РАЗРАБОТКА ФУНКЦИОНАЛЬНЫХ АЛГОРИТМОВ ПРОЕКТИРОВАНИЯ АВТОМАТИЗИРОВАННЫХ ЛИНИЙ ШВЕЙНЫХ ПРЕДПРИЯТИЙ

УДК 687.02:658.512.2:004.94

Abstract

The article discusses the development of functional algorithms for designing automated sewing lines, taking into account the overall dimensions of equipment and the efficient use of production space. An analysis of automated production lines developed by “Durkopp Adler” was carried out, and their characteristics and productivity were studied. It was established that machine productivity depends on the complexity of technological operations. A methodological approach is proposed, including mathematical modeling, optimization, and integration with information systems, and a design algorithm for automated lines has been developed. A method for forecasting knitted fabric consumption is presented to improve the accuracy of cost estimation.

Аннотация

В статье рассматривается разработка функциональных алгоритмов проектирования автоматизированных швейных линий с учётом габаритных размеров оборудования и эффективного использования производственных площадей. Проведён анализ автоматизированных производственных линий, разработанных компанией «Durkopp Adler», изучены их конструктивные характеристики и показатели производительности. Установлено, что производительность оборудования зависит от сложности выполняемых технологических операций. Предложен методический подход, включающий математическое моделирование, оптимизацию и интеграцию с информационными системами, а также разработан алгоритм проектирования автоматизированных линий. Представлен метод прогнозирования расхода трикотажного полотна, позволяющий повысить точность расчёта себестоимости продукции.

Keywords: technological processes of garment manufacturing, automated lines, productivity of automatic machines, algorithm, database.

Ключевые слова: технологические процессы швейного производства, автоматизированные линии, производительность автоматов, алгоритм, база данных.

Introduction

In the garment industry, the demand for automated systems that ensure efficiency, accuracy, and cost-effectiveness of production processes is steadily increasing. During the design process, in addition to improving functionality and productivity at enterprises, the issue of considering the overall dimensions of equipment arises when creating automated lines with software control.

The overall dimensions of automated machines play a key role in the design of automated lines. The RDB system machine of the 806 N-111 model produced by the company “Durkopp Adler” (Germany) has the following overall dimensions: length – 2300 mm, width – 1750 mm, height – 1750 mm. These dimensions determine the available floor space required for placing the machine, as well as the requirements for transporting and installing production lines.

Considering the need to optimize the use of limited space in production facilities, designers must strive to minimize the overall dimensions of the lines. Specialists involved in developing automated lines use various technological solutions to reduce dimensions and increase compactness. These include minimizing the number of operations, using unified components in garment models, and optimizing mechanisms and storage systems.

An example of successfully developing automated lines with consideration of overall dimensions is the integration of compact systems capable of performing multiple operations within a limited production area (Figure 1).

Methodological part

Automated production lines are typically designed with flexibility in mind, taking into account the needs of various customers and the changing requirements of product assortment. Such lines can be quickly adjusted to produce different types of garments and accommodate varying production volumes.

The development of production lines for machines with program control, while considering their overall dimensions, requires a comprehensive approach and innovative solutions. Automated production lines represent a modern and efficient solution for garment enterprises striving to improve productivity, quality, and competitiveness of their products [1,2,3].

Results and discussion

An analysis was carried out on automated production lines of the company “Durkopp Adler” designed for manufacturing men’s garments, including jackets, trousers, shirts, and denim clothing. The task was set to compile data on the functions, structural design, geometric dimensions, and productivity parameters of machines equipped with digital program control systems.

Initially, the productivity of automated lines for manufacturing men’s jackets by “Durkopp Adler” was analyzed over one work shift (450 minutes). In the automated line, the program-controlled machine of model 176-141621, intended for joining the back and front parts of a jacket, processes an average of 350 garment components within 8 hours.

According to the analysis results, the program-controlled machine model 745-35-10A demonstrated the highest productivity, processing up to 3,900 outer and inner pockets during a shift. The 745-35-10B machine, also designed for processing outer and inner pockets, handles about 2,400 pockets within 8 hours.

The Beisler 2111-5 machine is intended for processing small parts of a jacket and processes approximately 2,200 small components in 450 minutes.

Relatively low productivity was observed in the 650-10 OP 3000 machine, which is designed for setting sleeves into armholes, producing about 175 jacket sleeves in 8 hours (Figure 1).

