Abstract
A method and a system for manufacturing footwear. The footwear including at least two footwear parts. The footwear parts are at least partly connected together by stitching for forming at least part of an upper part of the footwear. The method includes providing a base layer and providing the at least two footwear parts. The at least two footwear parts are positioned on the base layer. The at least two footwear parts are fixated on the base layer in respective relative positions corresponding to predefined connected positions. The at least two footwear parts are connected with each other by an automated stitching. The at least two footwear parts in connected form to provide the footwear.
Claims
1. A method of manufacturing footwear, said footwear comprising at least two footwear parts, which are shoe parts, and which footwear parts are at least partly connected together by stitching for forming at least part of an upper part of said footwear, said method comprising: providing a base layer, providing said at least two footwear parts and positioning said at least two footwear parts on said base layer, fixating said at least two footwear parts on said base layer in respective relative positions corresponding to predefined connected positions, connecting said at least two footwear parts with each other by an automated stitching, and processing the at least two footwear parts in connected form to provide said footwear.
2. The method according to claim 1, wherein at least one of said at least two footwear parts is a leather footwear part.
3. The method according to claim 1, further comprising: providing a fixture for said base layer; and arranging the base layer to be held by said fixture.
4. The method according to claim 1, wherein a reference is provided for positioning said at least two footwear parts on said base layer.
5. (canceled)
6. The method according to claim 1, wherein said fixating said at least two footwear parts on said base layer in respective positions comprises adhering the at least two shoe parts on said base layer with an adhesive.
7. The method according to claim 6, wherein said adhesive is provided as a non-activated adhesive on said base layer, which is activated when fixating the at least two footwear parts on the base layer.
8.-9. (canceled)
10. The method according to claim 1, wherein the positioning of said at least two footwear parts on said base layer is performed by a robotic pick and place apparatus by sequentially picking each shoe part and placing each shoe part on the base layer at a predefined position.
11. (canceled)
12. The method according to claim 1, wherein the positioning of said at least two footwear parts on said base layer is performed using input from a visual detection system including using a camera or a vision system.
13. (canceled)
14. The method according to claim 1, wherein said at least two footwear parts subsequent to being positioned on said base layer, are transportable by moving said base layer.
15. (canceled)
16. The method according to claim 1, wherein an identifier is provided for identifying at least one of the base layer, the fixture, and at least one of the at least two footwear parts.
17. The method according to claim 1, wherein the automated stitching includes stitching at least part of one of said at least two footwear parts to the base layer.
18. (canceled)
19. The method according to claim 1, wherein the base layer is a lining of the footwear.
20.-25. (canceled)
26. A system for manufacturing footwear, said footwear comprising at least two footwear parts, which are shoe parts, and which footwear parts are at least partly connected together by stitching for forming at least part of an upper part of said footwear, said system comprising: a base layer holding device configured for holding a base layer, a positioning device for positioning at least two footwear parts on said base layer, an adhering activating device configured for fixating said at least two footwear parts on said base layer in respective relative positions, an automated stitching device configured for connecting said at least two footwear parts with each other, and at least a further processing device for facilitating further processing of the at least two footwear parts in connected form to provide said footwear.
27. (canceled)
28. The system according to claim 26, wherein said base layer holding device configured for holding said base layer is a fixture.
29. The system according to claim 28, wherein said fixture comprises conveyance arrangements configured for transport of said fixture.
30. The system according to claim 26, wherein said positioning device comprises a robotic apparatus including a robotic pick and place apparatus.
31. The system according to claim 26, wherein said positioning device comprises a visual detection system including one or more of a camera or a vision system.
32. The system according to claim 26, wherein said adhering activating device configured for fixating said at least two footwear parts on said base layer in respective relative positions comprises an arrangement for activating non-activated adhesive using at least one of friction, pressure, ultrasonic radiation, infrared radiation, or heat transfer.
33.-40. (canceled)
41. The system according to claim 30, wherein said robotic pick and place apparatus comprises a vacuum gripper.
42.-46. (canceled)
47. The system according to claim 26, wherein an identifier is provided for identifying at least one of the base layer, a fixture, and at least one of the at least two footwear parts.
