) is preferably servo-motor controlled.

There are holder tips and opener sleeves at bellowing station (20). The holder tips allow the bag to be opened from the mouth and hold the bag from the length junction of the bag in order to maintain the position of the bag during the bellowing process. Opener sleeves enter into the bag from the mouth of the bag. Opener sleeves are preferably positioned automatically with servo motor drive according to the size of the bag to be made. When entering into the bag, the opener sleeves in the closed position are opened with a scissor angle at the width of the bellows desired to be formed at the bottom of the bag moving both horizontally and vertically in the bag. Thus, triangular paddles are formed on the bottom of the bag and the bag becomes three-dimensional.

In the triangular cutting and sewing station (21 ), the paddles formed on the bottom of the bag are held in the position of the moving sewing unit and fixed by garment sewing while the opener sleeves are still in the open position and mechanically cut. At the triangular cutting and sewing station (21 ) there is a sewing head which applies garment sewing. The bag of which the paddles are cut comes to the bellow folding station (22). Flere, the bag which the bellows are formed is folded into the interior of the bag by guides moving inwardly from the side and bottom bellow surfaces. Following the completion of the bellow folding process, the bags are directed to the ironing and stacking station (23) to maintain the form of the bag and to reduce its volume during the stacking step. At the ironing and stacking station (23), the bags are preferably passed between the press and heat applying rollers.

The production system (10) used in the production of bellow bags or sacks with garment sewing is operated and controlled by an automation system. Thus, the bag within the compass of the production system (10), can be obtained without leaving the production line and as a result of mass production. In addition to this, wastes occur during cut of sack or bag material or handle installation with manual garment processes are prevented. In addition, all of the processes are provided within the automation system, so that possible time losses can be avoided, production costs are reduced and standardization of all products is provided.