Intelligent piece counting method and system for sewing machine

Abstract

The invention discloses an intelligent piece counting method for a sewing machine, and belongs to the technical field of sewing equipment control. The problems that in the prior art, sewing efficiency and quality are not high, and piece counting is not accurate enough are solved. The intelligent piece counting method of the sewing machine comprises the following steps: (1) initializing a system; (2) detecting material changing time; (3) judging the number of trimmed threads; (4) judging the number of threads; (5) judging sewing time; (6) increasing the counting number; and (7) data management. The intelligent piece counting method for the sewing machine has the advantages that accurate control over the whole process is achieved, the whole working process is optimized to improve the sewing efficiency and quality, and meanwhile piece counting is accurate.

Description

Technical Field

[0001] The present invention relates to the technical field of sewing equipment control, and in particular to an intelligent piece counting method and system for a sewing machine. Background Art

[0002] With the rapid development of intelligent manufacturing, the demand for intelligent sewing equipment is increasing. Traditional sewing operations mainly rely on manual operation and simple mechanical control, which has problems such as low efficiency and unstable quality. Especially in large-scale production, how to improve the efficiency and quality of sewing operations has become the focus of industry attention. As an emerging technical means, the intelligent piece-counting system can realize real-time monitoring and management of the entire sewing process through sensors, data collection and analysis technologies, thereby improving production efficiency and product quality.

[0003] At present, there are some intelligent piece-counting methods and systems based on sewing equipment on the market. For example, the Chinese patent with the public announcement number CN112760831A, named "An intelligent piece-counting method and system based on sewing equipment", describes the method as follows: 1) The administrator uses the Web client in the visual terminal to match the operator and the process according to the matching method provided by the system, to form a one-to-one or one-to-many task file for the operator and the process, and uploads it to the server; 2) After the operator logs in to the user terminal, the user terminal obtains the task file of the corresponding operator from the server, confirms the task and starts working. The operator completes machine learning for the first product through the working data of the sewing equipment obtained by the collector connected to the user terminal, and the user terminal binds the machine learning results with the operator and the corresponding task and uploads them to the server; 3) During the subsequent use of the sewing equipment by the operator, the working data of the sewing equipment obtained by the collector meets the results of machine learning, and the piece count is automatically increased by 1, and the user terminal uploads the piece count to the server in real time. The prior art collects the working parameters of the sewing machine (such as the number of needles, the number of thread trimming times, etc.) through sensors, and completes the piece count statistics and abnormal alarm functions in combination with basic algorithms. These technologies usually have the following characteristics:

[0004] Piece count: The sensor monitors the key parameters of the sewing machine, such as the number of stitches and thread trimming times, and automatically records the piece count for each operation.

[0005] Abnormal alarm: When it is detected that the number of thread trimming times is insufficient or the number of stitches is abnormal, the system will issue an alarm prompt.

[0006] Data storage: Supports storage of basic data for each operation (such as number of stitches, number of thread trimmings, etc.) for subsequent query.

[0007] However, in the process of implementing the technical solution of the invention in the embodiment of the present application, the inventors of the present application found that the above-mentioned prior art has at least the following technical problems:

[0008] Existing technologies mostly focus on piece counting and basic abnormal alarms. The detection is relatively simple and lacks multi-dimensional detection, which makes it impossible to comprehensively evaluate the efficiency and quality of the operation process, and it is impossible to achieve accurate control of the entire process to optimize the entire work process to improve sewing efficiency and quality. At the same time, piece counting is not accurate enough. For example: In actual production, a long material change time may seriously affect the overall production efficiency, but the existing technology cannot effectively monitor the material change time, so it is impossible to detect and correct this problem in time. Summary of the invention

[0009] The present application provides an intelligent piece counting method and system for sewing machines, which solves the technical problems in the prior art of single detection and lack of multi-dimensional detection, which leads to the inability to better optimize the workflow and thus low sewing efficiency and quality, and at the same time, the piece counting is not accurate enough. The application realizes precise control of the entire process to optimize the entire work process to improve sewing efficiency and quality, and at the same time achieves the technical effect of accurate piece counting.