48.-51. (canceled)
Description
THE FIGURES
[0144] The invention will be explained in further detail below with reference to the figures of which
[0145] FIG. 1 illustrates an exemplary footwear manufactured according to an embodiment of the invention,
[0146] FIG. 2a illustrates a top view of an exemplary vamp with a toe cap and facing according to an embodiment of the invention,
[0147] FIG. 2b illustrates a top view of an exemplary vamp with a toe cap, facing and quarter according to another embodiment of the invention
[0148] FIGS. 3a-c illustrate in perspective views an exemplary base layer, whereon footwear parts such as vamp and toe cap are positioned according to various embodiments of the invention,
[0149] FIG. 3d illustrates the connected footwear upper parts as shown in FIG. 3b being folded into a 3D upper,
[0150] FIGS. 4a-4d illustrate in perspective views an example of initial or preparatory steps of an automatic stitching method according to an embodiment of the invention,
[0151] FIG. 5a illustrates an outlay seen from above of a module-based manufacturing line according to an embodiment of the invention,
[0152] FIG. 5b illustrates a further outlay seen from above of a module-based manufacturing line according to an embodiment of the invention,
[0153] FIG. 6 is a schematic enlarged view of an example of a workstation for gripping a footwear part and placing it at a specific location at/on a base layer, seen from above,
[0154] FIG. 7 is a schematic enlarged view of an example of a workstation for automated stitching of an assembly of footwear parts at/on a base layer, seen from above,
[0155] FIG. 8 illustrates an outlay seen from above of a module-based manufacturing line in continuation according to an embodiment of the invention,
[0156] FIG. 9 illustrates a further example of an outlay seen from above of a module-based manufacturing line according to an embodiment of the invention, and
[0157] FIG. 10 illustrates a still further example of an outlay seen from above of a module-based manufacturing line according to an embodiment of the invention, where further operation processes for manufacturing a piece of footwear are illustrated.
DETAILED DESCRIPTION
[0158] FIG. 1 illustrates an exemplary footwear which may be made within the scope of the invention. The exemplified footwear is a shoe 10 comprising an upper 11 wherein the upper 11 comprises footwear defining parts. The footwear defining parts are exemplified with a vamp 60 located as the section of the upper that covers the front of the foot as far back as the join of the quarter; a tongue 13 defined as a strip of material located under the laces of a shoe. The tongue may sit on the top center part of the shoe on top of the bridge of the foot and may be attached to the vamp 60; quarter 14 located on the rear and sides of the upper that covers the heel that are behind the vamp. The heel section of the quarter 14 may be strengthened with a stiffener, which helps support the rear of the foot. Further, a toe cap 62 wherein toe caps can take various forms, but types may be complete replacements for the front upper of the shoe; stitched over toecaps that add an extra layer to the upper; solid toe caps for protection, such as steel toe caps. Stitch over toe caps may be decorative in nature. Also, an outer counter 17 located at the heel of the shoe as a stiff piece of material positioned between the lining and upper that helps maintain the shape of the shoe, eyelets 18 as the holes for shoelaces and facing 19 being the part of the shoe where the shoelace eyelets are located.
[0159] The illustrated shoe 10 may preferably comprise a lining 30 on the inner side of the quarter.
[0160] The illustrated shoe parts may preferably be attached to a sole 16 e.g. by adhesion, gluing, stitching, injection molding or any relevant methods of attaching a sole. The sole may comprise several parts and layers e.g. inner sole 20, mid-sole (not shown) and outer sole 16.
[0161] The shoe may of course comprise other not-shown features and parts and the shapes and configuration of the parts may be different. Most shoes may comprise more than 15 or 20 shoe defining parts.
[0162] FIG. 2a illustrates a top view of parts of an upper e.g. of the shoe of FIG. 1, comprising a vamp 60, a toe cap 62 and facing 19 made within the scope of the invention. The vamp 60 and toe cap 62 are assembled by fitting the toe cap 62 on top of the vamp 60 as illustrated and then attached together. The vamp and facing are in the same way assembled by fitting the facing 19 on top of the vamp 60 as illustrated and then attached to each other.
