Sewing system, control device and method, storage medium, and method for manufacturing a sewn object

Abstract

The present application relates to a sewing system, a control device and method, a storage medium, and a sewn article manufacturing method. Even if a material to be sewn before sewing is not fixed into a three-dimensional shape, the material to be sewn can be three-dimensionally sewn. The sewing system includes a sewing device that sews a first material to be sewn and a second material to be sewn that are overlapped, a robot that holds the first material to be sewn and the second material to be sewn, and a control device that controls the sewing device and the robot, and controls the robot to hold the second material to be sewn in an inclined state with respect to the first material to be sewn to perform sewing.

Description

Technical Field

[0001] This disclosure relates to sewing systems, control devices, control methods, non-transitory storage media, and methods for manufacturing sewn fabrics. Background Technology

[0002] Furthermore, Patent Document 1 (Japanese Patent Application Publication No. 2018-042882) describes a sewing system in which a sewing machine is mounted on a robotic arm. This sewing system includes: a sewing machine; a camera for capturing a reference position for sewing; a robotic arm for holding the sewing machine and the camera; and a control device. The control device performs motion control by forming a first needle-drop position through the needle drop of the sewing machine, causing the sewing machine to rotate at a predetermined angle around a rotation axis passing through a needle center position stored in the control device, and then forming a second needle-drop position through the needle drop of the sewing machine. Furthermore, based on the positions of the first and second needle-drop positions within the shooting range of an image obtained by capturing the first and second needle-drop positions with the camera, the control device performs correction processing to correct the needle center position stored in the control device. Summary of the Invention

[0003] The technical problem that the invention aims to solve

[0004] In order to sew the material to be sewn into a three-dimensional shape, as described in Patent Document 1 above, it is necessary to mount and fix the material to be sewn onto a three-dimensional mold. That is, in order to sew the material to be sewn in a three-dimensional manner, a three-dimensional mold needs to be prepared in advance.

[0005] This disclosure is made in view of the above-mentioned problems, and its purpose is to provide a sewing system, control device, control method, control program, non-temporary storage medium, and sewn material manufacturing method that can sew materials three-dimensionally even without fixing the sewn material into a three-dimensional shape before sewing.

[0006] Technical solutions for solving technical problems

[0007] To achieve the above objectives, the sewing system involved in the first method includes: a sewing device for sewing overlapping first and second materials to be sewn; a robot for holding the first and second materials to be sewn; and a control device for controlling the sewing device and the robot, controlling the robot to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing.

[0008] It should be noted that in the method of holding the second material to be sewn at an angle relative to the first material for sewing, the following situations are included: the portions through which the threads of the two materials to be sewn pass are inclined relative to each other, and sewing is performed by passing the thread through these portions. Additionally, in this method, the following situations are included: before passing the thread for sewing, with the needle positioned away from the two overlapping materials (upper side), the sewing portion of the second material is inclined relative to the sewing portion of the first material; and the two materials are sewn together tightly by passing the needle through the thread. Furthermore, in the case where a pressing mechanism intermittently presses the materials, the following situations are included: when the pressing mechanism is not pressing the two materials, the sewing portion of the second material is inclined relative to the sewing portion of the first material; during sewing, the pressing mechanism presses the two materials together to seal them, and the seam is performed. In the unpressed state of the pressing mechanism, the action occurs not only when the material being sewn is far away from it, but also when the material being sewn is tilted to the point of just contact with it. Furthermore, even when the pressing mechanism continuously presses the material without intermittent action, the action occurs when the portion is tilted relative to the other before the pressing force is overcome and the sewing is completed. Additionally, this method includes cases where two materials being sewn are tilted at different angles. Furthermore, this method includes cases where the materials being sewn are held in a relatively tilted state towards the near-sewing point. In this case, by applying a directional component different from the stitch direction to move the materials being sewn, deflection can be suppressed, and a three-dimensional shape can be sewn. Furthermore, one or both of the materials being sewn can be three-dimensional in addition to a planar shape. According to this method, which includes the above-described cases, a three-dimensional shape can be sewn without pre-positioning the materials in a three-dimensional manner.

[0009] Alternatively, the control device controls the robot such that the second piece of material to be sewn is held in a position close to the sewing point of the sewing device, and is held at an angle relative to the first piece of material to be sewn. This suppresses deflection of the material to be sewn when a force is applied in a direction different from the stitch direction. In the angled holding, besides the case where the portion of the sewing point of the material to be sewn is relatively angled, it also includes the case where the portions are parallel to each other. In the latter case, by applying a different component to move the material to be sewn in the direction of the stitch, deflection can be suppressed and a three-dimensional shape can be sewn. In the former case, a three-dimensional shape can be sewn even without adding the aforementioned component to move the material to be sewn.

[0010] Alternatively, the control device can control the robot to receive and support the first piece of material to be sewn parallel to the surface at the location surrounding the sewing point. Thus, by making one piece of material parallel to the surface, and since only one piece of inclined material needs to be sewn, the operation becomes easier.

[0011] Alternatively, when the materials to be sewn are stitched together in a curved, overlapping shape, the protruding side of the curved surface is used as the first material to be sewn, and the concave side is used as the second material to be sewn. The control unit controls the robot to hold the second material to be sewn on the concave side of the curved surface in an inclined position relative to the first material to be sewn on the protruding side of the curved surface for sewing. This allows for appropriate control of the protruding and concave sides when sewing into a curved shape.

