Generating stitch shading data for online line shading process

Abstract

A computer-implemented method (200) for generating stitch shading data for a line shading process, comprising: obtaining (210) first stitch shading data (114) based on a digital representation to be generated as a decorative line pattern; obtaining (220) at least one line color boundary (115) defining a color change from a first color to a second color; determining (230) residual stitch data (116) based on the at least one thread color boundary (115), the residual stitch data indicating a number of residual stitches required to perform the color change in the thread coloring process; and generating (240) second stitch shading data (117) based on the residual stitch data (116) such that a color change of the first stitch shading data (114) is considered in the line shading process.

Description

Technical Field

[0001] The present invention relates to the technical field of thread consuming devices. In particular, the present invention relates to a computer-implemented method for generating thread stitch coloring data for an in-line thread coloring process. The present invention also relates to associated systems, non-transient computer-readable storage media, and computer program products. Background Art

[0002] Thread consuming devices, such as embroidery machines, have traditionally relied on pre-colored threads, limiting design creativity and causing operational inefficiencies due to, for example, frequent thread changes. Online thread coloring technology provides a solution by coloring the thread during consumption, thereby achieving diverse designs with fewer thread changes. However, it has proven difficult to handle color transitions during online thread coloring. These challenges involve ensuring consistent color changes, synchronizing with the timing of thread consuming devices, providing accurate color calibration, maintaining thread quality, and integrating with existing machines, to name just a few examples.

[0003] The present inventors have recognized the above-mentioned deficiencies in the prior art and have proposed in-depth solutions. Summary of the invention

[0004] Therefore, the purpose of the present invention relates to managing the color transition in the process of thread coloring. In order to reproduce a decorative pattern using an embroidery device, a newer type of embroidery device includes a computerized controller suitable for receiving stitch coloring data, for example, via a computer file of a given format. The stitch coloring data is then processed so that it is possible to identify where a specific decorative pattern changes color, for example by analyzing the corresponding color values ​​and positions of the pixels of the stitch coloring data. The computerized controller then proceeds to determine where the portion of the thread will be cut in order to switch between various thread source representations that are each associated with a specific thread color representation. In the manner of this control process, the embroidery device can be controlled to perform a color transition by appropriately switching between a plurality of pre-colored thread sources so that the decorative pattern can be reproduced on a substrate.

[0005] Since the online thread coloring device utilizes a single thread source with a single color (usually white), which is colored when the thread is consumed in the embroidery device, the above control process cannot provide satisfactory results in the case of the online thread coloring process. In order to provide a reproduction of a decorative pattern using an online thread coloring device, it is important to properly manage the color transition, otherwise the coloring material may be smeared out. Coloring that is smeared out during the color transition is undesirable because they reduce the visual appeal, precision and professionalism of the embroidery, potentially leading to production inefficiencies and lower quality results. Ultimately, the coloring quality deteriorates, thereby deteriorating the embroidery results.

[0006] The inventors have realised that colour transitions can be controlled by a computer controlled process by monitoring thread colour boundaries defining colour changes and accordingly converting first stitch colouring data into second stitch colouring data taking into account the residual stitch required to perform the colour change.

[0007] Thus, in a first aspect of the present disclosure, a computer-implemented method for generating stitch coloring data for an online thread coloring process is provided. The method comprises: obtaining first stitch coloring data based on a digital representation to be generated as a decorative thread pattern, the first stitch coloring data having a set of color representations assigned to a corresponding group of thread source representations; obtaining at least one thread color boundary from the first stitch coloring data, each thread color boundary defining a color change from a first color to a second color in the color representation group; determining residual stitch data based on at least one thread color boundary, the residual stitch data indicating the number of residual stitches required to perform the color change in the online thread coloring process; and generating second stitch coloring data based on the residual stitch data, so that the color change of the first stitch coloring data is accounted for in the online thread coloring process, the second stitch coloring data having a set of color representations assigned to a single thread source representation.

[0008] The first aspect enables stitch coloring data to be converted from a traditional embroidery file (i.e., suitable for a non-online thread coloring process) to stitch coloring data suitable for an online thread coloring process. Thus, it should be understood that the first stitch coloring data is stitch coloring data suitable for a traditional embroidery device that adopts a plurality of pre-colored thread sources, and the second stitch coloring data is stitch coloring data suitable for an online embroidery device. This conversion effectively takes into account the required residual stitches that inevitably occur due to the coloring switching from one or more first colors to one or more second colors. The residual stitch data of the residual stitches required for performing the color change are included in the second stitch coloring data. Additional technical advantages can be envisioned from one or more of the following examples.

[0009] In some examples, the residual stitch data is determined by estimating the number of residual stitches suitable for performing on a residual substrate different from the substrate on which the decorative line pattern is to be produced.

[0010] In some examples, the substrate is adapted to be received by a main frame and the residual substrate is adapted to be received by at least one sub-frame.

[0011] In some examples, the residual stitch data is determined by estimating an amount of residual stitch suitable for execution as an underlay stitch on a substrate on which a decorative thread pattern is to be produced.

[0012] In some examples, the estimate of the number of residual thread traces depends on one or more operating conditions of the thread coloring process.

[0013] In some examples, determining the residual stitch data includes defining a line color boundary range indicating a range of residual stitches having an intermediate color between the first color and the second color, the line color boundary range having a starting value indicating the start of a color change and an ending value indicating the completion of the color change.

[0014] In some examples, the method further includes setting a corresponding buffer for each of the start value and the end value, the buffer indicating an amount of stitches to append to the residual stitch data at a corresponding end of the line color boundary range.

[0015] In some examples, the thread color boundary range depends on one or more of the number of stitches, the amount of thread consumed, substrate characteristics, thread characteristics, and combinations thereof.

[0016] In some examples, the color change is caused by one or more of a color transition in the digital representation, a wire cutting process, a relative movement of the substrate, and combinations thereof.

[0017] In some examples, the residual stitch data includes information of one or more of the length of the color change, the direction of the color change used to perform the color change, substrate properties on which the color change is to be performed, line properties of the line used to perform the color change, and combinations thereof.

[0018] In some examples, subsequent consumption of the thread source in the online thread coloring process includes: based on the second stitch coloring data, causing control of the online thread coloring process in the following ways: controlling the online thread coloring process of the thread; controlling the thread consumption process of the thread relative to the substrate; and controlling the residual embroidery process of the thread as one or both of the following: residual stitches applied to a residual substrate different from the substrate, and residual stitches as base stitches applied to the substrate.

[0019] In some examples, generating second stitch coloring data includes: obtaining pattern data from a digital representation, the pattern data including a plurality of pixels, each pixel being associated with a position and a color value in the digital representation; generating resolution data by processing the pattern data, wherein processing the pattern data includes determining a line arrangement including a plurality of stitches, wherein the entire line arrangement corresponds to the digital representation to be produced in an online line coloring process; and generating second stitch coloring data for the line based at least on the resolution data.

[0020] In some examples, processing the pattern data also includes determining information related to a length of the stitches, a direction of the stitches, and a type of connection used to connect one or more stitches to one another.

[0021] In a second aspect of the present disclosure, a control unit is provided, wherein the control unit comprises a processor configured to execute the steps of the method of the first aspect.

[0022] In a third aspect of the present disclosure, a system for processing at least one thread inline for use with a thread consumption device is provided. The system comprises: a processing unit comprising at least one discharge device, the discharge device comprising at least one nozzle, the nozzle arranged along the at least one thread, configured to dispense one or more coating substances onto the thread when activated; and a control unit configured to control the discharge device to dispense the coating substance onto the at least one thread based on the second thread coloring data generated by the method of the first aspect.