[0163] The attachment of the leather pieces may be mediated by adhesion e.g. glue or any suitable adhesions but may also be a more lose attachment or they may only be loosely assembled to each other.
[0164] The leather pieces may then be sewed together as illustrated with a stitching line 22 by the method according to the invention. Stitching methods applied may be any methods relevant for stitching shoes.
[0165] FIG. 2b illustrates in a similar manner a top view of parts of an upper e.g. of the shoe of FIG. 1, where the parts comprise a vamp 60, a toe cap 62, a facing 19 and a quarter 14 made within the scope of the invention. The vamp 60 and toe cap 62 are assembled by fitting the toe cap 62 on top of the vamp 60 as illustrated and then attached together. The vamp and facing are in the same way assembled by fitting the facing 19 on top of the vamp 60 as illustrated and then attached to each other.
[0166] The quarter 14 and the vamp 60 are in the same way assembled by fitting the quarter 14 on top of the vamp 60 at one side of the vamp as illustrated and then attached to each other.
[0167] The attachment of the leather pieces may be mediated by adhesion e.g. glue or any suitable adhesions but may also be a more lose attachment or they may only be loosely assembled to each other.
[0168] The leather pieces may then be sewed together as it is illustrated with a stitching line 22 by an embodiment of the method according to the invention. Stitching methods applied may be any methods relevant for stitching shoes.
[0169] As regards the embodiment shown in FIG. 2b, it is noted that subsequent to e.g. stitching of footwear pieces, the part of the quarter 14 pointing downwards in FIG. 2b may be assembled with the other side of the vamp 60, requiring that the parts are formed 3-dimensionally to essentially take the form of a shoe upper and stitched together as indicated with the stitching line 22 on the lower part of the quarter 14.
[0170] It will be understood that other shoe parts in addition to the parts illustrated in FIGS. 2a and 2b may be introduced in similar manners and assembled with the illustrated parts to eventually form an upper of a shoe.
[0171] FIGS. 3a-3c illustrate in perspective views an exemplary base layer 30, whereon footwear parts such as a vamp 60 and a toe cap 62 are positioned in accordance with various embodiments of the invention. FIG. 3a illustrates a lining 30 being used as a base layer and with shoe parts exemplified by a vamp 60 and a toe cap 62 positioned on the base layer 30. For reasons of clarity, only a few footwear parts are illustrated in FIGS. 3a-3c, but it will be noted that further footwear parts may be positioned on the base layer, e.g. corresponding to the footwear parts as illustrated in FIGS. 2a and 2b and/or FIG. 1, which footwear parts may be processed in essence as described in the following concerning the various embodiments of the method according to the present invention. However, it is further noted that any relevant shoe parts or even accessories in the shoe manufacturing may be relevant in connection with the invention. After being positioned on the base layer 30, e.g. by means of for example a pick and place robot, the vamp 60 and the toe cap 62 are being fixated on the base layer, for example by activating an adhesive on the base layer. The non-activated adhesive may be activated by using pressure, friction, ultrasonic radiation, infrared radiation, heat, possibly in any combination. When the footwear parts have been fixated, the base layer 30 comprising the fixated footwear parts can now—possibly after being inspected as regards quality—be transported to e.g. an automated stitching station, where the footwear parts are being connected to the base layer and/or each other by an automatic stitching process as will be described in further detail below.
[0172] FIG. 3b corresponds to FIG. 3a, but here it is illustrated that a quarter 14 has been positioned at one side of the vamp 60, fixated on the base layer 30, etc. in such a manner that by a subsequent stitching process the footwear parts are being connected together and to the base layer.