[0012] Alternatively, the control device controls the robot to hold the second material to be sewn at an angle, and controls the pressing part of the sewing device to move up and down intermittently. Thus, the material to be sewn is intermittently pressed against the sewing table, allowing the material to tilt significantly when not pressed, thereby increasing the controllable range.

[0013] Alternatively, the robots can be configured as a first robot holding the first material to be sewn and a second robot holding the second material to be sewn. The control device controls the first robot to receive and support the first material to be sewn parallel to the surface surrounding the sewing point, and controls the second robot to hold the second material to be sewn in an inclined state relative to the first material for sewing. It should be noted that the surface receiving and supporting the material surrounding the sewing point includes not only the connecting surface surrounding the entire circumference, but also multiple surfaces arranged to clamp or surround the sewing point. Therefore, by individually holding and controlling the materials to be sewn, even when one or both are three-dimensional, it is easy to make materials of different shapes move and sew at the desired inclination.

[0014] The second approach involves a control method executed by a computer to control a sewing device and a robot. The sewing device sews overlapping first and second materials, and the robot holds the first and second materials together. In the control method, the robot is controlled to hold the second material in an inclined state relative to the first material for sewing.

[0015] The control program involved in the third approach is a control method that enables a computer to perform control over a sewing device and a robot, wherein the sewing device sews overlapping first and second materials, and the robot holds the first and second materials, wherein the robot is controlled to hold the second material in an inclined state relative to the first material for sewing.

[0016] The sewing device involved in the fourth method includes a control unit that controls the sewing device and a robot. The sewing device sews overlapping first and second materials to be sewn. The robot holds the first and second materials to be sewn. The control unit controls the robot to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing.

[0017] The fifth method involves a non-temporary storage medium storing a control program that enables a computer to execute control over a sewing device and a robot, wherein the sewing device sews overlapping first and second materials to be sewn, and the robot holds the first and second materials to be sewn, wherein the robot is controlled to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing.

[0018] The sixth method involves a sewn fabric manufacturing method in which a computer controls a sewing device and a robot. The sewing device sews overlapping first and second materials to be sewn together, and the robot holds the first and second materials to be sewn together. In this sewn fabric manufacturing method, the robot is controlled to hold the second material to be sewn together in an inclined state relative to the first material to be sewn together, thereby using the sewing device and the robot to manufacture sewn fabric from the materials to be sewn together.

[0019] The effects of the invention

[0020] According to this disclosure, even if the material to be sewn is not fixed into a three-dimensional shape before sewing, it is possible to sew the material in a three-dimensional manner. Attached Figure Description

[0021] Figure 1 This is a diagram illustrating an example of the structure of the sewing system involved in the embodiment.

[0022] Figure 2 This diagram illustrates an example of a technical problem arising from deflection in three-dimensional sewing.

[0023] Figure 3 This is an example of holding the sewn material M2 parallel and at an angle.

[0024] Figure 4 This is a block diagram illustrating an example of the electrical structure of the control device involved in the implementation.

[0025] Figure 5 This is a block diagram illustrating an example of the functional structure of the control device involved in the implementation.

[0026] Figure 6 This is a diagram used to illustrate the predetermined sewing positions and sewing threads involved in the implementation method.

[0027] Figure 7 This diagram illustrates an example of the sewing thread L1 and sewing thread L2 involved in this embodiment.

[0028] Figure 8 This is a diagram used to illustrate the trajectory control of the sewn material M1 and sewn material M2 involved in this embodiment.

[0029] Figure 9 This is a sequence diagram illustrating an example of the processing flow of the control program involved in the implementation method.

[0030] Explanation of reference numerals in the attached figures

[0031] 10: Control device; 11: CPU; 11A: Setting unit; 11B: Control unit; 12: ROM; 13: RAM; 14: I / O; 15: Storage unit; 15A: Control program; 16: Connection unit; 20, 60: Robot; 30: Sewing machine; 40: Camera; 50: Sewing machine worktable; 100: Sewing system. Detailed Implementation

[0032] Hereinafter, an example of a method for implementing the technology of this disclosure will be described in detail with reference to the accompanying drawings. It should be noted that constituent elements and processes that perform the same action, function, or effect are given the same reference numerals throughout the drawings, and sometimes repeated descriptions are appropriately omitted. The drawings are merely schematic to provide a thorough understanding of the technology of this disclosure. Therefore, the technology of this disclosure is not limited to the examples shown in the drawings. Furthermore, in this embodiment, descriptions of structures not directly related to the technology of this disclosure, or well-known structures, are sometimes omitted.

[0033] Figure 1 This is a diagram illustrating an example of the structure of the sewing system 100 according to this embodiment.

[0034] Figure 1The sewing system 100 shown includes a control device 10, a robot 20, a robot 60, a sewing machine 30, and a camera 40. The sewing machine 30 is an example of a sewing device. The sewing system 100 automatically sews the materials M (M1 and M2) to be sewn using the robot 20, robot 60, and sewing machine 30. As an example, in... Figure 1 In the diagram, the X direction represents the left-right direction of the sewing machine 30, the Y direction represents the front-back direction of the sewing machine 30, and the Z direction represents the up-down direction of the sewing machine 30. The sewn material M can be any material through which the needle passes; there are no particular limitations, such as soft materials like cloth or leather. In this embodiment, the sewn material M will be described using the case of processing two components, M1 and M2, as an example. When the finished sewn object, formed by overlapping and sewing M1 and M2, is considered a three-dimensional shape, M1 is considered a curved surface, and M2 is considered a pasted part. Alternatively, one can be considered a sphere / ellipsoid, and the other a part of both. In the sewing system 100, a sewn object, which is a three-dimensional shape, is manufactured by three-dimensionally sewing the sewn materials M1 and M2. Hereinafter, the common elements in M1 and M2 will be referred to as the sewn material M. The sewn material M1 is an example of a first sewn material of this disclosure, and the sewn material M2 is an example of a second sewn material of this disclosure. The robot 20 is an example of a first robot of this disclosure, and the robot 60 is an example of a second robot of this disclosure.

