Instant wire dyeing method for electric embroidery machine, electric embroidery method, system and product

Abstract

The invention provides a wire rod instant dyeing method for an electric embroidery machine, an electric embroidery method and system based on instant dyeing and an electric embroidery product. The wire rod instant dyeing method comprises the following steps: in the process of conveying a target wire rod dyed by a preset spray head to the electric embroidery machine, the target wire rod is dyed by the preset spray head; the current embroidery needle number of the electric embroidery machine, the actual middle thread length of the target thread between the electric embroidery machine and the preset spray head and the electric embroidery edition band file are obtained to determine the to-be-dyed color of the to-be-dyed current section of target thread, and the preset spray head is used for dyeing the to-be-dyed color of the to-be-dyed current section of target thread. According to the scheme, the color data (namely the color to be dyed) of the current target wire to be dyed is dynamically calculated by obtaining the current embroidery needle number, the actual middle wire length of the dyed target wire and the electric embroidery edition band file in real time, so that the problem of dyeing position deviation caused by wire conveying delay in a traditional online dyeing technology is effectively solved; and the alignment precision of the color and the embroidery pattern is obviously improved.

Description

Technical Field

[0001] The present application relates to the technical field of wire dyeing, and in particular to a wire instant dyeing method for an electric embroidery machine, an electric embroidery method and system based on instant dyeing, and an electric embroidery product. Background Art

[0002] Currently, computerized embroidery machines rely primarily on pre-dyed single-color or space-dyed yarns to create multi-color patterns. Switching between colors requires the use of multiple needles and repeated thread cutting and changing. However, this technology has the following drawbacks: 1. Low efficiency: Each time the line is cut, the machine must be slowed down and stopped, and then accelerated again after the line is changed, which prolongs the production cycle; 2. Poor color gradient effect: Traditional embroidery thread cannot achieve delicate color gradient or customized multi-color transition, and can only be simulated by segmented dyeing yarn, which has a stiff effect; 3. Complex equipment: The multi-needle bar system and tangent mechanism increase the mechanical complexity and high maintenance cost.

[0003] Furthermore, cord embroidery, simple cord embroidery, or tape embroidery techniques typically use a single-color cord. Multicolor cord embroidery requires multiple sets of cord guide holes and cord cutting devices. These multiple sets of cord guides and cord cutting mechanisms complicate the machine structure, leading to high equipment costs and space requirements. Furthermore, frequent cord cutting and changing compromises production efficiency and makes it difficult to achieve a natural color transition.

[0004] To address the above issues, solutions based on real-time dyeing systems such as Coloreel have been proposed, which optimize dyeing positions by estimating wire consumption. However, this technology still has the following problems: 1. Dyeing hysteresis: There is a distance between the dyeing point and the needle of the embroidery thread, which causes the dyeing signal to be out of sync with the actual embroidery position, affecting the accuracy; 2. Tension fluctuation interference: During the embroidery process, the dynamic changes in the tension of the upper and lower threads (such as differences in needle length, fabric structure, etc.) lead to unstable thread usage, further aggravating the dyeing position deviation.

[0005] In summary, the existing technology is difficult to meet the requirements of high-precision, high-efficiency, and multi-color gradient embroidery. Therefore, an improved dyeing control method is urgently needed. Summary of the Invention

[0006] In order to solve one or more of the above-mentioned technical problems existing in the prior art, the embodiments of the present application provide a method for instant dyeing of wire for an electric embroidery machine, an electric embroidery method and system based on instant dyeing, and electric embroidery products, so as to solve the problems such as poor dyeing accuracy existing in the prior art.

[0007] In order to achieve the above objectives, the technical solutions adopted by this application to solve the technical problems are: In a first aspect, the present application provides a method for instant dyeing of thread for an electric embroidery machine, the method comprising: During the process of conveying the target thread material dyed by the preset nozzle to the electric embroidery machine, obtaining the current embroidery needle count of the electric embroidery machine, the actual middle length of the target thread material between the electric embroidery machine and the preset nozzle, and the electric embroidery stencil file, wherein the electric embroidery stencil file is an embroidery pattern file for instructing the electric embroidery machine; Determining the color to be dyed of the current segment of target thread to be dyed based on the current number of embroidery stitches, the actual middle thread length, and the electronic embroidery plate tape file; The preset nozzle is used to dye the current section of the target wire material to be dyed with the color to be dyed.

