Vision incorporated MUltichannel Feature Fusion Template Matching (MUFF-TM) and real-time sub-pixel coordinate localization for 2D textile surface in ultrasonic tacking systems

Abstract

Temporary stitches are essential in apparel manufacturing as they temporarily secure fabric pieces to prevent misalignment during machine sewing and ensure high-quality results. Manual ultrasonic tacking machines were introduced to enhance the precision of this process; however, the necessity for expert operators remains a major constraint. This work introduces a real-time system for ultrasonic tacking machines that combines vision-guided single-modal MUltichannel Feature Fusion Template Matching (MUFF-TM) to autonomously identify and align tacking points on textiles with sub-pixel spatial accuracy. To overcome the limitations of classic feature-based algorithms on smooth and deformable fabrics, the proposed method utilizes macro-contour extraction and equidistant boundary sampling rather than relying on unstable local textures. Experimental results demonstrate that MUFF-TM achieves a 100% target detection rate with a highly stable Mean Absolute Error (MAE) of under 5 pixels across various dynamic conditions, including changes in orientation, illumination, scale, and non-rigid deformation. By significantly outperforming traditional algorithms (SIFT, SURF, and ORB) in spatial precision, the developed software interface offers a robust, versatile, and scalable solution for advancing automated precision in the apparel industry. Copyright