[0035] Here, we illustrate an example of a technical problem in three-dimensional sewing. Figure 2 This diagram illustrates an example of a technical problem arising from deflection during three-dimensional sewing. For three-dimensional sewing to be performed, it is sometimes necessary to deform the material being sewn in the direction of sewing while sewing. For example, as shown in (A1), a force F is applied by the hand 64 to forcefully press the material M2 being sewn inward from the opposite side of the pressing part 34, thereby deforming the material M2 in the direction of sewing while sewing. However, as shown in (A2), deflection sometimes occurs on the material M2 being sewn due to deformation. If deflection occurs, accurate three-dimensional sewing cannot be performed. In this embodiment, by sewing the material M2 at an angle, the occurrence of deflection can be suppressed, thus enabling three-dimensional sewing.

[0036] Figure 3This is an example of holding the sewn material M2 parallel and at an angle. The sewn material M1, which is the main body, is held by the hand 24 of robot 20, and the sewn material M2, which is the adhesive part, is held by the hand 64 of robot 60. It should be noted that the hand 24 holds the sewn material M1 parallel to the surface surrounding the sewing point and the surface that receives the sewn material M1 during sewing (the sewing machine worktable 50 described later). The sewn material M1 is held at the same height as the surface. Alternatively, the hand 24 of robot 20 can also hold the sewn material M1 from above. Figure 3 In this process, material M2 is overlapped on material M1. In state (B1), material M2 is held parallel to the surface of material M1. If it is pressed inward in this state, it will deflect. Therefore, as in state (B2), the outer side of material M2 is lifted by hand 64 and held at an angle. Thus, three-dimensional sewing can be achieved by sewing with the materials tilted relative to each other. It should be noted that although one is a three-dimensional shape and the other is a planar shape, one or both can be planar or three-dimensional. In addition, for three-dimensional materials, there are cases where the materials are sewn with the tilt of the part at the sewing point tilted relative to the tilt of the part at another sewing point.

[0037] By tilting at an angle θ, even if the material M2 to be sewn is pressed inward, the upward stretching force due to the tilt can suppress deflection. Furthermore, the tilt angle only needs to be determined in relation to the size of the stitch curve and the hardness of the raw material of the sewn material, as described later. For example, an angle of approximately 5 to 10°. By being tilted, the direction in which the material M2 is sewn bends. The control device 10 of the sewing system 100 controls the robot 60 to sew in the tilted state of the material M2 as described above. It should be noted that the pressing method has been described as an example, but even without pressing, there may be a situation where the sewing point of the material M2 is relatively tilted. If sewing is performed in this state, even without pressing, the distance between the stitches of the sewn material can be different, resulting in a three-dimensional shape. Furthermore, since there is no pressing, deflection can be suppressed. The various structures of the sewing system 100 will be described below.

[0038] A sewing machine 30 is mounted on a sewing machine worktable 50. The sewing machine 30 includes a sewing machine body 31, a sewing machine control mechanism 32, a needle 33, a pressing part 34, and a feed part 35. The sewing machine body 31 moves the needle 33 up and down at a predetermined position (sewing point) to sew the work material M placed on the sewing machine worktable 50. It should be noted that the sewing point is, for example, the position where the needle 33 of the sewing machine 30 pierces the work material M when it descends to sew. The sewing point can also be the position where the needle 33 passes the upper surface of the sewing machine worktable 50, on which the work material M is placed, at the instant of sewing. The sewing machine control mechanism 32 is, for example, a motor. If a sewing machine command signal for indicating the feed speed of the sewing machine 30 is input from the control device 10, the up-and-down movement speed of the needle 33 can be adjusted based on this sewing machine command signal.

[0039] The sewing machine 30 includes a feeding mechanism for the sewn material M and a mechanism for the movement of the sewing needle 33. These mechanisms operate in conjunction with each other via the same motor at a certain speed ratio. In actual operation, the up-and-down movement of the sewing needle 33 (sewing action) and the feeding action of the sewn material M are performed alternately. The pressing part 34 intermittently presses the sewn material M to suppress and fix its curling. That is, the pressing part 34 presses the sewn material M from above near the position where the sewing needle 33 passes, and clamps the sewn material M between itself and the worktable surface located below the sewn material M to prevent the sewn material M from curling up when the sewing needle 33 moves downward to pierce the sewn material M. In addition, the pressing part 34 suppresses the curling up of the sewn material M when the sewing needle 33 moves upward to pull it out of the sewn material M. In addition, when sewing multiple sewn materials M, the pressing part 34 makes the sewn materials M overlap. Furthermore, after the pressing part 34 moves the sewing needle 33 up and down, it moves upward during the feeding of the material to be sewn M, releasing the pressing state. The feeding part 35 is located near the sewing point, and after the thread is passed through the material to be sewn M by the sewing needle 33, it feeds the material to be sewn M a distance in the sewing direction.

[0040] The sewing machine 30 uses the pressing part 34 and the feeding part 35 to intermittently press the edge of the sewing material M to perform an intermittent feeding action. In this embodiment, the feeding speed of the sewing machine 30 may be, for example, the average speed of the sewing needle 33, or it may be the average feeding speed that takes into account the feeding speed during the intermittent feeding action and the overall average feeding speed of the intermittent feeding action of movement / stop.