[0023] In a third aspect of the present disclosure, a non-transitory computer-readable storage medium is provided, wherein the storage medium includes instructions, which, when executed by one or more processors of a control unit, cause the processor to perform the functions of the method of the first aspect.

[0024] In a second aspect of the present disclosure, a computer program product is provided, comprising computer codes for executing the functions of the method of the first aspect.

[0025] In this context, the term "thread consuming device" is any device that consumes thread during use. For example, it may be an embroidery machine, a weaving machine, a sewing machine, a knitting machine, a weaving machine, a tufting machine, a thread winding machine or any other thread consuming device that may benefit from a surface treatment or coating or any other process involving subjecting the thread to a substance, such as dyeing.

[0026] In this context, the term "treatment" is any process designed to cause a change in the properties of the thread. These processes include, but are not limited to, coloring, wetting, lubricating, cleaning, fixing, heating, curing, dyeing, etc.

[0027] In this context, the term "representation of (various units)" is a digital representation of said units. Thus, a digital representation of a decorative line pattern is data digitally representing said line pattern, including, for example, pixels and related data. Moreover, a color representation is interpreted as how the actual color is represented in a digital format. For example, a color representation may include RGB color values. Further, a line source representation is a digital representation of a line source such as a spool. For example, a line source may be digitally represented as a data structure having arbitrary unit length data related to the actual length of the corresponding physical line source.

[0028] In this context, the term "residual stitch" is a stitch that cannot be visually presented in a decorative pattern. In some examples, the residual stitch is interpreted as a backing stitch, i.e., a stitch located on a side of a substrate opposite to the side where the decorative pattern is visually presented. In some examples, the residual stitch is interpreted as a "waste" or "waste" stitch, i.e., a stitch that is manufactured to a substrate different from the substrate used to produce the decorative thread pattern. Other similar interpretations of residual stitches other than backing or waste stitches can be easily envisioned, the basic idea being that the human eye cannot visually discern them. Correspondingly, the term "residual stitch data" is digitized data related to the residual stitch, for example, which digitally defines various characteristics of the physical stitch.

[0029] In this specification, all references to upstream and / or downstream should be interpreted as relative positions during normal operation of the thread-consuming apparatus (i.e., when the apparatus is operating to process an elongate substrate such as a thread that moves continuously through the apparatus in the normal operating direction). Thus, an upstream component is arranged so that a particular portion of the thread passes through it before passing through a downstream component. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Examples of the invention will be described in the following description of the invention; reference is made to the accompanying drawings which illustrate non-limiting examples of how the inventive concept may be put into practice.

[0031] Figure 1 is a schematic diagram of a system for an in-line processing line according to one example.

[0032] Figure 2 is a perspective view of a system having a thread consuming device, an embroidery frame, and a processing unit according to one example.

[0033] Figure 3is a schematic diagram of a processing unit for use with a system according to one example.

[0034] Figure 4 is a schematic diagram of an exhaust apparatus forming part of a processing unit according to one example.

[0035] Figure 5 is a schematic diagram of a wire applied to a substrate according to one example.

[0036] Figure 6 is a schematic diagram of the color transition of a line applied to a substrate according to one example.

[0037] Figure 7 is a schematic diagram of converting first stitch coloring data into second stitch coloring data according to an example.

[0038] FIG. 8A to FIG. 8D is a schematic top view of an embroidery frame according to different examples.

[0039] Fig. 9 is a schematic top view of an embroidery frame according to an example.

[0040] FIG. 10A to FIG. 10B is a schematic top view of an embroidery frame according to an example, Fig. 10A A first side of a substrate is shown, Fig. 10B Shows Fig. 10A A second opposite side of the substrate.

[0041] Fig.11 is a schematic top view of a decorative pattern to be generated according to an example.

[0042] Fig.12 is a schematic top view of determining residual stitch data according to an example.

[0043] Fig.13 is a schematic diagram of a method according to an example.

[0044] Fig.14 is a schematic diagram of a method according to an example. DETAILED DESCRIPTION

[0045] Figure 11 is a schematic diagram of a system 10 for processing thread online. The system 10 includes a processing unit 100 having a discharge device 150 configured to distribute one or more coating substances onto at least one thread. The system 10 is connected to at least one thread consumption device 15, which can be in the form of, for example, one or several embroidery machines, looms, sewing machines, knitting machines, tufting machines, winding machines, etc. In the following, the thread consumption device may be referred to as an embroidery machine in various examples. The system 10 thus forms a thread consumption unit, including at least one embroidery machine 15 and the processing unit 100. It should be noted that more than one thread can be used in (one or more) thread consumption devices.

[0046] The processing unit 100 allows the embroidery machine 15 to operate without providing the unique pre-colored thread required by conventional thread consuming devices. Instead, the processing unit 100 provides online coloring of the thread according to a predetermined coloring pattern so that colored embroidery can be produced. Thus, the processing unit 100 replaces the individual spools of thread each having pre-colored thread that exist in the conventional systems of the prior art consuming thread.

[0047] Figure 2 The thread consumption device 15 is illustrated as an embroidery machine, illustrated here as a single-head embroidery machine, which is equipped with a processing unit 100. The embroidery machine 15 may include a movable table 2b carrying a substrate 3 to be embroidered. During operation, the movable table 2b can be controlled to change its position in the X and Y directions (i.e., in this case, the horizontal plane, but it can also be in the vertical plane). The speed of the movable table 2b can be controlled according to the operation of the embroidery machine 15. In some examples, the substrate 3 to which the thread 20 is to be applied is arranged in a frame 30. If there is a movable table 2b, the frame 30 can be arranged on the top of the table 2b. The embodiment of this frame 30 will be described in more detail later in this disclosure.

[0048] The substrate 3 is preferably a textile, fabric or cloth. In some examples, the substrate 3 has a fixed set of properties, such as a specific thickness or elastic constant. The substrate 3 can be divided into different parts, wherein each part can have different properties related to, for example, the thickness and / or elasticity of the substrate 3.

[0049] Figure 3Various components of the processing unit 100 according to one example are shown. It is contemplated that other examples may include fewer, additional or alternative components than those shown in the figure. Most of the components are arranged in a housing 105. Immediately downstream of the spool 120, a wire feeder 130 may be arranged, which is configured to pull the wire forward through the processing unit 100. The wire feeder 130 is not further described herein, but typically the wire feeder 130 is arranged to receive one or more wires 20 from the spool 120 and transfer the wires 20 to other components of the processing unit 100. The wire feeder 130 is controlled by a control unit 109. Preferably, the wire feeder 130 is also configured to control the wire tension, for example, by means of a driven roller, an encoder wheel and / or one or more wire guides. After passing through the wire feeder 130, the wire 20 engages with the wire guide device 140.

[0050] The wire guide apparatus 140 may be in the form of, for example, one or more guide rollers 142 , 144 or other suitable devices which ensure that the wire 20 is aligned with one or more treatment nozzles forming part of the discharge apparatus 150 .