[0173] FIG. 3c corresponds essentially to the scenario as shown in FIG. 3b, but in FIG. 3c it is illustrated that the base layer material is exploited to a greater degree by placing footwear parts, e.g. a further vamp 60, toe cap 62 and quarter 14, forming a further footwear upper, where these further parts form a mirrored version of the first mentioned footwear parts such that the first may relate to a left footwear upper and the second may relate to a right footwear upper. Another advantage may be that a pair of footwear uppers, e.g. relating to one and the same size, type, etc. in this manner may be processed simultaneously and/or following each other in the manufacturing process.
[0174] FIG. 3d illustrates the footwear upper parts as shown in FIG. 3b after they have been connected by stitching and where the superfluous parts of the base layer have been trimmed off, thus leaving essentially only the base layer 30 that is on the underside of the parts 14, 60 and 62. Hereafter, a folding of the connected footwear parts into a 3D upper may be performed as illustrated by the arrow A. Subsequently, the footwear upper may be connected and stitched as it has been explained above in connection with FIG. 2b. It is noted that the base layer material will thus serve as a lining in the manufactured footwear upper.
[0175] FIGS. 4a-4d illustrate an example of initial or preparatory steps of an automatic stitching method according to an embodiment of the invention, wherein a fixture 40 is utilized in the processing steps as it will be explained in detail further below. The fixture may be configured in a multitude of variations. However, in order to elucidate the invention, the fixture 40 is here illustrated, seen in a perspective view partly from above and partly from the side, as being an essentially rectangular fixture frame 42 as shown in FIG. 4a, which fixture frame serves to withhold a base layer. Further, it is noted that the fixture 40 comprises or can be combined with conveyance arrangements 44 (indicated in FIG. 4a), e.g. placed underneath the fixture frame 42 and configured for facilitating a controllable transport, e.g. along a conveyor, along a track or in any other suitable manner.
[0176] As indicated in FIG. 4b, the fixture 40, e.g. the fixture frame 42 is configured for holding a base layer 50. For example, the fixture frame 42 may have a clamping function, e.g. by being openable and closable, and a base layer 50 may thus be gripped by the fixture frame 42 along the outer perimeter of the base layer. The base layer 50, which is an essentially non-stretchable material, is held by the fixture 40 in such a manner that the base layer 50 extends in a plane defined by the fixture and essentially without deviating from the plane at locations within the inner of the fixture frame. As further indicated in FIG. 4b, a reference 52 may be defined in the 2-dimensional plane defined by the base layer 50, e.g. for example at a corner of the fixture frame 42, which reference may serve as reference point for the further processing, e.g. when positioning footwear parts, when stitching, etc. as it will be exemplified further below. The reference 52 may be defined in other manners, e.g. by having a marking on the base layer 50, for example visible and/or detectable by e.g. vision equipment, detecting apparatus, etc.
[0177] In FIG. 4c it is shown that the fixture 40 with a base layer 50 mounted has been placed in a processing line and based on the reference 52 and in accordance with work instructions, e.g. control software, a footwear part such as e.g. a vamp 60 is positioned on the base layer 50 in a position and possibly with an orientation in accordance with the work instructions, e.g. the control software. The footwear part may for example be gripped and positioned on the base layer by a pick and place robot or another type of robotic apparatus.
[0178] In the next step, it is illustrated in FIG. 4d that a further footwear part, e.g. a toe cap 62, has been positioned at least partly overlapping the previously positioned footwear part. The toe cap 62 may be positioned based on the reference 52 and in accordance with work instructions, e.g. control software, for e.g. a pick and place robot or the like. It is noted that the control software may receive input not only regarding the reference 52 but may also receive input as regards the actual position and/or orientation of the previously placed footwear part. It is noted that it is a possibility that the latter positioned part, e.g. the toe cap 62, may be positioned based alone on the position of the former positioned part, e.g. the vamp 60. A combination may be preferable, though.
[0179] Furthermore, it is indicated in FIG. 4d that an identifier 70 may be arranged on the fixture 40, e.g. on, at or in the fixture frame 42. Instead or in addition such an identifier 70′ may be arranged in connection with the base layer 50. Further, it is noted that the identifier, which in such case will be referred to as 70″, instead or additionally may be arranged in connection with the footwear parts, e.g. on or in one or more of the footwear parts.