[0041] The sewing machine 30 feeds the material M to be sewn, held by the robot 20 and the robot 60, toward the sewing point at a preset feed speed, and performs sewing on the material M that has been fed to the sewing point.

[0042] The sewing machine worktable 50 is a platform that receives and supports the material M being sewn from below at a position surrounding the sewing point when the sewing needle 33 descends from above and passes through the material M being sewn for sewing purposes. On this surface at the surrounding position, in addition to the connecting surface that surrounds the entire circumference, there are multiple separate surfaces arranged to clamp or surround the sewing point. An opening is provided on the sewing machine worktable 50 at the portion where the sewing needle 33 descends. The material M1 being sewn is placed on and supported on the surface of the sewing machine worktable 50.

[0043] Camera 40 is used to photograph the sewing material M placed on the sewing machine worktable 50 from above, and to capture the sewing process of the material M. Furthermore, the camera 40, the robot 20, and the sewing machine 30 are positioned in a specific relationship.

[0044] (Robot 20)

[0045] The robot 20 includes a support platform 21, a robot controller 22, a robotic arm 23, and a hand 24. The hand 24 is located at the front end of the robot 20. The robotic arm 23 is a multi-jointed arm, with the support platform 21 connected to one end and the hand 24 connected to the other end. The support platform 21 supports the robotic arm 23 and houses the robot controller 22. The hand 24 presses down on the sewing material M1 placed on the sewing machine worktable 50 from above, causing the sewing material M1 to slide and move on the sewing machine worktable 50, feeding it to the sewing needle 33 of the sewing machine 30.

[0046] When a robot command signal for instructing the robot 20 to move is input from the control device 10, the robot controller 22 moves the robotic arm 23 and the hand 24 based on the robot command signal. Thus, the hand 24 holds the sewing material M1 on the sewing machine table 50. Then, in this state, by moving the hand 24 in the direction that moves the sewing material M1, the sewing material M1 moves in the feed direction relative to the sewing needle 33 of the sewing machine 30. The sewing material M1 moves through intermittent feed movements, for example, while sliding on the sewing machine table 50. The robot 20 holds the sewing material M1. The robot 20 holds the material M1 with a robot holding position indicating the position where the robot 20 holds the sewing material M1 and a robot holding direction indicating the holding direction.

[0047] (Robot 60)

[0048] The robot 60 includes a support platform 61, a robot controller 62, a robotic arm 63, and a hand 64. The hand 64 is located at the front end of the robot 60. The robotic arm 63 is a multi-jointed arm, with the support platform 61 connected to one end and the hand 64 connected to the other end. The support platform 61 supports the robotic arm 63 and houses the robot controller 62. The hand 64 holds the sewn material M2 at an angle relative to the material being sewn.

[0049] When a robot command signal for instructing the robot 60 to move is input from the control device 10, the robot controller 62 causes the robotic arm 63 and hand 64 to move based on the robot command signal.

[0050] The hand 64 of the robot 60 only needs to be a mechanism capable of tilting and holding the sewn material M2. Furthermore, the robot 60 can perform circumferential position control in a direction different from the feed direction, i.e., relative to the sewing point P of the sewing machine 30, by means of a circumferential θ, and press inwards through position control. When the hand 64 applies force in a direction component different from the stitch direction, it can suppress the deflection of the sewn material. Additionally, by using the hand 64 to tilt and hold, a portion of the sewing point of the sewn material M2 can be made relatively tilted. This also includes cases where these portions are parallel to each other.

[0051] Hand 64 can, for example, function as a roller mechanism that passively follows the tension force of the feed direction of the sewing machine 30. In the roller mechanism, the clamping member is cylindrical or a plurality of discs of the same radius arranged with their axes aligned together, and rotates with the external force applied to the held sewing material M2. By making hand 64 a roller mechanism, the sewing material M2 can be slid in the feed direction and supplied to the sewing needle 33 of the sewing machine 30. The direction of hand 64 is determined according to the free curve of the predetermined sewing position (described later) and is controlled to be approximately a translational direction relative to the feed direction fd. Therefore, the rotation of the roller is controlled to rotate in a direction corresponding to the translational direction relative to the feed direction fd. Corresponding to the translational direction means that as long as there is a translational component, it also includes the case where the sewing material M2 is held at an angle. As a result, with the intermittent feeding action of the sewing machine 30, a tensile force is generated on the sewn material M2, causing it to rotate on the holding roller. Therefore, the sewn material M2 moves in a way that it is stretched in the feeding direction while sliding.

[0052] (Hardware structure of the control device)

[0053] The control device 10 is connected to the robot 20, robot 60, sewing machine 30, and camera 40 respectively. It performs image processing on the image obtained from camera 40 and controls the controllers of the robot 20, robot 60, and sewing machine 30 respectively. A general-purpose computer device such as a personal computer (PC) is used in the control device 10.

[0054] Figure 4 This is a block diagram illustrating an example of the electrical structure of the control device 10 according to this embodiment.

[0055] like Figure 4 As shown, the control device 10 according to this embodiment includes a CPU (Central Processing Unit) 11, a ROM (Read Only Memory) 12, a RAM (Random Access Memory) 13, an input / output interface (I / O) 14, a storage unit 15, and a connection unit 16.

[0056] CPU11, ROM12, RAM13, and I / O14 are interconnected via a bus. Functional units, including storage unit 15 and connection unit 16, are connected to I / O14. These functional units can communicate with CPU11 via I / O14.