[0051] The discharge device 150 is configured to discharge a treatment substance (such as a coloring substance) onto the line 20 when the line 20 passes through the discharge device 150. For this purpose, the nozzle is preferably arranged in the longitudinal direction of the line 20. The discharge device 150 can be moved by means of a drive unit (not shown). Having a drive unit will make it possible to arrange the discharge device 150 in different operating states in order to perform different tasks, such as a first state in which a coating substance is distributed to the line and a second state in which a cleaning process or other maintenance or idling is performed. For this purpose, the drive unit can be connected to the discharge device 150. The drive unit can be configured to move the discharge device 150 between an idle position and an operating position, which is achieved by means of a transmission device with different transmission ratios during the movement from the idle position toward the operating position.

[0052] A further wire guiding device 160 may be arranged downstream of the discharge device 150. The second wire guiding device 160 cooperates with the first wire guiding device 140 so that the position of the wire 20 is correct during its travel along the discharge device 150. The second wire guiding device 160 may be, for example, in the form of one or more guide rollers 162, 164, but it may also be designed to cause a rotation of the wire 20 along its longitudinal axis.

[0053] The processing unit 100 may also include a wire speed sensor (not shown) configured to measure the speed of the wire 20 passing through the processing unit 100. The wire speed sensor may be arranged outside or inside the housing 105. The wire speed sensor may be arranged just before the discharge device 150. In some examples, the wire speed sensor may replace or supplement the wire guide device 140. In some examples, the wire speed sensor may be arranged just after the discharge device 150. In some examples, the wire speed sensor may replace or supplement the second wire guide device 160. In yet other examples, two wire sensors are provided, the first one being arranged before the discharge device 150 and the second one being arranged after the discharge device 150, for example as the first wire guide device 140 and the second wire guide device 150.

[0054] The wire 20 is then fed forward to pass through one or more fixation units 170, which are provided to fix the treatment substance to the wire 20. The fixation unit 170 preferably includes a heating device, such as a hot air supply or heating element, or a UV light source, so that the treatment substance (e.g., coloring substance) is cured or fixed to the wire 20. The fixation unit 170 can be arranged horizontally, vertically, or at an angle between horizontal and vertical.

[0055] Before leaving the housing 105, the wire 20 may pass through a cleaning unit 180, such as an ultrasonic bath, where unwanted particles are removed from the wire 20. When the treatment substance is fixed to the wire 20, the cleaning unit 180 will leave the treatment substance unaffected.

[0056] The processing unit 100 may also include a lubrication unit 185 disposed inside the housing 105. Additional line buffers and feeders (not shown) may also be included in the processing unit 100, disposed at various locations in the line path.

[0057] The thread 20 preferably leaves the processing unit 100 through an aperture or the like, from which the thread 20 is forwarded to an associated thread-consuming device, such as an embroidery machine 15 .

[0058] During operation, preferably, the thread feeder 130 and other components engaging the thread 20 are configured so that the force required to pull the thread 20 from the processing unit 100, i.e., the pulling force applied by the downstream embroidery machine 15, is approximately the same as when the processing unit 100 is replaced by a prior art spool.

[0059] A control unit 109 with associated electronics, such as power electronics, communication modules, memory, etc. is also provided. The control unit 109 is connected to the thread feeder 130, the discharge device 150 and the fixing unit 170 so as to allow the operation of these components to be controlled. Further, the control unit 109 is configured to control the operation of the entire processing unit 100 including the cleaning unit 180, the lubrication unit 185, the interruption of the thread 20, the line speed at various locations along the processing unit 100, the line buffer, etc. The control unit 109 may also be configured to receive control signals from one or more components of the processing unit 100, such as control signals for triggering specific controls, or other information related to, for example, thread consumption of the embroidery machine 15. The control unit 109 is also configured to receive information from a second control unit 110, which will be described in more detail later.

[0060] The control unit 109 may include one or more processors configured to be implemented by any commercially available CPU ("central processing unit"), DSP ("digital signal processor") or any other electronic programmable logic device, or a combination of such processors or other electronic programmable logic devices. The control unit 109 may be implemented using instructions capable of implementing hardware functions, for example, by using executable computer program instructions in a general or special processor, which may be stored on a computer-readable storage medium (disk, memory, etc.) to be executed by such a processor.

[0061] In some examples, a user interface is also provided, preferably via a display 195 arranged at the front end of the housing 105. The display 195 allows a user to interact with the control unit 109, and thereby connect thereto, so that control parameters of the line feeder 130, the discharge device 150, the fixing unit 170, etc. can be set according to the process specifications. The display 195 can also be used to warn the user of critical situations, whereby the display 195 can be used to control the control unit 109 to issue an alarm, etc.

[0062] The control unit 109 may be configured to receive digital content. The digital content may be a photograph captured by a camera unit, included in the system 300 or provided externally to the system 300. The digital content may alternatively be virtually presented by the control unit or some other type of device capable of presenting digital content.

[0063] The control unit 109 may be configured to communicate via a communication interface with any known short-range or long-range communication standard known in the art. Short-range communication interfaces include, for example, IEEE 802.11, IEEE 802.15, ZigBee, WirelessHART, WiFi, BLE, RFID, QR, WLAN, MQTT IoT, CoAP, DDS, NFC, AMQP, LoRaWAN, Z-Wave, Sigfox, Thread, EnOcean, mesh communication, or any other form of proximity-based device-to-device radio communication signal, such as LTE Direct. Long-range communication interfaces include, for example, W-CDMA / HSPA, GSM, UTRAN, or LTE.

[0064] A memory unit (not shown) may be associated with the control unit 109, such as residing therein, and implemented with any known memory technology, including but not limited to E(E)PROM, S(D)RAM or flash memory. The memory unit may alternatively be a cloud storage unit. The cloud storage unit may be deployed as a SQL data model, such as MySQL, PostgreSQL or OracleRDBMS. Alternatively, a deployment based on a NoSQL data model such as MongoDB, Amazon DynamoDB, Hadoop or Apache Cassandra may be used. Alternatively, the memory unit may reside in an external server configured as any type of client-server or peer-to-peer (P2P) computer architecture. The server configuration may, for example, relate to any combination of, for example, a network server, a database server, an email server, a network proxy server, a DNS server, an FTP server, a file server, a DHCP server (just to name a few examples).

[0065] In some examples, the memory unit can be integrated with the control unit or inside it. The memory unit can store program instructions for execution by the control unit and temporary and permanent data used by the control unit. The program instructions and / or temporary and permanent data belong to the online stitch coloring data and other data used by the control unit to generate the online stitch coloring data. The stored online stitch coloring data can be used for direct (with at least some expected delays, as readily understood by those skilled in the art of computer networking) or at a later stage to color the line.

[0066] It should be noted that the above components may not necessarily be included in the independent processing unit 100. In other examples, the components of the processing unit 100 are divided into several units, wherein at least one unit thereof is an independent unit. Preferably, the independent unit includes at least one discharge device 150.

[0067] The control unit 109 may be part of the system 10, the processing unit 100, the line consumer 15, or may be an external control unit.

[0068] like Figure 3For example, the control unit 109 may communicate with another control unit 110. The control unit 110 may be configured to generate thread coloring data for an online coloring process, as will be described with reference to FIG. Figure 7 The above technical description of the first control unit 109 also applies to the second control unit 110 (e.g., communication technology, memory, processor 112). It should also be noted that the first control unit 109 and the second control unit 110 can be a single control unit. Therefore, separate controllers and control units 110 can be configured in series to operate according to aspects and related examples of the present disclosure.

