Despite steady advances in flexible automation in sectors such as electronics and automotive manufacturing, apparel automation remains challenging because fabrics are deformable and difficult to manipulate with robots. This paper presents a deployment-oriented case study of a robotic sewing system for denim manufacturing, emphasizing the system-level integration required for practical adoption. At the engineering level, a digital thread module parses DXF production drawings into process parameters and executable robot trajectories, reducing manual programming effort and enabling rapid re-targeting across sewing operations. In parallel, a digital twin of the workcell is used during pre-deployment to validate reach and clearance, refine layout and sequencing, evaluate operator access, and assess cycle-time compatibility with upstream and downstream tasks, thereby reducing commissioning risk. At deployment, the system integrates a collaborative robot with conventional sewing equipment, welding, suction fixtures, and machine-level controllers through an interoperability layer. Runtime monitoring and verification, including seam monitoring, collision checking, and trajectory-level validation, improve robustness under environmental variability, while operator-facing training and guidance tools support setup, troubleshooting, and technology adoption. Two staged factory deployments on denim shorts, covering 2D pocket operations and 3D garment-shaping seams, show that digital-twin-based validation, digital-thread-driven task generation, interoperability, runtime verification, and operator training are important for scaling robotic apparel automation.

翻译：尽管在电子和汽车制造等领域的柔性自动化取得了稳步进展，但由于织物具有可变形性且难以通过机器人操控，服装自动化仍然充满挑战。本文以牛仔布制造为背景，提出了一项面向部署的机器人缝纫系统案例研究，重点阐述了实际应用所需的系统级集成。在工程层面，数字线程模块将DXF生产图纸解析为工艺参数和可执行的机器人轨迹，减少了人工编程的工作量，并实现了跨缝纫工序的快速重新定位。同时，在部署前使用工作单元的数字孪生来验证可达性和间隙，优化布局和顺序，评估操作员的可访问性，并评估周期时间与上下游任务的兼容性，从而降低调试风险。在部署阶段，系统通过互操作层将协作机器人与传统缝纫设备、焊接设备、吸附夹具以及机器级控制器集成在一起。运行时监测与验证（包括缝迹监测、碰撞检测和轨迹级验证）提高了在环境变化下的鲁棒性，而面向操作员的培训与指导工具则支持设置、故障排除和技术采用。针对牛仔短裤的两个阶段性工厂部署（涵盖二维口袋操作和三维成衣造型缝迹）表明，数字孪生验证、数字线程驱动的任务生成、互操作性、运行时验证以及操作员培训对于扩大机器人服装自动化规模至关重要。