[0057] The control unit comprises CPU11, ROM12, RAM13, and I / O14. The control unit can be configured as a sub-control unit controlling a portion of the operation of the control device 10, or as part of a main control unit controlling the overall operation of the control device 10. Some or all of the blocks of the control unit may use integrated circuits or IC chipsets, such as LSI (Large Scale Integration). These blocks may use individual circuits or circuits that integrate some or all of them. The blocks may be integrated as a single unit or may be separate units. Furthermore, a portion of each block may be used independently. The integration of the control unit is not limited to LSI; dedicated circuits or general-purpose processors may also be used.

[0058] The storage unit 15 may be, for example, an HDD (Hard Disk Drive), an SSD (Solid State Drive), or flash memory. The control program 15A according to this embodiment is stored in the storage unit 15. It should be noted that the control program 15A may also be stored in the ROM 12.

[0059] The control program 15A can be pre-installed in the control device 10, for example. The control program 15A can also be implemented by storing it in a non-volatile, non-transitory storage medium, or by distributing it via a network and appropriately installing it in the control device 10. It should be noted that examples of non-volatile, non-transitory storage media include CD-ROMs (Compact Disc Read Only Memory), optical discs, HDDs, DVD-ROMs (Digital Versatile Disc Read Only Memory), flash memory, memory cards, etc.

[0060] The connecting part 16 is an interface for connecting the robot controller 22 of the robot 20, the robot controller 62 of the robot 60, the sewing machine control mechanism 32 of the sewing machine 30, and the camera 40 respectively.

[0061] The CPU 11 of the control device 10 in this embodiment writes the control program 15A stored in the storage unit 15 into the RAM 13 and executes it, thereby serving as... Figure 5 Each of the shown parts performs its function.

[0062] Figure 5 This is a block diagram illustrating an example of the functional structure of the control device 10 according to this embodiment. For example... Figure 5 As shown, the CPU 11 of the control device 10 according to this embodiment functions as a setting unit 11A and a control unit 11B.

[0063] (Control related to robot 20)

[0064] Here, the control related to robot 20 will be explained. When sewing arbitrary shapes that are not simply straight lines or fixed curves, the distance between the robot and the sewing machine changes constantly.

[0065] In the sewing system 100 of this embodiment, a robot 20, which holds the sewn material M1 at a position away from the sewing point of the sewing machine 30, moves the sewn material M1 while performing sewing of arbitrary shapes that are not simply straight lines or fixed curves. It should be noted that, for the position where the sewn material M1 is placed, the control device 10 controls the robot holding position and robot holding direction of the robot 20 in a manner that moves the sewn material M1 and is parallel to the upper surface of the sewing machine worktable 50.

[0066] The setting unit 11A sets a predetermined sewing position for the material M1 to be sewn. The predetermined sewing position refers to a predetermined sewing location on the material M1. The predetermined sewing position is represented as a set of consecutive points. This set of consecutive points is, for example, set on a continuous free curve (see reference). Figure 6 The stitching on the seam. Figure 6 This is an example of setting a sewing line on the material M1 to be sewn based on a predetermined sewing position. "Continuous free curve" refers to an irregular, continuous line, which may include straight lines, shaping lines, and turning points. The sewing line may be set based on a characteristic shape that marks the material M1, or it may be set at a position a certain distance away from the end of the material M1. A stitch is formed after sewing along the sewing line. For example, the predetermined sewing position is set while displaying an image of the material M1 taken by camera 40 on a monitor. The predetermined sewing position may be represented as two-dimensional or three-dimensional coordinates, for example, using a specific position on the sewing machine table 50 as a reference position. Specifically, the control device 10 includes an input device such as a mouse or keyboard, which can be used to input various sewing conditions, such as sewing range, seam edge, and sewing spacing. Thus, an appropriate predetermined sewing position is set on the material M1. If multiple consecutive predetermined sewing positions are set, the predetermined sewing direction is determined based on the positional relationship of the predetermined sewing positions.

[0067] The control unit 11B outputs robot command signals to the robot controller 22 to instruct the actions of the robot 20, and outputs sewing machine command signals to the sewing machine control mechanism 32 to instruct the feed speed of the sewing machine 30.

[0068] The control unit 11B controls the robot holding position and robot holding direction of the robot 20, so that the predetermined sewing position of the sewn material M1 is aligned with the sewing point, and the sewn material M1 moves in the predetermined sewing direction determined by the predetermined sewing position. The robot command signal output by the control unit 11B includes the robot holding position and robot holding direction. The robot holding position and robot holding direction represent the position and direction in which the robot 20 holds the sewn material M1, i.e., the position and direction of the hand 24.

[0069] The control unit 11B uses the relationship between the predetermined sewing position and the predetermined sewing direction (referred to as the "robot / sewing machine correspondence") determined when the robot is maintaining its position and moving in its direction to calculate another speed corresponding to one of the speeds representing the robot's position-maintaining movement speed and the predetermined sewing position speed representing the predetermined sewing position movement speed. It controls the robot 20 to move at the robot position-maintaining speed while maintaining its position, and controls the sewing machine 30 to make the predetermined sewing position speed the feed speed of the sewing machine 30. The robot / sewing machine correspondence is, for example, expressed as the sewing machine's feed speed (sewing machine feed speed = f(robot speed, vector T)).

[0070] For the control of the sewing machine 30 and the robot 20, the control unit 11B controls the feed speed of the sewing machine 30 based on the robot's holding position speed and corresponding to a predetermined sewing position speed determined based on the robot's holding position speed. Alternatively, the robot's holding position speed can be synchronized with the predetermined sewing position speed based on the predetermined sewing position speed.