[0069] Figure 4 1 shows an exhaust device 150 according to one example. The exhaust device 150 forms part of the processing unit 100 as described above. The direction of movement of the wire 20 in use is determined by Figure 4 The thick arrows 152a and 152b indicate the longitudinal direction of the wire 20, i.e. the longitudinal direction. The discharge device 150 comprises a plurality of nozzles 152a-f arranged at different longitudinal positions (e.g. separated by a distance d1) along the wire 20 passing through the processing unit 100 during use. Each nozzle 152a-f is arranged to dispense a coating substance, such as ink, onto the wire 20 when the nozzle is activated. When the wire 20 is twisted about its longitudinal axis, the coating substance is absorbed by the wire 20 at different circumferential positions of the wire 20. The relative positions of two adjacent dispensed droplets of the coating substance can be selected so that the droplets will overlap.

[0070] The processing unit 100 includes one or more discharge devices 150. Each discharge device 150 is preferably formed as a series of inkjet print heads 151a-d, each print head 151a-d having one or more nozzle arrays. Each nozzle array typically includes hundreds or thousands of nozzles. For illustrative purposes, only six nozzles 152a-f are shown for one print head 151a-d; however, it should be appreciated that each nozzle array may be provided with hundreds or thousands of nozzles 152 each. As an example, each print head 151a-d may be associated with a single color; in the example shown, the discharge device 150 has four print heads 151a-d, each print head 151a-d being associated with a specific color according to the CMYK standard. However, other coloring models may also be used.

[0071] The exact configuration of the discharge device 150 arranged in the processing unit 100 may vary. For example, the processing unit 100 may be equipped with a single discharge device 150 having a plurality of print heads 151a-d. Each print head 151a-d may in turn be provided with a plurality of nozzles 152a-f.

[0072] In some examples, the processing unit 100 is equipped with several discharge devices 150 arranged in series or in parallel. Then, each discharge device 150 is provided with a plurality of print heads 151a-d. If arranged in series, the upstream discharge device 150 may have print heads 151a-d associated with one or more colors of a specific color standard, while the downstream discharge device 150 has print heads 151a-d associated with other colors of the same color standard. If arranged in parallel, each discharge device 150 may have print heads 151a-d associated with all colors of a specific color standard, but with different lines 20. For such an example, two separate lines 20 can be processed simultaneously and in parallel. Combinations of parallel / serial configurations are of course also possible.

[0073] In still other examples, the discharge device 150 has only a single print head 151a - d . Dynamic coloring of the line 20 would then require several discharge devices 150 of the processing unit 100 .

[0074] Each nozzle 152a-f can distribute coating materials with colors according to the CMYK color model, wherein the primary colors are cyan, magenta, yellow and black. Thus, by activating the nozzles 152a-f, multiple colors can be distributed to the line so that the entire coloring material of a specific length of the line 20 will be a mixture of coloring materials distributed by the nozzles 152a-f. As previously mentioned, this is preferably achieved by having a number of print heads 151a-d arranged in series, whereby the nozzles 152a-f of a specific print head 151a-d are dedicated to a single color. In some examples, each nozzle 152a-f distributes coating materials with colors including a mixture of two or more primary colors of the CMYK color model. It should be noted that the nozzles can be arranged to distribute different types of coating materials, not just color coatings.

[0075] The control unit 109 is configured to control the activation of the nozzles 152a-f so that the coating substance is discharged onto the thread 20 as it passes through the processing unit 100, in particular through the discharge device 150. With this configuration, very precise coloring of the thread 20 is possible, for example, in order to provide visually very complex advanced embroidery patterns with the help of the coloring provided by the processing unit 100. For the coloring operation, the control unit 109 receives one or more input signals specifying the desired color and / or coloring effect. The color input preferably includes information about the exact color and the longitudinal start and stop position of the thread 20 for that particular color. If the line speed is determined, the longitudinal start and stop positions can be represented by specific time values.

[0076] The coloring operation can generate different visual effects on the line. Visual effects can include, for example, gradients, stripes, spots, etc. More specifically, the typical effects used include i) color changes in terms of absolute line length (such as 3cm red, 23cm green), ii) color changes in terms of relative line length (such as 30% red, 70% green), iii) pure color, iv) gradient, v) noise, vi) operations (such as changes in hue, tone, brightness, contrast, etc.), vii) mixing (i.e., the merging of different samples). Each of these effects can be repeated multiple times in the area of ​​a specific effect. In this context, the term "noise" refers to one or more colors to which a certain operation, such as saturation or brightness, is added, where the operation is fractal, Gaussian or other. The term "swatch" refers to the setting of a specific distribution pattern of a coating substance that will be generated for a specific design portion. The design portion can be a part of a pattern, graphic, shape, text, logo, symbol, color gradient, etc. The sample can be, for example, a solid color, a gradient, or a transformation from a solid color, which is transformed into a gradient between two colors after a certain length.

[0077] Further references Figure 5 In the example of , the thread consumption device 15 is arranged to provide a thread arrangement into the substrate 3 using a colored thread. The thread 20 is applied to the substrate 3 by a plurality of continuous thread portions 24. The thread arrangement corresponds to a decorative thread pattern to be produced, such as an embroidered object 26. Thus, the plurality of thread portions 24 form an object 26 (which serves as a decorative thread pattern) onto the substrate 3. The object 26 may be a specific pattern, graphic, shape, text, logo, symbol, etc. The object 26 may be a logo or a company name, for example in the form of embroidery.

[0078] The thread portion can be a stitch. In this context, the stitch can be, for example, a single turn of thread, a single loop of thread, a single turn of yarn, or a single loop of yarn. For example, the stitch can be applied using sewing, knitting, embroidery, crocheting, and / or needle lace making.

[0079] Depending on the specific details of the thread consuming device 15, the thread arrangement may be a stitch pattern (such as in the case of an embroidery, knitting or sewing machine), a weaving pattern (such as in the case of a loom) or a tuft pattern (such as in the case of a tufting machine).

[0080] In embroidery, stitches can be viewed as, for example, a flat stitch that passes through the fabric in a simple up and down motion, a backstitch stitch that passes through the fabric in a circular motion, a chain stitch that captures loops on the surface of the fabric, a knotted stitch formed by wrapping the thread around a needle. The stitch can be formed by creating two insertion points in the substrate 30.

[0081] In knitting, a stitch can be viewed as a single loop of yarn that is secured to the loop next to it to form a row or course of stitches, and secured to the loops above and below it to form a wale. The next stitch can be passed from below or above the previous loop while the previous stitch is secured in a wale. In crocheting, a stitch can be viewed as being made by pulling a loop through a previous stitch. Although specific types of stitches have been mentioned, it should be noted that all types of stitches can be used with the system disclosed herein.

[0082] Figure 6 A decorative line pattern 5 with two different color parts 5a, 5b according to one example is shown. In this example, the line part 5a is arranged with color A and the line part 5b is arranged with color B. When a decorative line pattern including a plurality of different colors is produced on a substrate, it is important to correctly determine the color transition. Therefore, it is necessary to accurately control the color change from color A to color B. The inventors of the present invention have realized a novel way that produces accurate color transitions and converts different pattern data to take into account these specific color changes. Usually, this is achieved by adding additional line parts that handle color transitions. In order to provide a decorative object that looks beautiful on a substrate, it is beneficial if the color transition is accurate and the additional line parts (such as stitches) that take into account the color change are hidden from the final object. This can be achieved in at least two different ways. The first option is by adding an additional line part as a base line part, which is not visually shown in the finished object. The second option is by adding an additional line part on a residual substrate that does not form part of the object. Any of these options can be achieved individually or in combination.