[0180] Hereby, the fixture, the base layer with the parts being positioned on it and/or the footwear part(s) may be e.g. tracked along a processing line and in case a control system has been provided with information concerning the involved identifiers, the relevant processing may be performed in accordance with e.g. a predefined set of specifications as the parts proceed along the processing line. Further, it is noted that the use of such identifiers may allow that e.g. a particular fixture, base layer and/or footwear parts may be removed from e.g. the processing line and later added again, at which stage the identifier may be read by a reader and an e.g. status of steps already performed may be provided to the control system as well as the actual characteristics of the work in progress.
[0181] As an example, it may be mentioned that the identifier devices may be RFID devices or any other suitable electronically readable devices.
[0182] Furthermore, it should be noted that the exemplary footwear parts shown in FIGS. 4c and 4d, e.g. a vamp 60 and a toe cap 62, are for illustrative purposes only and that other footwear parts may be used as exemplary footwear parts such as shown and explained in connection with FIGS. 2a, 2b and 3a-3c. Thus, it will also be understood that a fixture 40 with a base layer 50 may be utilized when positioning footwear parts for a single footwear upper, e.g. as it has been illustrated in FIGS. 4c and 4d, but that advantageously a pair of footwear uppers may be processed on a single fixture with a base layer such as it has been explained with reference to FIG. 3c. Further configurations are possible, e.g. with a single fixture frame 42 and its associated base layer 50 carrying parts for more than two footwear uppers, etc. if the sizes permits. Even further, as mentioned above, it should be noted that the base layer 50 may be utilized in a completed footwear upper as a lining 30.
[0183] In FIG. 5a a possible outlay of a module-based manufacturing line 100 according to an embodiment of the invention is illustrated, seen from above. Here, a number of modules 101-109 are shown, which may be utilized in connection with a manufacturing line for footwear and where e.g. footwear parts, materials, etc. necessary for the manufacture as well as subparts of the e.g. footwear may be transported along the manufacturing line 100, e.g. generally from left to right in FIG. 5a, while manufacturing steps, handling, etc, are being performed along the line 100. As illustrated in FIG. 5a, the transport, e.g. conveying may take place along the hatched route and as illustrated with the arrows as it will be further elucidated in the following.
[0184] It should be noted that the respective modules are configured with interfaces, e.g. clear mechanical, pneumatic, electronic and/or communication interfaces, thereby enabling a quick reconfiguration of the modules and the line 100 to accommodate manufacture of e.g. new or changed products, to enable additional modules to be included, e.g. a further workstation for automatic stitching, etc.
[0185] The module 101 is a module for a stacking device, where stacks of e.g. footwear parts, base layers, etc. S1, S2, S3 and Sn may be fed to the line. In particular, the module 101 may handle stacks of fixtures 40, each comprising a fixture frame 42 and a base layer 50 that may be a lining material 30, which e.g. one by one are fed to the manufacturing line 100. From this module 101 for a stacking device the objects may be forwarded to different locations via a module 102 for 3-way transfer as illustrated by the arrows, e.g. moved across the module 103 to the next module 104 or directed to the module 103, e.g. a work station, at the side. Also, the module 102 for 3-way transfer may serve to forward objects from the module 103, e.g. a work station, to the next module 104. The module 103 at the side of the line may be a work station such as a module for a pick and place device, which furthermore may comprise a visual detection system to enable the pick and place device to e.g. grip a footwear part and place it at a specific location at/on a base layer. Furthermore, the pick and place device at the module 103 may e.g. grip one or more further footwear part(s) and place it (them) at a further specific location at the base layer and/or at overlapping positions on the first placed footwear part. Also, it should be noted that the pick and place device may place the footwear part(s) with a desired orientation, e.g. in relation to the base layer and/or in relation to a previously placed footwear part.
[0186] As it will be understood from the foregoing, the object being transported from the module 103 to the module 104 may be a base layer, upon which two or more footwear parts are positioned. At the module 104 a heat press device or another type of device for activating a layer of non-activated adhesive on the base layer is arranged for activating the adhesive as previously discussed, thereby fixating the footwear parts on the lase layer in the positions, in which they have been placed.