[0008] This application solution dynamically calculates the color data of the current target wire to be dyed (i.e., the color to be dyed) by obtaining the current embroidery stitch count, the actual middle line length of the dyed target wire, and the electric embroidery plate tape file in real time. This effectively solves the problem of dyeing position deviation caused by wire delivery delay in traditional online dyeing technology, and significantly improves the alignment accuracy of color and embroidery pattern.

[0009] In a specific embodiment, determining the color of the current target wire segment to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery tape file includes: Calculating the number of intermediate stitches corresponding to the actual intermediate thread length based on a pre-learned correspondence between the number of stitches and thread length; The number of stitches corresponding to the target thread of the current segment is calculated according to the number of intermediate stitches and the current number of embroidery stitches; The color to be dyed of the current segment target wire is determined from the electronic embroidery tape file according to the number of stitches corresponding to the current segment target wire.

[0010] This application solution achieves precise optimization of dyeing control through the correspondence between the number of needles and thread length. It can automatically compensate for the difference in thread usage caused by different needle types (flat needle / tatami needle), and can dynamically correct thread length deviations caused by factors such as target thread tension and embroidery base material.

[0011] In a specific embodiment, the calculating the number of intermediate stitches corresponding to the actual intermediate thread length based on the pre-learned correspondence between the number of stitches and the thread length includes: The number of intermediate stitches corresponding to the actual intermediate thread length is calculated based on the pre-learned correspondence between the number of stitches and the thread length and the needle method and / or embroidery substrate currently used by the electric embroidery machine.

[0012] The present application solution realizes dynamic compensation of stitch length by establishing the relationship between needle method and / or embroidery base material and thread length, reduces the error of stitch number prediction, and thus achieves accurate matching of embroidery thread length and dyeing position.

[0013] In a specific embodiment, determining the color of the current target wire segment to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery tape file further includes: Obtain the current pre-dyeing needle number, which is the number of needles corresponding to the dyed wire; Calculating an estimated middle thread length according to the current number of embroidery needles and the current number of pre-dyeing needles; The estimated middle wire length is compared with the actual middle wire length, and the coloring of the target wire of the current segment is adjusted according to the comparison result.

[0014] The present application scheme realizes real-time and precise control of the embroidery dyeing process by adjusting the dyeing position according to the current number of embroidery needles and the current number of pre-dyeing needles.

[0015] In a specific embodiment, comparing the estimated intermediate wire length with the actual intermediate wire length and adjusting the coloring of the current target wire section according to the comparison result includes: If the estimated middle line length is greater than the actual middle line length, the length of the current section of wire dyed with the color to be dyed is increased by the difference between the estimated middle line length and the actual middle line length; or, If the estimated middle line length is less than the actual middle line length, the target wire material that has been dyed between the electric embroidery machine and the preset nozzle is reduced by the length of the difference between the estimated middle line length and the actual middle line length.

[0016] This application solution achieves accurate matching of dyeing length and embroidery requirements by establishing an error compensation mechanism based on the estimated middle line length and the actual middle line length.

[0017] In a specific embodiment, the method further includes a pre-learning process of the correspondence between the number of stitches and the thread length, including: Using the target thread material and the target pattern on the basis of the embroidery pattern tape file, the target pattern is embroidered by the embroidery machine to obtain an embroidery sample; Calculating the target thread length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample; The correspondence between the number of needles and the wire length is generated according to the length of the target wire corresponding to each needle.

[0018] This application solution achieves accurate modeling of the relationship between the number of needles and line length through intelligent analysis of line consumption.

[0019] In a specific embodiment, calculating the target thread length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample includes: Obtaining the thread amount and number of stitches corresponding to different stitches, and calculating the target wire length corresponding to each stitch of each stitch according to the thread amount and number of stitches corresponding to different stitches; Generating the correspondence between the number of needles and the wire length according to the length of the target wire corresponding to each needle includes: The correspondence between the number of stitches and the wire length is generated according to the length of the target wire corresponding to each stitch of the various stitches.

[0020] This application solution further improves the accuracy of the relationship between the number of needles and thread length by analyzing the relationship between the number of needles and thread length corresponding to different needle techniques.

[0021] In a specific embodiment, the current embroidery stitch count includes: Using a sensor to identify the number of driving rotations of the electric embroidery machine, and calculating the number based on the number of driving rotations; or, The electric embroidery machine identifies the real-time needle number.

[0022] In a specific embodiment, the target wire material includes yarn or a rope for cord embroidery.

[0023] In a specific embodiment, the method further comprises: Before delivering the target wire dyed by the preset nozzle to the electric embroidery machine, the undyed target wire is dyed by the preset nozzle based on the electric embroidery plate file, and the dyed target wire is passed through the needle of the electric embroidery machine.