[0010] The present application provides a sewing machine intelligent piece counting method, which is characterized by comprising the following steps:

[0011] (1) System initialization: After the sewing machine is started, the intelligent piece counting system is automatically initialized and enters the state of waiting for detection;

[0012] (2) Material change time detection: real-time monitoring of material change operation, comparing the actual material change time with the user-preset material change time range; if the time exceeds the time limit, a voice or display alarm is triggered to prompt the operator to start the sewing machine;

[0013] (3) Thread trimming number judgment: The number of thread trimming actions is recorded by the sensor, and the actual number of thread trimming actions is compared with the error range of the thread trimming number preset by the user. If it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped;

[0014] (4) Needle count judgment: monitor the number of sewing stitches and compare the actual number of stitches with the error range of the number of stitches preset by the user; if it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped;

[0015] (5) Sewing time judgment: The sewing time is monitored by a timer, and the actual time is compared with the sewing time error range preset by the user; if it exceeds the range, an alarm is issued and the piece counting process is stopped;

[0016] (6) Piece count increase: When the material change time, thread trimming number, stitch number and sewing time are within the preset range, the piece count will be automatically increased by 1 and the current piece count data will be recorded;

[0017] (7) Data management: Stores the number of thread cuts, number of stitches, and sewing time for each piece count, and provides data analysis functions to optimize production efficiency.

[0018] In the above-mentioned intelligent piece counting method for sewing machines, the error range of the number of thread trimmings in step (3) is set in sections according to the number of thread trimmings, including:

[0019] When the number of trimming threads is 0-4, the error range is ±0;

[0020] When the number of trimming threads is 5-10, the error range is -0 to +1;

[0021] When the number of trimmings is >10, the error range is -0 to +2.

[0022] In the above-mentioned intelligent piece counting method for sewing machines, the stitch count error range in step (4) is ±20%, and can be set by the user to support dynamic adjustment of the ±20% threshold.

[0023] In the above-mentioned intelligent piece counting method for a sewing machine, the sewing time error range in step (5) is 0-100% of the timeout, wherein, if the timeout is 0-5%, the piece counting process continues; if the timeout is 5%-100%, the "process timeout" alarm is triggered but the piece counting process continues; if the timeout exceeds 100%, the "process serious timeout" alarm is triggered and the process is stopped; the sewing time error range of 0-100% and the 5% that triggers the "process timeout" alarm but continues the piece counting process can be customized by the user, and supports dynamic adjustment of the 0-100% and 5% thresholds.

[0024] In the above-mentioned intelligent piece counting method for a sewing machine, the material change time range in step (2) is 10s-20s and is customized by the user. The system supports real-time modification of preset values ​​to adapt to different process requirements.

[0025] In the above-mentioned intelligent piece counting method for a sewing machine, the step (7) also includes a fault self-diagnosis function, and when a sensor abnormality or data logic conflict is detected, an alarm prompt is triggered through voice or display screen.

[0026] An intelligent piece counting system for a sewing machine, characterized by comprising:

[0027] Initialization module, used to automatically enter the waiting state after the system starts;

[0028] Refueling detection module, used to monitor the refueling time and compare it with the preset range;

[0029] The thread trimming judgment module is used to judge the compliance of the thread trimming number based on the segmentation error range;

[0030] The stitch number judgment module is used to monitor the stitch number and compare it with the dynamic error threshold;

[0031] Sewing time judgment module, used for grading alarm timeout events;

[0032] The piece counting module is used to increase the piece counting when the above-mentioned material change time, thread trimming number, stitch number and sewing time are all in compliance;

[0033] Data management module, used to store and analyze production data.

[0034] In the above-mentioned intelligent piece counting system for sewing machines, the thread trimming judgment module includes a segmented error calculation unit, which dynamically switches the error threshold according to the number of thread trimmings.

[0035] In the above-mentioned intelligent piece-counting system for sewing machines, the data management module supports exporting piece-counting data and provides visual charts to analyze production efficiency and quality trends.

[0036] A computer-readable storage medium, characterized in that: a computer program is stored, and when the computer program is executed by a processor, the above-mentioned intelligent piece counting method for a sewing machine is implemented.

[0037] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:

[0038] 1. The technology adopts the coordinated detection of parameters in multiple dimensions, such as material change time, thread trimming number, needle number and sewing time. Therefore, it effectively solves the technical problems in the prior art, such as single detection and lack of multi-dimensional detection, which lead to poor optimization of the work process and low sewing efficiency and quality, and inaccurate piece counting. It then realizes the precise control of the whole process to optimize the whole work process to improve sewing efficiency and quality, and achieves the technical effect of accurate piece counting.