[0083] In the following examples of the present disclosure, the line portion can therefore be a stitch, and the residual stitch can be one or more of 1) a stitch on a residual fabric or 2) a backing stitch. The residual fabric is not intended to be produced with a decorative line pattern as part of a finished product. The fabric can be considered as a residual fabric, a waste fabric, etc. The fabric is configured to receive at least one undesirable or residual stitch considering a color change. Therefore, the color change of the thread can be controlled on a substrate that is not part of the finished product. With regard to the residual stitches that are conceived as backing stitches, these stitches are arranged on the opposite side of the decorative pattern produced so that a person viewing the decorative pattern cannot visually recognize them from his viewpoint. For this reason, the backing stitches do not have to be arranged on the side of the substrate opposite to the side on which the decorative pattern is produced, but can be arranged on the opposite side of the decorative pattern itself.

[0084] Figure 71 shows exemplary inputs and outputs of the control unit 110 as defined herein. The control unit 110 is configured to receive, process and transmit the inputs and outputs so as to convert the first stitch coloring data 114 into the second stitch coloring data 117. The first stitch coloring data 114 is understood to be data suitable for a conventional (non-online) system, while the second stitch coloring data 117 is understood to be data suitable for an online system, such as Figure 7 To this end, the control unit 110 is configured to enable the online system to process stitch coloring data that was originally configured for a non-online system.

[0085] The first stitch coloring data 114 includes a set of color representations 114a and a corresponding set of line source representations 114b. In a non-online process, a color is usually associated with a corresponding line source. Therefore, in its representation, a specific color representation 114a is assigned to a specific line source representation 114b, thereby forming a 1-1 relationship. Any suitable data structure can be used to store the distribution of color representations to line source representations, such as a hash map, array, tuple, set, graph, etc.

[0086] The control unit 110 is configured to obtain the first stitch coloring data 114. The first stitch coloring data 114 may be obtained from a user interface (such as a reference Figure 3 The image may be obtained from the display 195 of the illustrated embodiment, or alternatively from an external device such as a mobile phone, tablet computer, laptop computer, to name a few examples.

[0087] The control unit 110 is configured to obtain at least one line color boundary 115 from the first stitch coloring data 114. The line color boundary defines a color change from a first color to a second color in the group of color representations 114a. By obtaining the line color boundary from the first stitch coloring data 114, the control unit 110 can identify where one or more color transitions occur in the digital representation. In general, the color change can be the result of one or more of a color transition in the digital representation on which the first stitch coloring data is based, a cutting process of the thread, a relative movement of the substrate, and a combination thereof.

[0088] Identifying the locations where the one or more color transitions occur may include, by the control unit 110, obtaining pattern data from the first stitch coloring data 114. The pattern data includes information about pixels in the digital representation. Therefore, the pattern data includes a plurality of pixels, wherein each pixel is associated with a position and a color value in the digital image. In examples where the digital representation is a digital image, the pattern data may be considered as image data. Since the digital representation is typically two-dimensional, the position indicates a two-dimensional position. As an example, a pixel located in the upper left corner of the digital image may have a position 0,0, and a pixel located in the lower right corner of the digital image may have a position row max ,colmax , where row max is the maximum number of pixel rows in a digital image, col max Is the maximum number of pixel columns in a digital image. In this example, if the resolution of the digital representation is 1080p (1920×1080), the pixel located at the bottom right corner of the digital image has a position of 1080, 1920. Similar pixel positions can be implemented for other image resolutions, such as 2K, 4K, 8K, etc.

[0089] The color value may belong to any color space known in the art, such as RGB or CMYK color space. Thus, if the color value of a pixel in the RGB color space is extracted as 0,0,0, then the color value represents black.

[0090] After obtaining the pattern data of the first stitch coloring data, the method also includes generating resolution data. The resolution data is generated by processing the digitally represented pattern data. During the process, information related to the line arrangement of a plurality of continuous line portions of the pattern to be formed / generated is determined. The processing of the pattern data may include determining information related to the length of the line portion, the direction of the line portion, and / or the type of connection used for the continuous line portion.

[0091] The control unit 110 is further configured to determine residual stitch data 116 based on (at least one) line color boundary 115. The residual stitch data indicates the amount of residual stitch required to perform a color change in the line coloring process. The residual stitch data may be determined differently depending on how the residual stitch is performed in a future line coloring process, as will be discussed later in this disclosure.

[0092] The residual stitch data may include information of one or more of the length of the color change, the direction of the residual stitch for performing the color change, the substrate characteristics of the color change to be performed, the line characteristics of the line for performing the color change, and a combination thereof. The residual stitch data may include information related to the type of residual stitch to be used. The type of residual stitch is related to whether the base stitch or the residual stitch is to be used. This information can be automatically determined by the control unit 110 (e.g., based on other data of the residual stitch data). For example, if the residual stitch data indicates that the length of the color change is 5cm, the direction of the residual stitch is the longitudinal direction of the substrate, the substrate is a specific material, such as linen, and a specific thread, such as polyester, is used, then the control unit 110 can be configured to automatically set the type of residual stitch to the base stitch or the residual stitch on the residual substrate based on the information. Thus, this selection can depend on the respective applicability of different types of information of the residual stitch data. In an alternative example, the type of residual stitch can be selected by the user.

[0093] The control unit 110 is configured to generate the second stitch coloring data 117 based on the residual stitch data 116, so that the color change of the first stitch coloring data 114 is considered in the online thread coloring process. In the context of the present disclosure, the term "accounted for" generally corresponds to the need for additional stitches in the future use of the second stitch coloring data 117 compared with the use of the first stitch coloring data 114. This is because the color change in the online process is not as intuitive as the corresponding color change in the non-online process. In the online process, due to the (re) coloring of the line from the first color to the second color, there are usually some intermediate colors between the first color and the second color. In contrast, in the non-online process, the color change will occur immediately as a response to the switch between the first line source and the second line source, and the corresponding line source stores lines of different colors. This switch is usually achieved by accurately cutting the line at the appropriate position of the line color boundary. However, this is impossible for the online process because it is inevitable to envision one or more additional stitches to consider the (re) coloring of the line. In addition, for the online process, it may sometimes be difficult to accurately predict the appropriate position of the line color boundary.

[0094] In view of the above, the second stitch coloring data 117 is suitable for being processed by a system for online thread coloring, such as the previously described system 10. The conversion can be performed in the same system as the system that obtained the first stitch coloring data 114 or in another system. Thus, it is envisioned that the second stitch coloring data 117 can be received by another system for subsequent production of decorative patterns. It is also envisioned that the second stitch coloring data 117 can be consumed by the same system after it has been generated based on the first stitch coloring data. This is because the second stitch coloring data 117 is packaged into a file suitable for transmission to other online thread coloring systems.

[0095] The first stitch coloring data 114 and the second stitch coloring data 117 may be managed in a corresponding file, such as an embroidery file. Since the embroidery file includes information related to the digital representation to be generated as a decorative thread pattern, the embroidery file may be managed in a bitmap graphic format, including but not limited to GIF, JPEG, PNG, TIFF, XBM, BMP, PCX, etc. The digital representation may alternatively be virtually presented by a control unit or some other type of device capable of presenting digital content.

[0096] In the following examples of the present disclosure, various ways of determining the residual stitch data will be defined. Although these examples relate to physical components such as a frame, it should be understood that the determination of the residual stitch data is performed by the control unit 110 before the actual decorative pattern has been generated. The illustrative drawings are provided for the purpose of explanation only and should be understood to convey the following meaning: what will happen once the second stitch coloring data is used in the line coloring process (based on the residual stitch data previously determined according to the line color boundaries obtained by the first stitch coloring data).