[0024] In a second aspect, the present application further provides an electric embroidery method based on instant dyeing, the method comprising: Based on the instant thread dyeing method for an electric embroidery machine as described in any one of the first aspects, an instant dyeing device is used to dye a target thread and the dyed target thread is conveyed to the electric embroidery machine; The target pattern is embroidered by using the dyed target thread material on an electric embroidery machine based on the electric embroidery plate tape file.

[0025] This application scheme realizes the integrated automatic operation from thread dyeing to pattern embroidery through the coordinated work of the instant dyeing device and the electric embroidery machine, significantly improving the production efficiency and process consistency. The dyeing process is directly controlled based on the electric embroidery plate file to ensure that the color of the dyed thread is highly matched with the design pattern, solving the color difference problem that may exist in traditional pre-dyed thread, and can break through the color limitations of traditional embroidery thread, support any complex color combination and gradient effect, and provide a broader space for embroidery art creation.

[0026] In a specific embodiment, the electric embroidery method further comprises: The electric embroidery machine obtains the current number of embroidery needles and sends the current number of embroidery needles to the instant dyeing device.

[0027] In a specific embodiment, each set of needles of the electric embroidery machine corresponds to one instant dyeing device; The method of using the electric embroidery machine to embroider the target pattern based on the electric embroidery plate tape file by using the dyed target wire comprises: The target pattern is embroidered on the target wire dyed by the electric embroidery machine using a plurality of the instant dyeing devices based on the electric embroidery plate tape file.

[0028] This application solution can achieve efficient and accurate multi-color embroidery production through a multi-needle collaborative instant dyeing device.

[0029] In a third aspect, the present application further provides an electric embroidery system based on instant dyeing, the system comprising: An instant dyeing device configured to dye a target thread based on the instant thread dyeing method for an electric embroidery machine as described in any one of the first aspects; The electric embroidery machine is configured to be communicatively connected with the instant dyeing device, and embroiders a target pattern based on the electric embroidery plate tape file using the dyed target wire material based on the instant dyeing electric embroidery method as described in any one of the second aspects.

[0030] In a fourth aspect, the present application further provides an electric embroidery product, which is prepared based on the electric embroidery method based on instant dyeing as described in any one of the second aspects or prepared using the electric embroidery system based on instant dyeing as described in the third aspect. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0032] Figure 1This is a flow chart of a method for instant thread dyeing for an electric embroidery machine provided in some embodiments of the present application; Figure 2 A flowchart of determining the color to be dyed of the current segment of target thread to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery plate tape file provided in some embodiments of the present application; Figure 3 A flowchart of determining the color to be dyed of the current segment of target thread to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery tape file provided in other embodiments of the present application; Figure 4 This is a flowchart of a pre-learning process for the correspondence between the number of needles and thread length provided in some embodiments of the present application; Figure 5 It is a schematic diagram of conventional needlework and towel embroidery provided in some embodiments of the present application; Figure 6a-6c is a schematic diagram of toothbrush embroidery provided in some embodiments of the present application; Figure 7 is a flow chart of an electric embroidery method based on instant dyeing provided in some embodiments of the present application; Figure 8 This is a structural block diagram of an electric embroidery system based on instant dyeing provided in some embodiments of the present application; Figure 9 is a structural block diagram of an electric embroidery system based on instant dyeing provided in other embodiments of the present application; Figure 10a-Figure 10d It is a schematic diagram of a partial structure of an instant dyeing device provided in some embodiments of the present application. DETAILED DESCRIPTION

[0033] To make the purpose, technical solutions, and advantages of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0034] As described in the background, existing instant dyeing methods suffer from, on the one hand, a lack of synchronization between the dyeing signal and the actual embroidery position due to the distance the embroidery thread travels from the dyeing point to the needle, affecting precision. On the other hand, during the embroidery process, the tension of the upper and lower threads dynamically changes (e.g., due to differences in stitch length and fabric structure), leading to unstable thread usage and further exacerbating dyeing position deviations. To address one or more of these issues, this application proposes a novel instant dyeing method for thread on an electric embroidery machine. By acquiring the current stitch count, the actual mid-length of the dyed target thread, and the electric embroidery pattern file in real time, the method dynamically calculates the color data of the current target thread to be dyed (i.e., the color to be dyed). This method effectively addresses the dyeing position deviation problem caused by thread delivery delays in traditional online dyeing techniques, significantly improving the alignment accuracy of colors and embroidery patterns.