[0071] (Control related to robot 60)

[0072] The setting unit 11A sets a predetermined sewing position for the material M2 to be sewn. This predetermined sewing position corresponds to the predetermined sewing position of the material M1 to be sewn, resulting in a three-dimensional shape upon completion of the sewing. While both the material M1 and M2 can be set as continuous free curves, the length and shape are set differently to achieve a three-dimensional shape. Furthermore, the control device 10 controls, for example, the robot holding position and robot holding direction of the robot 60, such that the position where the material M2 is placed is near the sewing point on the sewing machine 30, and it is held in this holding position in an inclined state relative to the material M1. It should be noted that if the hand 64 is a roller mechanism, it does not need to be replaced; however, if it is a different mechanism, it must be replaced.

[0073] The control unit 11B outputs robot command signals to the robot controller 62 to instruct the actions of the robot 60. The control unit 11B controls the robot holding position and robot holding direction relative to the robot 60, ensuring that the predetermined sewing position of the sewn material M2 aligns with the sewing point, and moves the sewn material M2 in the predetermined sewing direction determined by the predetermined sewing position. Furthermore, while the robot 60 holds the sewn material M2, the control unit 11B controls the robot holding position and robot holding direction relative to the robot 60, causing the sewn material M2 to tilt relative to the sewn material M1. As it moves in the predetermined sewing direction, the control unit 11B performs circumferential position control relative to the sewing point P of the sewing machine 30 by a distance of θ.

[0074] Additionally, the control unit 11B can control the robot 60 to hold the sewn material M2 at an angle, and control the pressing part 34 of the sewing machine 30 to move up and down intermittently. As a result, the sewn material M2 is intermittently pressed against the sewing table, and the sewn material M2 can be tilted significantly when not pressed, thus increasing the controllability.

[0075] Based on the above structure, in this embodiment, the control device 10 controls the speed of the robot 20 and the sewing machine 30 to be synchronized, and controls the robot 60 to hold the sewing material M2 in an inclined state relative to the sewing material M1 for sewing.

[0076] It should be noted that in the control of robots 20 and 60, when the materials to be sewn are stitched together in a curved overlapping state, the control is performed by using the protruding side of the curved surface as the material to be sewn M1 and the concave side as the material to be sewn M2. Therefore, the control device 10 controls robot 60 to hold material to be sewn on the concave side of the curved surface in an inclined state relative to the material to be sewn M1 on the protruding side of the curved surface for sewing. On the inclined sewing material M2 side, it can be sewn with a greater curvature than the other material to be sewn M1, and the stitch distance on the inclined side is longer than the stitch distance on the non-inclined side. This tilts the materials to be sewn, making it suitable for the concave side of the curved surface when overlapping and sewing.

[0077] Figure 7 This diagram illustrates an example of the sewing thread L1 and sewing thread L2 involved in this embodiment. Figure 7 As shown, the length or shape of the sewing thread L1 set on the sewing material M1 is different from the length or shape of the sewing thread L2 set on the sewing material M2. The sewing thread L1 represents a set of multiple stitches a1 to a7. Each stitch is a predetermined sewing position. Similarly, the sewing thread L2 represents a set of multiple stitches b1 to b7. The multiple stitches a1 to a7 of the sewing thread L1 and the multiple stitches b1 to b7 of the sewing thread L2 are set so that a predetermined three-dimensional shape is formed by merging and sewing the multiple stitches a1 to a7 of the sewing thread L1 and the multiple stitches b1 to b7 of the sewing thread L2. It should be noted that in... Figure 7 In the text, for ease of understanding, the differences in length and shape are exaggerated. However, in reality, during stitching, although the tightness is also related to the curvature of the curve, the differences in length or shape are sometimes very small. Within each stitch, the difference is further distributed, with the ratio remaining the same but the amount decreasing.

[0078] Figure 8This is a diagram used to illustrate the trajectory control of the sewn materials M1 and M2 involved in this embodiment. (Example) Figure 8 As shown, the control unit 11B controls the movement of both robots 20 and 60, causing the sewing threads L1 and L2, set by the setting unit 11A, to overlap with the same number of stitches, while ensuring that the start and end points of sewing threads L1 and L2 are aligned. In trajectory control, to create a three-dimensional sewn product, stitches are pre-set on both the sewn material M1 and the sewn material M2. By overlapping the stitches a1 to a7 and b1 to b7, the finished sewn product becomes three-dimensional.

[0079] Next, the operation of the control device 10 according to this embodiment will be explained. Figure 9 This is a sequence diagram illustrating an example of the sewing process flow of the control program 15A according to this embodiment. If an instruction is given to perform sewing processing, the control program 15A is started using the CPU 11, and the following steps are executed.

[0080] In step S100, the CPU 11 of the control device 10 generates sewing machine command signals and robot command signals for each robot.

[0081] In step S102, CPU11 outputs sewing machine command signals and robot command signals for each robot. It outputs sewing machine command signals for sewing machine 30 to sewing machine control mechanism 32, robot command signals for robot 20 to robot controller 22, and robot command signals for robot 60 to robot controller 62.

[0082] In step S104, the sewing machine control mechanism 32 controls the feed action (feed speed of the sewing machine) of the sewing machine 30 based on the sewing machine command signal.

[0083] In step S106, the robot controller 22 controls the robot holding position and robot holding direction of the robot 20 based on robot command signals. The robot 20, under this control, holds the sewn material M1 parallel to the upper surface of the sewing machine table 50 while moving in the predetermined sewing direction.