[0039] 2. Introduce a multi-level alarm mechanism. Sewing timeout is divided into "process timeout" and "process serious timeout" and the process is stopped. Combined with real-time feedback from voice / display screen, the refinement and timeliness of exception handling are enhanced, so as to more finely optimize each detail process to improve sewing quality and efficiency;

[0040] 3. Combined with the segmented error range (such as setting different tolerances for the number of trimmings in 0-4, 5-10, and >10 segments), the piece counting is more in line with reality and the piece counting accuracy is significantly improved;

[0041] 4. Support users to customize preset parameter ranges (such as material change time, thread trimming error, needle number error range, sewing time error range, etc.), and automatically compare actual data with the preset range through the system to reduce manual intervention and simplify the operation process;

[0042] 5. Completely record the material change time, thread trimming number, needle number, sewing time and other data of each operation, and provide data analysis module to support efficiency evaluation, quality optimization and fault self-diagnosis, providing decision-making basis for production management;

[0043] 6. Through segmented error range and user-defined presets, the system's adaptability to different production scenarios is indirectly improved, reducing dependence on fixed templates. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a flow chart of the intelligent piece counting method for sewing machines. DETAILED DESCRIPTION

[0045] The embodiments of the present application provide an intelligent piece counting method and system for sewing machines, thereby solving the technical problems in the prior art of single detection and lack of multi-dimensional detection, which lead to the inability to better optimize the workflow and thus low sewing efficiency and quality, and at the same time, the piece counting is not accurate enough. The method and system achieve precise control of the entire process to optimize the entire work process to improve sewing efficiency and quality, and at the same time achieve the technical effect of accurate piece counting.

[0046] The technical solution in the embodiment of the present application is to solve the above-mentioned problems of low sewing efficiency and quality and inaccurate piece counting. The overall idea is as follows:

[0047] By collaboratively detecting parameters in multiple dimensions such as material change time, thread trimming number, number of stitches and sewing time, and storing the material change time, thread trimming number, number of stitches and sewing time data for each piece count, these data are managed and analyzed to optimize the details of each process, thereby improving sewing efficiency and quality, and at the same time improving the accuracy of piece count.

[0048] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0049] Embodiment 1

[0050] like Figure 1 As shown, a method for intelligent piece counting of a sewing machine is provided, comprising the following steps:

[0051] (1) System initialization: After the sewing machine is started, the intelligent piece counting system is automatically initialized and enters the state of waiting for detection;

[0052] (2) Material change time detection: real-time monitoring of material change operation, comparing the actual material change time with the user-preset material change time range; if the time exceeds the time limit, a voice or display alarm is triggered to prompt the operator to start the sewing machine;

[0053] The material change time range is 10s-20s and is user-defined. The system supports real-time modification of the preset material change time range value to adapt to different process requirements;

[0054] (3) Thread trimming number judgment: The number of thread trimming actions is recorded by the sensor, and the actual number of thread trimming actions is compared with the error range of the thread trimming number preset by the user. If it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped;

[0055] Among them, the error range of the number of trimming threads is set in sections according to the number of trimming threads, including:

[0056] When the number of trimming threads is 0-4, the error range is ±0;

[0057] When the number of trimming threads is 5-10, the error range is -0 to +1;

[0058] When the number of trimmings is >10, the error range is -0 to +2;

[0059] The setting of segmented error range makes piece counting more in line with reality and significantly improves piece counting accuracy;

[0060] (4) Needle count judgment: monitor the number of sewing stitches and compare the actual number of stitches with the error range of the number of stitches preset by the user; if it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped;

[0061] The error range of the number of needles is ±20%, and can be set by the user. It supports dynamic adjustment of the threshold of ±20%. The error range of the number of needles can be adjusted according to actual needs.

[0062] (5) Sewing time judgment: The sewing time is monitored by a timer, and the actual time is compared with the sewing time error range preset by the user; if it exceeds the range, an alarm is issued and the piece counting process is stopped;

[0063] The sewing time error range is 0-100% overtime, where if the overtime is 0-5%, the piece counting process will continue; if the overtime is 5%-100%, the "process timeout" alarm will be triggered but the piece counting process will continue; if the overtime exceeds 100%, the "process serious timeout" alarm will be triggered and the process will be stopped; the sewing time error range of 0-100% and the 5% that triggers the "process timeout" alarm but continues the piece counting process can be set by the user, and the thresholds of 0-100% and 5% can be dynamically adjusted;

[0064] A multi-level alarm mechanism is introduced. Sewing timeout is divided into "process timeout" and "process serious timeout" and the process is stopped. Combined with real-time feedback from voice / display, the refinement and timeliness of exception handling are enhanced, so as to more finely optimize each detail process to improve sewing quality and efficiency.