[0187] The base layer with the fixated footwear parts may next be forwarded to a module 105 having a process quality inspection system, e.g. having a vision or camera component for checking e.g. the positions of the footwear parts, the overlap, etc. In case there is any flaw, the specific base layer with footwear parts may proceed e.g. directly to the end of the line, may be redirected without being used or may be removed in another manner, in all cases possibly for being corrected, used for other purposes or in other manners reused.
[0188] When the base layer with footwear parts passes the module 105 having the process quality inspection system, it reaches a second module 106 having a 3-way transfer as illustrated by the arrows. Here, the base layer with footwear parts may be directed to module 107, e.g. a workstation having an automated stitching device in the form of e.g. a robotic stitching system, by means of which the fixated footwear parts and possibly the base layer are being connected to each other by stitching.
[0189] When having been stitched, the base layer with the fixated and now connected footwear parts is being transported to a module 108 for a stacking device, where a stacking of the processed base layers with the fixated and now connected footwear parts is being performed before being subjected to further processing in order to provide a completed piece of footwear. Here, the further processing may include removal of the base layer 50 with the connected footwear parts from the fixture frames 42, whereafter the fixture frames may be prepared for being returned to the input of the manufacturing line 100.
[0190] Furthermore, a module 109 is illustrated, which is a module for a fixture or jig preparation device, where for example base layers 50 may be mounted in or on the individual fixtures 40 and in general made ready to enter a manufacturing line 100 as illustrated in FIG. 5. The module 109 may for example comprise a movable magazine, which can be moved to the module 101 when the magazine has been filled with fixtures 40, which have been provided with new base layer material.
[0191] In FIG. 5b a further example of a manufacturing line 100 is illustrated. This corresponds in essence to the manufacturing line that has been shown in FIG. 5a and has been explained in connection with FIG. 5a. However, in FIG. 5b the fixture preparation module 109 is placed in front of the manufacturing line 100. Further, the fixture preparation module 109 as well as the module 108 for a stacker device at the end of the manufacturing line 100 may comprise an elevator each. Even further, an underlying conveyor 111, e.g. a conveyor belt, is arranged, leading from the module 108 to the fixture preparation module 109. This underlying conveyor 111 may be arranged in lower parts of the respective modules, e.g. arranged under a conveyor 110 that transports fixtures in the manufacturing direction. Thus, fixture frames that arrive at the module 108 may be lowered down by the elevator and transported to the fixture preparation module 109 by the underlying conveyor 111. Here, they are lifted upwards and may be prepared by removing any base material left and by mounting a new piece of base layer material in the fixture frame. This may be done by an operator 118, who also pushes the now prepared fixture frame to the module 101 for a stacking device, ready to be used in the manufacture. The module 101 for a stacking device may hold a plurality, e.g. 5 or more, of fixture frames and may thus serve as a buffer.
[0192] The fixture handling and transport arrangement shown in FIG. 5b may be used in connection with other manufacturing line configurations as well, e.g. the examples shown in FIGS. 8, 9 and 10.