[0084] In step S108, the robot controller 62 controls the robot holding position and robot holding direction of the robot 60 based on robot command signals. The robot 60, through this control, moves to hold the sewing material M2 in an inclined state relative to the sewing material M1 for sewing, while simultaneously moving in a predetermined sewing direction.

[0085] According to the above control, the robot 20 is controlled to hold the sewn material M1 parallel to the upper surface of the sewing machine table 50, while moving in the predetermined sewing direction.

[0086] According to this embodiment, by sewing one side of the material M2 to be sewn while tilting it relative to the material M1 to be sewn, the material to be sewn can be sewn in a three-dimensional manner even if the material to be sewn before sewing is fixed in a three-dimensional shape. In addition, the deflection that occurs during three-dimensional sewing can be suppressed.

[0087] It should be noted that in the above embodiments, processor refers to processor in a broad sense, including general-purpose processors (e.g., CPU: Central Processing Unit, etc.) and special-purpose processors (e.g., GPU: Graphics Processing Unit, ASIC: Application Specific Integrated Circuit, FPGA: Field Programmable Gate Array, programmable logic device, etc.).

[0088] Furthermore, the operation of the processor in the above embodiments can be constituted not only by a single processor, but also by the coordinated operation of multiple processors located in physically separate positions. Additionally, the order of the processor's actions is not limited to the order described in the above embodiments and can be appropriately modified.

[0089] The control device described above is an example of the embodiment. The embodiment may also be a program for causing a computer to execute the functions of the various parts of the control device. The embodiment may also be a computer-readable, non-transitory storage medium storing these programs.

[0090] Furthermore, the structure of the control device described in the above embodiment is an example, and it can be modified according to the situation without departing from the main idea. For example, in the above embodiment, the case where two robots hold the sewing material separately was described as an example, but it is not limited to this. For example, a single robot can be used to hold the other sewing material in an inclined state relative to the other robot, and the degree of inclination can be changed according to the shape to perform sewing. For the inclination, a clamp can be inserted between them, or a multi-finger robot can be used to hold the material separately to control the interval.

[0091] Furthermore, the process flow described in the above embodiments is also an example. Unnecessary steps can be deleted, new steps can be added, or the processing order can be changed without departing from the main idea.

[0092] Furthermore, while the above embodiments describe the implementation of the processing involved in the embodiments using a computer through a software structure by executing a program, the implementation is not limited to this. Embodiments can be implemented, for example, through a hardware structure or a combination of hardware and software structures.

Claims

1. A sewing system, comprising: A sewing device for sewing overlapping first and second materials; The robot holds the first and second materials to be sewn together. as well as A control device controls the sewing device and the robot, positioning the robot at an angle relative to the first material to be sewn to hold the second material to be sewn for sewing. The control device controls the robot such that the second piece of material to be sewn is held in a position close to the sewing point of the sewing device, and is held at an angle relative to the first piece of material to be sewn in this position. The robot maintains the first piece of material being sewn by means of a robot holding position, which indicates the position of the robot holding the material, and a robot holding direction, which indicates the direction of holding. The control device displays an image of the first material to be sewn captured by a camera on a monitor while setting a predetermined sewing position. It controls the robot holding position and robot holding direction for the robot, ensuring that the predetermined sewing position of the first material to be sewn aligns with the sewing point. It also moves the first material to be sewn in a predetermined sewing direction determined by the predetermined sewing position. Using the relationship between the predetermined sewing position and the predetermined sewing direction determined during the movement of the robot holding position and the robot holding direction, it calculates another speed corresponding to either the robot holding position speed (representing the speed of movement of the robot holding position) or the predetermined sewing position speed (representing the speed of movement of the predetermined sewing position). It controls the robot to move the robot holding position at the robot holding position speed and controls the sewing device to make the predetermined sewing position speed the feed speed of the sewing device. Based on the robot holding position speed, and corresponding to the predetermined sewing position speed determined based on the robot holding position speed, it controls the feed speed of the sewing device.

2. The sewing system according to claim 1, wherein, The control device controls the robot such that the first material to be sewn receives and supports the second material to be sewn parallel to the surface at the location surrounding the sewing point.

3. The sewing system according to claim 1, wherein, When the first and second materials to be sewn are sewn together in a curved overlapping state, the protruding side of the curved surface is used as the first material to be sewn, and the concave side of the curved surface is used as the second material to be sewn. The control device controls the robot to hold the second material to be sewn on the concave side of the curved surface in an inclined state relative to the first material to be sewn on the protruding side of the curved surface for sewing.

4. The sewing system according to claim 1, wherein, The control device controls the robot to hold the second material to be sewn at an angle, and controls the pressing part of the sewing device to move up and down intermittently.

5. The sewing system according to claim 1, wherein, The robots are respectively used as a first robot to hold the first material to be sewn and a second robot to hold the second material to be sewn. The control device controls the first robot to receive and support the second material to be sewn parallel to the first material to be sewn along the surface surrounding the sewing point, and controls the second robot to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing.