[0097] FIG. 8A to FIG. 8D Different examples of determining residual stitch data are shown. In these examples, the residual stitch data is determined by estimating the number of residual stitches suitable for execution on a residual substrate 3b different from the substrate 3a on which a decorative thread pattern is to be produced. Once a color transition from a first color to a second color is to be performed, a predetermined number of stitches closest to the start of the color transition will be made on the residual fabric 3b rather than on the fabric 3a that forms the finished product (i.e., the fabric 3a on which a decorative thread pattern is to be produced). Therefore, when a stitch 6b of the second color is to be made, a stitch 6a associated with the first color will be made on the fabric 3b until a color transition from color A to color B occurs. Once a line color boundary range is reached, stitches will be performed on the fabric 3a. The boundary range may depend on the number of stitches, the amount of thread consumed, and / or a combination of these two parameters. These values ​​are typically stored as some parts of the residual stitch data.

[0098] In order to allow the visual effect of the decorative line pattern to be generated, the control unit 110 is configured to determine the object to be generated as the decorative line pattern. According to the object (which can be, for example, a graphical representation of an item, an image, a logo, etc.), the control unit 110 is also configured to determine a line arrangement comprising a plurality of continuous line portions, each line portion having a line portion direction, wherein the entire line arrangement corresponds to the object to be produced. The control unit 110 can be configured to receive line arrangement data from another control unit. For example, the line consumption device 15 can be provided by a first supplier, and the processing unit 100 is provided by a second supplier. In this case, the control unit 110 can be equipped with the processing unit 100 and configured to receive line arrangement data from the control unit 110 of the line consumption device 15.

[0099] In these examples, a frame 30 is used. The frame 30 is arranged to hold a substrate 3 having two parts 3a, 3b. In these examples, the substrate 3 is a fabric 3. The embroidery frame 30 includes a main frame 32 and at least one sub-frame 34. The main frame 32 is configured to receive a fabric 3a to be produced with a decorative line pattern. The sub-frame 34 is configured to receive a fabric 3b that is not intended to be produced with a decorative line pattern, i.e., a residual fabric 3b. The embroidery frame 30 includes four sides 31a-d: two longitudinal sides 31a, 31b and two transverse sides 31c, 31d. The longitudinal side has a length H3, and the transverse side has a length L3. The sub-frame 34 is preferably smaller in size than the main frame 32. This is preferred because the main frame 32 is a frame configured to hold a fabric 3a to be produced with a decorative line pattern.

[0100] exist Fig. 8A In the example of FIG. 3 , the length of H3 is greater than the length of L3. However, as will be appreciated, L3 may be equal to H3, or the length of L3 may be greater than the length of H3. Also, the frame 30 may have a different shape, such as a circle. The sub-frame 34 is disposed above the main frame 32. However, it will be appreciated that the sub-frame 34 may have a different placement relative to the main frame 32, such as FIG. 8B to FIG. 8D The examples further illustrate the above.

[0101] exist Figure 8B In the example shown in FIG. 5 , the sub-frame 34 is arranged below the main frame 32 .

[0102] exist Figure 8C In the example shown in FIG. 5 , the sub-frame 32 is arranged along the longitudinal side of the main frame 32 .

[0103] exist Fig.8D In the example of FIG. 3 , the sub-frame 34 has the same length L3 as the main frame 32, and the height H2 of the sub-frame 34 is less than the height H1 of the main frame 32. The frame 30 is constituted only by the main frame 32. Therefore, there is no sub-frame 34. However, the main frame 32 includes two different fabrics: the fabric 3a to be produced with a decorative thread pattern and the fabric 3b configured to receive at least one undesired / residual stitch. Fig. 9 A similar example is shown in , where the frame has a generally circular shape.

[0104] The relationship between the sizes of the sub-frame 34 and the main frame 32 can be changed. Thus, the frame 30 has fixed dimensions, while the sizes of the sub-frame 34 and the main frame 32 are adaptable. For example, this dimensional adaptation can be achieved by making the main frame and the sub-frame 34 slidable relative to each other. Alternatively, the main frame 32 and the sub-frame 34 have fixed dimensions.

[0105] As mentioned above, the frame 30 can be arranged on the movable stage 2b. Thus, the frame 30 can be moved relative to at least one needle of the thread consumption device 15. The movement of the movable stage 2b can be performed based on instructions from the thread consumption device 15, the processing unit 100 and / or from the control unit 110.

[0106] Fig. 9 Another example of determining residual stitch data is shown. FIG. 8A to FIG. 8D The residual stitch data is determined by estimating the number of residual stitches suitable for being performed on a residual substrate 3b different from the substrate 3a on which the decorative thread pattern is to be produced. Also, in this example, the frame 30 is circular. In this example, the decorative thread pattern is a parakeet having four colors c1, c2, c3, c4.

[0107] In this example, the stitching order is determined to start with a first color c1 corresponding to the color of the parakeet's head, continue to a second color c2 corresponding to the color of the parakeet's wings, continue to a third color c3 corresponding to the color of the parakeet's body, and end with a fourth color c4 corresponding to the color of the parakeet's feet. The residual stitch data is determined by identifying three color changes: c1 to c2, c2 to c3, and c3 to c4. For each color change, the number of residual stitches is estimated. To this end, the parakeet will be produced according to the following steps: (i) coloring the thread with the first color c1, and sewing the head of the parakeet on the substrate 3a using the thread colored with the first color c1; (ii) recognizing the upcoming color switch, thereby starting the residual sewing at the first stitch patch on the residual substrate 3b using the thread colored with the first color c1, and simultaneously starting to (re)color the thread into the second color c2; (iii) recognizing the completion of the color switch, thereby starting to sew the wings of the parakeet on the substrate 3a using the thread colored with the second color c2; (iv) recognizing the upcoming color switch, thereby starting to sew the wings of the parakeet on the substrate 3a using the thread colored with the second color c2. (v) recognizing that the color switching is completed, thereby starting the residual sewing of the parakeet's body on the substrate 3a using the thread colored with the third color c3; (vi) recognizing the upcoming color switching, thereby starting the residual sewing of the parakeet at the third stitch patch on the residual substrate 3b using the thread colored with the third color c3, and simultaneously starting the (re)coloring of the thread with the fourth color c4; and (vii) recognizing the completion of the color switching, thereby completing the sewing of the parakeet by sewing the parakeet's feet on the substrate 3a using the thread colored with the fourth color c4.

[0108] In the above examples and in other examples of identification of color switching, various different methods known in the art can be used to achieve these purposes. For example, color recognition can be performed using an illuminator device configured to illuminate the area where the line is located and an image sensor (such as a camera) configured to capture an image of the illuminated line. Thereafter, one or more image processing techniques can be used to determine the color data of the line using, for example, color analysis or color segmentation. The color data can be compared with the expected color data to output a determination of whether a color change has been made. The illuminator device and the image sensor can be arranged at appropriate locations in the system 10, and the control unit 110 can be configured to control their operation and perform appropriate image processing techniques.

[0109] FIG. 10A to FIG. 10B Another example of determining the remaining stitch data is shown. In this example, the remaining stitch data is determined by estimating the number of remaining stitches suitable for being performed as underlay stitches on a substrate on which a decorative thread pattern is to be produced.