[0193] In FIG. 6 an example of a schematically shown workstation 103 for gripping a footwear part and placing it at a specific location at/on a base layer is shown in an enlarged view from above. Here, it is shown that a fixture 40 comprising a base layer 50 have been transported to the workstation 103 by e.g. a conveyor 110. The workstation comprises a pick and place robot 114, which has a robot arm 115, for example an articulated and extendable arm that may be rotated around a base part and which has a gripper such as a vacuum gripper 116. It is noted that various types of robots may be utilized for picking and placing the footwear parts and it should be mentioned that for example a SCARA robot may be utilized. It is furthermore noted that in case a robotic vacuum gripper is used, this may be equipped with a plurality of relatively small suctions cups or the like, e.g. arranged in an array corresponding to e.g. the size of footwear parts to be gripped. The individual suction cups or the like may be individually supplied with vacuum. Additionally, it is noted that a further axis of the vacuum gripper robot may be implemented by having the active suctions cups or the like, e.g. the suction cups actually gripping a footwear part, be controlled to be extended or in another configuration by having the inactive suction cups be controlled to be retracted, when gripping, positioning and/or moving etc. a footwear part. Hereby, a number of advantages may be achieved, e.g. that the inactive suctions cups or the like that are actually not involved in gripping a footwear part, will not be near or will at least be positioned a distance from the footwear part, thus making it easier to maneuver the vacuum gripper and/or the gripped footwear part, e.g. because the inactive suctions cups or the like are less likely to collide with other objects, for example a fixture for the base layer, conveyor parts or other parts involved in the processing. Hence, the robotic vacuum gripper may, when implemented in such a manner with a further axis, be used with greater delicacy, with greater precision and in general with greater degrees of freedom as regards e.g. the ability to turn or in general angularly maneuver a footwear part, position a footwear part near a frame or fixture for the base layer, utilize the available base layer area to a greater extent, etc.
[0194] The workstation 103 may furthermore comprise a visual detection system to enable the pick and place device to operate, where the visual detection system may comprise a detector device 112 that may be connected to various detectors, cameras, vision devices in order to provide the desired to the e.g. robot 114.
[0195] The robot 114 is controlled by software to pick individual footwear parts, e.g. leather parts and place these on the base layer 50 at specified positions, in a certain order, etc. as it has been explained above. These footwear parts may be picked from e.g. leather part supplies 120. When the fixture 40 with the base layer 50 has received for example two assemblies 64 of footwear parts, it may be transported further on in the processing line, e.g. to the module 104 for activating adhesive or to another module. Also, it may be parked for a longer or shorter time until processing capacity is ready, for example at the workstation 103 that may also serve as a buffer.
[0196] In FIG. 7 an example of a schematically shown workstation 107 for automated stitching is shown in an enlarged view from above. Here, it is shown that a fixture 40 comprising a base layer 50 and whereon for example two assemblies 64 of footwear parts are fixated has been transported to the workstation 107 by e.g. a conveyor 110.
[0197] The workstation 107 comprises a schematically illustrated automated stitching apparatus 130, which is arranged in connection with a gantry device 132, possibly a gantry robot, in such a manner that relative movement in the transverse as well as the conveyor direction (the longitudinal direction) is facilitated. Thus, the footwear parts of the e.g. two assemblies 64 may in this manner be stitched to the base layer 50 and to each other.
[0198] The workstation 107 may furthermore comprise a visual detection system to enable the automated stitching apparatus 130 to operate, where the visual detection system may comprise a detector device 112 that may be connected to various detectors, cameras, vision devices in order to provide the desired control signals to the e.g. gantry device 132 and the automated stitching apparatus 132. These are controlled by software to e.g. perform a stitching along predefined routes, along certain edges of the footwear parts or in any other manner to provide a predefined stitching of the footwear parts. When the stitching of the two assemblies 64 of footwear parts have been performed, the fixture 40 with the base layer 50 and the two assemblies 64 of footwear parts may be transported further on in the processing line, e.g. to the module 108 for further processing. However, it may be parked for a longer or shorter time until processing capacity is ready, for example at the workstation 107 that may also serve as a buffer.
[0199] In FIG. 8 a possible outlay of a continuation of a module based manufacturing line 100 according to an embodiment of the invention is illustrated, seen from above. Here, the modules are illustrated as a continuation of modules e.g. from a series of modules 100 that may be a series of modules as illustrated in FIG. 5a. It may also be a continuation of the illustrated modules to other manufacturing processes relevant for footwear making.
[0200] In FIG. 9 a further example of a manufacturing line 100 is illustrated. This corresponds in essence to the manufacturing line that has been shown in FIG. 5a and has been explained in connection with FIG. 5, but in FIG. 9 it is exemplified that quality inspection may be performed at different steps in the manufacturing line 100. In FIG. 5a it was shown that a module 105 for process quality inspection was placed following the module 104 for activation of adhesive. As shown in FIG. 9, the module 105 for process quality inspection may instead be placed following immediately after the automated stitching has been performed, e.g. after the module 107 for automated stitching and the module 106 for 3-way transfer. It will be apparent that a process quality inspection may be performed at both of these exemplified positions, at only one of these and/or at any other suitable position.