[0065] (6) Piece count increase: When the material change time, thread trimming number, stitch number and sewing time are within the preset range, the piece count will be automatically increased by 1 and the current piece count data will be recorded;

[0066] (7) Data management: store the number of thread cuts, number of stitches, and sewing time data for each piece count, and provide data analysis functions to optimize production efficiency;

[0067] It includes a fault self-diagnosis function. When a sensor abnormality or data logic conflict is detected, an alarm prompt is triggered through voice or display.

[0068] The technical solutions in the above embodiments of the present application have at least the following technical effects or advantages:

[0069] Traditional piece counting systems rely on a single parameter (such as the number of thread trimmings or the number of needles), which makes it difficult to cover the multi-variable collaborative judgment in complex processes (such as material change time, number of thread trimmings, number of needles, sewing time, etc.), and are prone to misjudgment due to single parameter deviation, thereby reducing the accuracy of piece counting. This embodiment simultaneously monitors multi-dimensional data such as material change time, number of thread trimmings, number of needles, sewing time, etc., combined with a segmented error range (such as setting different tolerances for the number of thread trimmings in 0-4, 5-10, and >10 segments), and only counts when all parameters meet the conditions, significantly improving the accuracy of piece counting.

[0070] Traditional methods have a single judgment on timeout or illegal operation (such as only triggering "timeout"), cannot distinguish the severity (such as process timeout and serious timeout), and lack dynamic response. This embodiment introduces a multi-level alarm mechanism (such as material change timeout only prompts to continue the operation, while sewing time timeout is divided into "process timeout" and "process serious timeout" and stops the process), combined with real-time feedback from voice / display screen, to enhance the refinement and timeliness of exception handling, so as to better optimize the workflow and improve sewing efficiency and quality.

[0071] The prior art requires frequent manual adjustment of preset parameters (such as the number of thread trimmers and the threshold value of the number of stitches), which is cumbersome and error-prone when switching processes. The present embodiment supports users to customize the preset parameter range (such as material change time, thread trimmer number error, needle number threshold and sewing time error range, etc.), and automatically compares the actual data with the preset range through the system, thereby reducing manual intervention, simplifying the operating process and improving sewing efficiency.

[0072] The existing system has simple data recording and lacks in-depth analysis functions, making it difficult to support production optimization. The present embodiment can fully record the material change time, thread trimming number, stitch number, sewing time and other data of each operation, and provide a data analysis module to support efficiency evaluation, quality optimization and fault self-diagnosis, providing a decision-making basis for production management, so as to systematically optimize the detailed processes of work production and improve sewing efficiency and quality.

[0073] Embodiment 2

[0074] Provided is an intelligent piece counting system for a sewing machine, comprising:

[0075] Initialization module, used to automatically enter the waiting state after the system starts;

[0076] Refueling detection module, used to monitor the refueling time and compare it with the preset range;

[0077] The thread trimming judgment module is used to judge the compliance of the thread trimming number based on the segmentation error range;

[0078] The stitch number judgment module is used to monitor the stitch number and compare it with the dynamic error threshold;

[0079] Sewing time judgment module, used for grading alarm timeout events;

[0080] The piece counting module is used to increase the piece counting when the above-mentioned material change time, thread trimming number, stitch number and sewing time are all in compliance;

[0081] Data management module, used to store and analyze production data.

[0082] Among them, the preset material change time range is 10s-20s and is customized by the user. The system supports real-time modification of the preset material change time range value to adapt to different process requirements.

[0083] The thread trimming judgment module includes a segmented error calculation unit, which dynamically switches the error threshold according to the number of thread trimmings, as follows: The error range of the thread trimming number is set in segments according to the number of thread trimmings, including:

[0084] When the number of trimming threads is 0-4, the error range is ±0;

[0085] When the number of trimming threads is 5-10, the error range is -0 to +1;

[0086] When the number of trimmings is >10, the error range is -0 to +2;

[0087] The setting of segmented error range makes piece counting more in line with reality and significantly improves piece counting accuracy.

[0088] The error range of the needle count is ±20%, and can be customized by the user. It supports dynamic adjustment of the ±20% threshold. The error range of the needle count can be customized according to actual needs.

[0089] The specific timeout event used for graded alarm is as follows: the sewing time is monitored by a timer, and the actual time is compared with the sewing time error range (+5%) preset by the user; if the timeout is 5%-100%, the "process timeout" alarm is triggered; if the timeout exceeds 100%, the "process serious timeout" alarm is triggered and the process is stopped.