6. A control method comprising a computer controlling a sewing device and a robot, the sewing device sewing overlapping first and second materials to be sewn, and the robot holding the first and second materials to be sewn, wherein in the control method, The robot is controlled to hold the second material to be sewn in an inclined position relative to the first material to be sewn for sewing. The holding position of the second material to be sewn is a proximal position conveyed to the sewing point of the sewing device, and it is held in this holding position in an inclined position relative to the first material to be sewn. The robot maintains the first piece of material being sewn by means of a robot holding position, which indicates the position of the robot holding the material, and a robot holding direction, which indicates the direction of holding. While displaying an image of the first material to be sewn captured by a camera on a monitor, the predetermined sewing position is set. The robot's holding position and robot holding direction are controlled such that the predetermined sewing position of the first material to be sewn aligns with the sewing point, and the first material to be sewn moves in the predetermined sewing direction determined by the predetermined sewing position. Using the relationship between the predetermined sewing position and the predetermined sewing direction determined when the robot is in a position and moving in a direction, another speed is determined that corresponds to one of the speeds representing the robot's movement while maintaining its position (robot position holding speed) and the predetermined sewing position speed (predetermined sewing position speed). The robot is controlled to maintain its position and move at a speed that allows it to maintain that position, and the sewing device is controlled so that the predetermined sewing position speed becomes the feed speed of the sewing device. Based on the robot's position holding speed, and corresponding to the predetermined sewing position speed determined based on the robot's position holding speed, the feed speed of the sewing device is controlled.

7. A control device, wherein, The control device includes a control unit that controls a sewing device and a robot. The sewing device sews overlapping first and second materials to be sewn, and the robot holds the first and second materials to be sewn. The control unit controls the robot to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing. The holding position of the second material to be sewn is a position close to the sewing point of the sewing device, and it is held in an inclined state relative to the first material to be sewn in this holding position. The robot maintains the first piece of material being sewn by means of a robot holding position, which indicates the position of the robot holding the material, and a robot holding direction, which indicates the direction of holding. The control device While displaying an image of the first material to be sewn captured by a camera on a monitor, the predetermined sewing position is set. The robot's holding position and robot holding direction are controlled such that the predetermined sewing position of the first material to be sewn aligns with the sewing point, and the first material to be sewn moves in the predetermined sewing direction determined by the predetermined sewing position. Using the relationship between the predetermined sewing position and the predetermined sewing direction determined when the robot is in a position and moving in a direction, another speed is determined that corresponds to one of the speeds representing the robot's movement while maintaining its position (robot position holding speed) and the predetermined sewing position speed (predetermined sewing position speed). The robot is controlled to maintain its position and move at a speed that allows it to maintain that position, and the sewing device is controlled so that the predetermined sewing position speed becomes the feed speed of the sewing device. Based on the robot's position holding speed, and corresponding to the predetermined sewing position speed determined based on the robot's position holding speed, the feed speed of the sewing device is controlled.

8. A non-transitory storage medium storing a control program that enables a computer to execute control over a sewing device and a robot, the sewing device sewing overlapping first and second materials to be sewn, and the robot holding the first and second materials to be sewn, wherein... The robot is controlled to hold the second material to be sewn in an inclined position relative to the first material to be sewn for sewing. The holding position of the second material to be sewn is a proximal position conveyed to the sewing point of the sewing device, and it is held in this holding position in an inclined position relative to the first material to be sewn. The robot maintains the first piece of material being sewn by means of a robot holding position, which indicates the position of the robot holding the material, and a robot holding direction, which indicates the direction of holding. The control program causes the computer to perform the following steps: While displaying an image of the first material to be sewn captured by a camera on a monitor, the predetermined sewing position is set. The robot's holding position and robot holding direction are controlled such that the predetermined sewing position of the first material to be sewn aligns with the sewing point, and the first material to be sewn moves in the predetermined sewing direction determined by the predetermined sewing position. Using the relationship between the predetermined sewing position and the predetermined sewing direction determined when the robot is in a position and moving in a direction, another speed is determined that corresponds to one of the speeds representing the robot's movement while maintaining its position (robot position holding speed) and the predetermined sewing position speed (predetermined sewing position speed). The robot is controlled to maintain its position and move at a speed that allows it to maintain that position, and the sewing device is controlled so that the predetermined sewing position speed becomes the feed speed of the sewing device. Based on the robot's position holding speed, and corresponding to the predetermined sewing position speed determined based on the robot's position holding speed, the feed speed of the sewing device is controlled.

9. A method for manufacturing sewn fabric, wherein a computer controls a sewing device and a robot, the sewing device sewing overlapping first and second materials to be sewn, and the robot holding the first and second materials to be sewn, wherein in the method for manufacturing sewn fabric... By controlling the robot to hold the second material to be sewn in an inclined state relative to the first material to be sewn for sewing, the second material to be sewn is held in a position close to the sewing point of the sewing device, and is held in this position in an inclined state relative to the first material to be sewn. The robot maintains the first piece of material being sewn by means of a robot holding position, which indicates the position of the robot holding the material, and a robot holding direction, which indicates the direction of holding. The computer performs the following steps: While displaying an image of the first material to be sewn captured by a camera on a monitor, the predetermined sewing position is set. The robot's holding position and robot holding direction are controlled such that the predetermined sewing position of the first material to be sewn aligns with the sewing point, and the first material to be sewn moves in the predetermined sewing direction determined by the predetermined sewing position. Using the relationship between the predetermined sewing position and the predetermined sewing direction determined when the robot is in a position and moving in a direction, another speed is determined that corresponds to one of the speeds representing the robot's movement while maintaining its position (robot position holding speed) and the predetermined sewing position speed (predetermined sewing position speed). The robot is controlled to maintain its position and move at a speed that allows it to maintain that position, and the sewing device is controlled so that the predetermined sewing position speed becomes the feed speed of the sewing device. Based on the robot's position holding speed, and corresponding to the predetermined sewing position speed determined based on the robot's position holding speed, the feed speed of the sewing device is controlled.

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