Figure 1. Productivity of the automated production line by “Durkopp Adler” designed for manufacturing men’s jackets

The productivity of program-controlled machines is directly related to the complexity of the technological operation. In designing automated production lines, the types and number of machines are determined based on the workshop’s shift production capacity. For example, if the shift production capacity is  units, it is necessary to install 6 units of the 650-10 OP 3000 program-controlled machine in the line.

The analysis results show that when designing automated lines in garment enterprises, it is important to determine the daily production capacity based on the hourly productivity of each machine, ensure proper placement of automated units, define the exact number of machines required for producing men’s jackets, and establish production standards.

An analysis was also conducted on automated lines of “Durkopp Adler” designed for the production of men’s trousers. In the automated line, the program-controlled machine model 171-131610E208/0.4 intended for joining the front and back parts of trousers, processes an average of 700 garment components in 8 hours.

According to the analysis, the highest productivity was demonstrated by the Beisler 743-121-01/221-01 program-controlled machine, which processes up to 6,225 trouser darts in one shift. The 173-141610 (550-2-2) machine, designed for fly processing, handles about 4,000 units per shift. The Beisler 2111-5 machine is used for automatically folding the edge of a facing and stitching it onto a pocket bag, with a productivity of about 3,900 parts per shift [4,5].

Relatively lower productivity was observed in the 275-740642-01 and 176-141621 machines, intended for processing the trouser waistband, which process about 425 parts in 8 hours.

An analysis was conducted of automated production lines by “Durkopp Adler” designed for manufacturing men’s shirts. In the automated line, the program-controlled machine model 173-141610 (550-15-5), intended for sewing shirt cuffs, processes an average of 1,000 garment components in 8 hours.

According to the analysis results, the highest productivity was demonstrated by the program-controlled machine model 971-01, which processes up to 5,000 cuff components during one shift (Figure 2). The program-controlled machine model 806N-121-01, designed for pocket processing, handles about 2,400 pockets per shift. The Beisler 739-23-1 machine is intended for sewing cuff plackets, with a productivity of approximately 1,700 parts per shift [6,7,8].

Relatively low productivity is observed in operations that require more time, such as setting shirt sleeves into armholes. The 272-140342-01E75/N471 machine, designed for this process, handles about 200 components in 8 hours.

Based on the analysis results, a productivity diagram of the automated production line for men’s shirts was developed. An analysis was also conducted on automated lines by “Durkopp Adler” designed for the production of denim garments. In the automated line, the program-controlled machine model 261-160362, intended for joining the front and back parts of denim garments, processes an average of 720 garment components in 8 hours.

Based on the analysis results, a productivity diagram of the automated production line for men’s denim garments was developed.

When designing technological processes, it is necessary to determine the dimensions of each program-controlled machine, wet-heating processing equipment, automated stacking stations, and auxiliary tables. For this reason, during the study, the structure and geometric parameters of the machines were identified.

During the analysis, complete information on the functions, structural design, and geometric dimensions of program-controlled machines in the RDB system was compiled. This information serves as the primary reference for the correct placement of machines in automated lines and for determining line length.

The development of functional algorithms includes several key stages:

Mathematical modeling of the production process — constructing formalized models of sewing operations that include parameters such as time, costs, operation sequences, and interactions between automated devices. These models allow for forecasting production performance and identifying bottlenecks in the line before its physical implementation.

Algorithmic optimization — creating procedures and rules that ensure efficient resource allocation, workload balancing between line sections, and minimization of

equipment downtime. Methods such as linear and nonlinear programming, heuristic algorithms, and simulation modeling are applied for this purpose (Figure 2).

Integration with information and control systems — implementing algorithms into software complexes that provide automatic monitoring of line operation, data collection, and adjustment of operating modes in real time. This increases production adaptability to changing conditions and maintains consistent product quality.

Figure 2.  Digital programmable control system automated line design algorithm

Conclusion

The developed algorithms show the procedure for calculating material consumption at the technical sketch stage for new models and for designing automated production lines. This study examines the development of functional algorithms for designing automated production lines in sewing workshops of garment enterprises. The proposed approach focuses on optimizing technological processes, improving workflow coordination, and integrating digital control systems.

The results demonstrate that the implementation of automated systems contributes to stable product quality and increased competitiveness of garment enterprises. Further research may focus on integrating these algorithms with advanced intelligent control systems and artificial intelligence technologies.

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