[0090] The data management module supports the export of piece-count data and provides visual charts to analyze production efficiency and quality trends, thereby optimizing workflow details to improve sewing efficiency and quality.

[0091] Embodiment 3

[0092] A computer-readable storage medium is provided, which stores a computer program. When the computer program is executed by a processor, the intelligent piece counting method for a sewing machine of the first embodiment is implemented.

[0093] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0094] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0095] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0096] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0097] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0098] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. An intelligent piece counting method for a sewing machine, characterized in that: The following steps are involved: (1) System initialization: After the sewing machine is started, the intelligent piece counting system is automatically initialized and enters the waiting state; (2) Material change time detection: real-time monitoring of material change operation, comparing the actual material change time with the user-preset material change time range; if the time exceeds the time limit, a voice or display alarm is triggered to prompt the operator to start the sewing machine; (3) Thread trimming number judgment: The number of thread trimming actions is recorded by the sensor, and the actual number of thread trimming actions is compared with the error range of the thread trimming number preset by the user. If it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped; (4) Needle count judgment: monitor the number of sewing stitches and compare the actual number of stitches with the error range of the number of stitches preset by the user; if it exceeds the range, the "illegal operation" alarm is triggered and the piece counting process is stopped; (5) Sewing time judgment: The sewing time is monitored by a timer, and the actual time is compared with the sewing time error range preset by the user; if it exceeds the range, an alarm is issued and the piece counting process is stopped; (6) Piece count increase: When the material change time, thread trimming number, stitch number and sewing time are within the preset range, the piece count will be automatically increased by 1 and the current piece count data will be recorded; (7) Data management: Stores the number of thread cuts, number of stitches, and sewing time for each piece count, and provides data analysis functions to optimize production efficiency.

2. The intelligent piece counting method for a sewing machine as claimed in claim 1, characterized in that: In the step (3), the error range of the number of thread trimmings is set in sections according to the number of thread trimmings, including: When the number of trimming threads is 0-4, the error range is ±0; When the number of trimming threads is 5-10, the error range is -0 to +1; When the number of trimmings is >10, the error range is -0 to +2.

3. The intelligent piece counting method for a sewing machine as claimed in claim 1, characterized in that: The needle count error range in step (4) is ±20%, and can be customized by the user to support dynamic adjustment of the ±20% threshold.

4. An intelligent piece counting method for a sewing machine as claimed in claim 1, 2 or 3, characterized in that: In the step (5), the sewing time error range is 0-100% of the timeout, wherein, if the timeout is 0-5%, the piece counting process continues; if the timeout is 5%-100%, the "process timeout" alarm is triggered but the piece counting process continues; if the timeout exceeds 100%, the "process serious timeout" alarm is triggered and the process is stopped; the sewing time error range of 0-100% and the 5% that triggers the "process timeout" alarm but continues the piece counting process can be set by the user, and supports dynamic adjustment of the 0-100% and 5% thresholds.

5. The intelligent piece counting method for a sewing machine as claimed in claim 4, characterized in that: The material change time in step (2) ranges from 10s to 20s and is set by the user. The system supports real-time modification of preset values ​​to adapt to different process requirements.

6. The intelligent piece counting method for a sewing machine as claimed in claim 5, characterized in that: The step (7) also includes a fault self-diagnosis function, which triggers an alarm prompt through voice or display screen when a sensor abnormality or data logic conflict is detected.

7. An intelligent piece counting system for a sewing machine, characterized in that: include: Initialization module, used to automatically enter the waiting state after the system starts; Refueling detection module, used to monitor the refueling time and compare it with the preset range; The thread trimming judgment module is used to judge the compliance of the thread trimming number based on the segmentation error range; The stitch number judgment module is used to monitor the stitch number and compare it with the dynamic error threshold; Sewing time judgment module, used for grading alarm timeout events; The piece counting module is used to increase the piece counting when the above-mentioned material change time, thread trimming number, stitch number and sewing time are all in compliance; Data management module, used to store and analyze production data.

8. The intelligent piece counting system for sewing machines according to claim 7, characterized in that: The thread trimming judgment module includes a segmentation error calculation unit, which dynamically switches the error threshold according to the number of thread trimmings.

9. An intelligent piece counting system for sewing machines as claimed in claim 7 or 8, characterized in that: The data management module supports the export of piece-rate data and provides visual charts to analyze production efficiency and quality trends.

10. A computer-readable storage medium, characterized in that: A computer program is stored, and when the computer program is executed by a processor, the intelligent piece counting method for a sewing machine described in any one of claims 1 to 6 is implemented.

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