[0110] Fig. 10A A first side 3a-1 of a substrate 3 arranged in a frame 30 is shown in which a parakeet is to be produced. Fig. 9 Unlike the case where there is residual substrate in the example of FIG, it is determined that the backing stitch is made on the other side 3a-2 of the decorative pattern. Fig. 10B Thus, the residual stitch required to perform the color switch is determined to be made on the back of the decorative pattern to be made, usually randomly, as indicated in the figure.

[0111] Fig.11 is another more advanced example of determining residual stitch data. This process is similar to Fig. 9 The steps (i) to (vii) defined are performed similarly, but instead of residual stitch patches, the residual stitch is produced in a plurality of continuous rows. In this example, the residual stitch is produced at the same substrate 3a as that on which the decorative thread pattern is produced, but in its lower part. Alternatively, a different substrate may be used, as discussed herein. Fig. 9 The four different colors in the example are different. Fig.11 The example of uses eight different colors. However, in this example, the general method also applies with respect to identifying color changes and controlling the generation of residual stitch data accordingly.

[0112] Whatever method is used to estimate the number of residual stitches, the estimation may depend on one or more operating conditions of the online thread coloring process. The operating conditions may relate to the equipment in which the online thread coloring is performed, the substrate used, the thread used and / or external conditions. Alternatively, the number of residual stitches may be set to a fixed stitch value such as 10 stitches, or a fixed thread length value such as 20 cm, or indeed any other suitable fixed value of any type.

[0113] Fig.12 Various examples of determining residual stitch data by defining different types of line color boundary ranges r1, r2, r3, r4 are shown. In these examples, the range is defined as a row, but other examples such as patches, circles, etc. can also be envisioned. The line color boundary range is not mixed with the line color boundary of the first stitch coloring data because it belongs to the residual stitch data as the basis for generating the second stitch coloring data. For this reason, the line color boundary range is the range required for the (re) coloring of the line from the first color to the second color in time, rather than a fixed boundary. Thus, the line color boundary range indicates the range of residual stitches with an intermediate color between the first color and the second color. The line color boundary range has a starting value indicating the start of a color change and a final value indicating the completion of a color change. Similar to the above example, the line color boundary range can be automatically determined by the control unit 110 based on the operating conditions of the online line coloring process. During the operation of the online line coloring process, the line color boundary range can be changed. The line color boundary range can be selected by the operator.

[0114] The first line color boundary range r1 has a starting value s1 and a final value e1. For the second, third and fourth line color boundary ranges r2, r3, r4, various buffers are defined. The purpose of adding a buffer to the range is to provide an additional guarantee that the entire color change has been completed before returning to the sewing decorative line pattern. The size of the buffer can vary. The number of buffers can vary. The buffer can be assigned to the starting value and / or the final value of the line color boundary range. Typically, the buffer added to the starting value will be associated with the first color, while the buffer added to the final value will be associated with the second color, and the range therebetween is a combination of some type of intermediate colors between the first color and the second color. Similar to the line color boundary range, the buffer can be automatically determined by the control unit 110 based on the operating conditions of the line coloring process. Moreover, the buffer can be changed during the operation of the line coloring process. In addition, the buffer can be selected by the operator.

[0115] The second line color boundary range r2 has a starting value s2 and a final value e2. Further, two buffers b1-1 and b1-2 are defined, and each of the starting value s2 and the final value e2 corresponds to a buffer. The third line color boundary range r3 has a starting value s3 and a final value e3. Further, a buffer b2-1 is defined for the starting value s3. The fourth line color boundary range r4 has a starting value s4 and a final value e4. Further, a buffer b3-2 is defined for the final value e4.

[0116] Fig.13 An exemplary schematic diagram of a method 200 for generating thread coloring data for an online thread coloring process is shown. The dashed boxes of the method 200 are optional steps.

[0117] The method 200 comprises a step 210 of obtaining first stitch coloring data based on a digital representation to be generated as a decorative thread pattern, the first stitch coloring data having a set of color representations assigned to a corresponding group of thread source representations. The method 200 comprises a step 220 of obtaining at least one thread color boundary from the first stitch coloring data, each thread color boundary defining a color change from a first color to a second color in the color representation group. The method 200 comprises a step 230 of determining residual stitch data based on at least one thread color boundary, the residual stitch data indicating the number of residual stitches required to perform the color change during the thread coloring process. The method 200 comprises a step 240 of generating second stitch coloring data based on the residual stitch data, so that the color change of the first stitch coloring data is taken into account during the thread coloring process, the second stitch coloring data having a set of color representations assigned to a single thread source representation.

[0118] The step 240 of generating second stitch coloring data may include the step 242 of obtaining pattern data from the digital representation, the pattern data including a plurality of pixels, each pixel being associated with a position and a color value in the digital representation. The step 240 may also include the step 244 of generating resolution data by processing the pattern data, wherein processing the pattern data includes determining a line arrangement including a plurality of stitches, wherein the line arrangement corresponds to the digital representation to be generated in the line line coloring process. The step 240 may also include the step 246 of generating second stitch coloring data for the line based at least on the resolution data.

[0119] The method 200 may also include subsequent consumption of the thread source in the online thread coloring process. This may be performed based on the second stitch coloring data and the initiation control of the online thread coloring process by controlling the online thread coloring process of the thread at step 250, controlling the thread consumption process of the thread relative to the substrate at step 252, and controlling the residual embroidery process of the thread at step 254. The residual embroidery process may be controlled as one or both of the following: residual stitches applied to a residual substrate different from the substrate, and residual stitches as a lining stitch applied to the substrate.

[0120] Fig.14 The method 300 of the control unit 109, 110 configured to perform the method in the line coloring process is illustrated. In the following example, the method is described using FIG. 8A to FIG. 8D The control unit 109, 110 is configured to cause 305 the thread consumption device 15 to perform a stitch on the fabric 3a to be produced with a decorative thread pattern arranged in the main frame 32, and cause 310 the thread consumption device to cut at least one thread for performing at least one stitch.

[0121] The control unit 109, 110 is also configured to cause 315 relative movement between the needle of the thread consuming device and the subframe 34. In one embodiment, this is performed by causing the movable stage 2b to move the frame 30. In yet another embodiment, the control unit 109, 110 is configured to cause movement of the needle of the thread consuming device 15.

[0122] Once the needle and the sub-frame 34 are in position relative to each other, the control unit 109, 110 is further configured to cause 320 the thread consuming device to perform at least one remaining stitch on the remaining fabric 3b.

[0123] Once the residual stitch(s) are made in the textile 3b, the control unit 109, 110 is configured to cause 325 the thread consuming device 15 to cut off at least one thread 20 used to perform the at least one residual stitch.

[0124] The control unit 109, 110 is also configured to cause 330 a relative movement between the needle of the thread consuming device and the main frame 32. In one embodiment, this is performed by causing the movable stage 2b to move the frame 30. In yet another embodiment, the control unit 109, 110 is configured to cause movement of the needle of the thread consuming device 15.

[0125] The method of cutting the thread also applies to the backing stitch.

[0126] Further alternative aspects of the present disclosure are described in the following examples.

[0127] An embroidery frame 30 is provided for use with a system for online processing of thread and a thread consumption device 15. The embroidery frame 30 includes a main frame 32 configured to receive a first portion of one or more substrates, wherein the first portion is to be produced with a decorative thread pattern, and at least one sub-frame configured to receive a second portion of one or more substrates, wherein the second portion is a residual substrate.

[0128] The sub-frame has smaller dimensions than the main frame 32. The dimensions of the main frame 32 and the at least one sub-frame may be adapted relative to each other.