[0201] Furthermore, it should be noted that other configurations of the various modules 101-109 are possible in addition to the configurations exemplified in the figures. For example, it is noted that whereas is it shown that the modules 103 and 107 relating to the robotic positioning of shoe parts on fixture frames holding base layer and the automated stitching, respectively, are exemplified as stations, where the objects are being removed from a main process line and are being processed in e.g. a loop configuration, it is a possibility that these operations may be performed as inline processes, e.g. being performed in the main process line without being looped out.
[0202] In FIG. 10 a further example of a configuration of a manufacturing line 100 is illustrated. This corresponds in essence to the manufacturing line that has been shown in FIG. 5 and has been explained in connection with FIG. 5, but here it is further shown that the output from the module 108, e.g. base layers with stitched footwear parts that have been stitched in a 2 dimensional plane and where e.g. the surplus base layer has been trimmed so that the remaining base material may serve as lining, is being forwarded to a further 3D processing 140. This 3D processing 140 may e.g. include closing the footwear uppers by stitching them together as it has been explained above, e.g. in connection with FIG. 3d and may further comprise attaching Strobel material to the 3D upper in advance of e.g. injection of sole material. Further processes may be performed here at 140, as it will be apparent to a person skilled within the field of footwear manufacture. Next, the completed footwear upper is forwarded to a sole attachment process, such as for example a direct injection production (DIP) 150 and related operations, resulting in a completed piece of footwear 10.
[0203] In principle, the leather can derive from any source, including animal-sources such as bovine hide, cow hide, horse hide, goat skin, sheep skin, kangaroo hide, reptiles, fish and the like. The leather may also derive from a non-animal sources such as e.g. natural materials derived from e.g. plants, unicellular or multicellular organisms. Even so, preferably the leather is a mammal or marsupial leather (i.e. derives from a hide from a mammal such as horse or bovine e.g. cow, or a marsupial such as a kangaroo. Mammal leathers are most often used. However, it should be noted that one or more of the footwear parts being used for the manufacture of e.g. footwear uppers in connection with the present invention may comprise other materials, e.g. synthetic materials such as polyester, polyamide and/or polyurethanes.
LIST OF REFERENCE NUMBERS
[0204] 10 Shoe [0205] 11 Upper [0206] 13 Tongue [0207] 14 Quarter [0208] 16 Outer sole [0209] 17 Outer counter [0210] 18 Eyelet [0211] 19 Facing [0212] 20 Inner sole [0213] 22 Stiches [0214] 30 Lining [0215] 40 Fixture [0216] 42 Fixture frame [0217] 44 Conveyance arrangements [0218] 50 Base layer [0219] 52 Reference [0220] 60 Vamp [0221] 62 Toe cap [0222] 64 Assembly of footwear parts [0223] 70, 70′, 70″ Identifier [0224] 100 Manufacturing line [0225] 101 Module for a stacking device [0226] 102 Module for 3-way transfer [0227] 103 Workstation [0228] 104 Module for activating adhesive [0229] 105 Module for process quality inspection [0230] 106 Further module for 3-way transfer [0231] 107 Workstation for automated stitching [0232] 108 Further module for a stacking device [0233] 109 Fixture preparation module [0234] 110 Conveyor [0235] 111 Underlying conveyor [0236] 112 Detector device [0237] 114 Pick and place robot [0238] 115 Robot arm [0239] 116 Vacuum gripper [0240] 118 Operator [0241] 120 Leather part supply [0242] 130 Automated stitching apparatus [0243] 132 Gantry device [0244] 140 3-dimensional (3D) processing [0245] 150 Direct injection production (DIP) [0246] A Folding of 3D upper [0247] S1-Sn Stacks of footwear parts, base layers, etc.