[0129] The substrate of the subframe is configured to receive at least one unwanted / residual stitch.

[0130] At least one of the unwanted / residual stitches is associated with a color transition.

[0131] The embroidery frame 30 is configured to be arranged on the movable table 2 b so that the base material in the embroidery frame 30 can be moved relative to the thread consuming device 15 .

[0132] The control units 109 , 110 are configured to cause a relative movement between the needle of the thread consuming device 15 and the secondary frame, or to cause a relative movement between the needle of the thread consuming device 15 and the main frame 32 .

[0133] The control units 109, 110 are also configured to: enable the thread consumption device 15 to execute at least one stitch, wherein at least one thread uses at least one needle, and on the substrate 3a to be produced with a decorative thread pattern arranged in the main frame 32, enable the thread consumption device 15 to cut the at least one thread used to execute at least one stitch, enable the needle of the thread consumption device 15 and the sub-frame to move relative to each other, enable the thread consumption device 15 to execute at least one residual stitch on the residual substrate 3b, enable the thread consumption device 15 to cut the at least one thread used to execute at least one residual stitch, and enable the needle of the thread consumption device 15 and the main frame 32 to move relative to each other.

[0134] A system for in-line processing of thread for use with a thread consuming device 15 is provided, comprising an embroidery frame 30. The system is in operative communication with a control unit 109, 110, which is configured to cause relative movement between the needle and the secondary frame of the thread consuming device 15, or between the needle and the main frame 32 of the thread consuming device 15.

[0135] As will be appreciated by those skilled in the art, the concept of the present invention encompasses different variations of these examples. For example, the processing unit 100 may be arranged with a control unit 110a, while the line consumer 15 relies only on an external control unit 110c. Moreover, although not shown, the movable station 2b may be arranged with a separate control unit.

[0136] Although the present invention has been described above with reference to specific examples, the present invention is not limited to the specific forms set forth herein. On the contrary, the present invention is limited only by the appended clauses. As will be appreciated by the skilled person, the examples defined herein may be interpreted as embodiments of the present invention.

[0137] The term "comprising" does not exclude the presence of other elements or steps. In addition, although individual features may be included in different clauses, these features may be advantageously combined, and inclusion in different clauses does not mean that the combination of features is not feasible and / or disadvantageous. In addition, singular references do not exclude pluralities. The terms "a", "an", "first", "second", etc. do not exclude a plurality. The reference numerals in the clauses are provided only as illustrative examples and should not be interpreted as limiting the scope of the clauses in any way.

Claims

1. A computer-implemented method (200) for generating stitch coloring data for an online thread coloring process, comprising: obtaining (210) first stitch coloring data (114) based on a digital representation to be generated as a decorative thread pattern, the first stitch coloring data (114) having a set of color representations (114a) assigned to a corresponding set of thread source representations (114b); obtaining (220) at least one thread color boundary (115) from the first thread coloring data (114), each thread color boundary (115) defining a color change from a first color to a second color in the set of color representations (114a); determining (230) residual stitch data (116) based on the at least one thread color boundary (115), the residual stitch data (116) indicating the number of residual stitches required to perform the color change during the thread coloring process; as well as Second stitch coloring data (117) are generated (240) based on the residual stitch data (116) so that color changes of the first stitch coloring data (114) are taken into account during the thread coloring process, and the second stitch coloring data (117) has a set of color representations (117a) assigned to a single thread source representation (117b).

2. The method (200) according to claim 1, wherein: The residual stitch data (116) is determined by estimating the number of residual stitches suitable for being performed on a residual substrate (3b) different from the substrate (3a) on which the decorative thread pattern is to be produced.

3. The method (200) according to claim 2, wherein: The substrate (3a) is adapted to be received by a main frame (32), and the residual substrate (3b) is adapted to be received by at least one sub-frame (34).

4. The method (200) according to any one of the preceding claims, wherein: The remaining stitch data (116) is determined by estimating the number of remaining stitches suitable for being performed as underlay stitches on a substrate on which the decorative thread pattern is to be produced.

5. The method (200) according to any one of claims 2 to 4, wherein: The estimate of the number of residual thread traces depends on one or more operating conditions of the thread coloring process.

6. The method (200) according to any one of the preceding claims, wherein: Determining the residual stitch data (116) includes defining a line color boundary range indicating a range of residual stitches having an intermediate color between the first color and the second color, the line color boundary range having a starting value indicating the start of the color change and a final value indicating the completion of the color change.

7. The method (200) of claim 6, further comprising: A corresponding buffer is set for each of the start value and the final value, the buffer indicating the number of stitches to be appended to the residual stitch data at the corresponding end of the thread color boundary range.

8. The method (200) according to claim 6 or 7, wherein: The thread color boundary range depends on one or more of the number of stitches, the amount of thread consumed, substrate characteristics, thread characteristics, and combinations thereof.

9. The method (200) according to any one of the preceding claims, wherein: The color change is caused by one or more of a color transition in the digital representation, a cutting process of the thread (20), a relative movement of the substrate, and a combination thereof.

10. The method (200) according to any one of the preceding claims, wherein: The residual stitch data (116) includes information of one or more of the length of the color change, the direction of the residual stitch for performing the color change, the characteristics of the substrate on which the color change is to be performed, the line characteristics of the thread (20) for performing the color change, and a combination thereof.

11. The method (200) according to any one of the preceding claims, wherein: Subsequent consumption of the thread source in the online thread coloring process includes: based on the second thread coloring data (117), causing control of the online thread coloring process in the following manner: Control (250) the online line coloring process of line (20); controlling (252) thread consumption of the thread (20) relative to the substrate (3a); and The residual embroidery process of the thread (20) is controlled (254) as one or both of: a residual stitch applied to a residual substrate (3b) different from the substrate (3a), and as a residual stitch applied to a backing stitch on the substrate (3a).

12. The method (200) according to any one of the preceding claims, wherein: Generating (240) the second stitch coloring data (117) includes: obtaining (242) pattern data from the digital representation, the pattern data comprising a plurality of pixels, each pixel being associated with a position (p) and a color value (cv) in the digital representation; generating (244) resolution data by processing the pattern data, wherein processing the pattern data includes determining a line arrangement including a plurality of line traces, wherein the line arrangement corresponds to a digital representation to be produced in the line line shading process; and Based at least on the resolution data, the second stitch coloring data for the thread (20) is generated (246).

13. The method (200) of claim 12, wherein: Processing the pattern data further includes determining information about the length (23) of the stitches, the direction (24) of the stitches and the type of connection (25) used to connect one or more stitches to each other.

14. A control unit (110) comprising a processor (112) configured to perform the steps of the method (200) according to any one of claims 1 to 13.

15. A system (10) for in-line processing of at least one wire (20) for use with a wire consuming device, the system (10) comprising: a processing unit (100) comprising at least one discharge device (150), the discharge device comprising at least one nozzle, the nozzle being arranged along the at least one wire (20) and being configured to dispense one or more coating substances onto the at least one wire (20) when activated; as well as A control unit (109) configured to control the discharge device (150) to dispense the coating substance onto the at least one thread based on the second thread coloring data (117) generated by the method (100) according to any one of claims 1 to 13.

16. A non-transitory computer-readable storage medium (300) comprising instructions which, when executed by one or more processors (112) of a control unit (110), cause the processor (112) to perform the functions of the method (200) according to any one of claims 1 to 13.

17. A computer program product comprising computer code for executing the functions of the method (200) according to any one of claims 1 to 13.

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