[0035] The solution of this application will be described in detail below with reference to the accompanying drawings and various embodiments.

[0036] Example 1 In order to realize the solution of the present application, the embodiment of the present application provides a method for instant dyeing of wire for an electric embroidery machine. It should be noted that instant dyeing in the embodiment of the present application refers to dyeing the wire in real time during the embroidery / sewing process, that is, dyeing the wire while using the dyed wire for embroidery / sewing. Figure 1 As shown, the method includes the following steps: S100: In the process of conveying the target wire material dyed by the preset nozzle to the electric embroidery machine, the current embroidery needle number of the electric embroidery machine, the actual middle line length of the target wire material between the electric embroidery machine and the preset nozzle, and the electric embroidery plate tape file are obtained. The electric embroidery plate tape file is an embroidery pattern file for indicating the electric embroidery machine.

[0037] It is understandable that there is a certain distance between the electric embroidery machine and the preset nozzle of the instant dyeing device. Therefore, there will be a certain length of wire between the needle of the electric embroidery machine and the preset nozzle. In the embodiment of the present application, the length of this wire is defined as the actual middle line length.

[0038] In some specific embodiments, the initial actual middle length of the thread corresponding to the embroidery pattern to be embroidered by the electric embroidery machine does not need to be dyed, so the target thread is directly pulled from the preset nozzle to the needle of the electric embroidery machine and the target thread is passed through the needle of the electric embroidery machine, and then the electric embroidery machine and the instant dyeing device are turned on to start working.

[0039] In a specific embodiment, the initial actual middle length of the thread corresponding to the embroidery pattern to be embroidered by the electric embroidery machine also needs to be dyed, and the method further includes: Before delivering the target wire dyed by the preset nozzle to the electric embroidery machine, the undyed target wire is dyed by the preset nozzle based on the electric embroidery plate file, and the dyed target wire is passed through the needle of the electric embroidery machine.

[0040] That is, before the electric embroidery machine starts working, it is necessary to turn on the instant dyeing device first, and then pull the target wire from the preset nozzle to the needle of the electric embroidery machine, while using the preset nozzle of the instant dyeing device to dye the undyed target wire based on the electric embroidery plate file, and then lead the dyed target wire to the needle of the electric embroidery machine, and turn on the electric embroidery machine to start working.

[0041] During the delivery of the target thread dyed by the preset nozzles to the embroidery machine, precise coordination between dyeing and embroidery is achieved through real-time monitoring of key parameters. These include, but are not limited to, the current stitch count of the embroidery machine, the actual intermediate length of the target thread between the machine and the preset nozzles, and the embroidery pattern file. By establishing a three-dimensional control system of "stitch count-thread length-command," the industry challenge of dyeing lag is resolved, significantly improving the pass rate of the real-time dyeing process.

[0042] It should be understood that the embroidery pattern files in the embodiments of this application are embroidery pattern files used to instruct embroidery machines. They typically contain embroidery pattern design information, specific stitch count information, stitching information, stitch coordinate information, embroidery pattern color information (including but not limited to stitch count and color correspondence information), and instructions for how to embroider on fabric. These instructions can precisely control the needle movement trajectory and needle bar raising and lowering timing of the embroidery machine. These files are typically created using specialized computer embroidery pattern-making software. They can be recognized by computer embroidery machines and used to guide them in completing complex embroidery tasks.

[0043] It should be noted that the specific file type of the electronic embroidery pattern tape file is not limited in the embodiments of this application. As an example and not a limitation, the electronic embroidery pattern tape file in the embodiments of this application can be a DST format file. In the DST format file, each stitch is equivalent to a coordinate point, based on which the total thread length required to complete the embroidery pattern can be preliminarily estimated.

[0044] It is understandable that by replacing the traditional multi-needle bar thread changing or pre-dyed yarn process with instant dyeing, the number of thread cutting and thread changing can be greatly reduced, production efficiency can be improved, and equipment complexity and maintenance costs can be reduced.

[0045] It should be noted that the preset nozzle of this application can adopt a multi-channel nozzle array, and different nozzles can spray different colors, so that the same wire can have a gradient color or multiple sections of different colors after being dyed.

[0046] S200: Determine the color to be dyed of the current segment of target wire material to be dyed based on the current number of embroidery stitches, the actual middle thread length, and the electronic embroidery tape file.

[0047] It's understood that the current stitch count refers to the number of stitches already completed by the embroidery machine for the embroidery pattern. The current target thread segment to be dyed refers to the segment of thread currently undyed but about to be dyed at the preset nozzle. By combining the stitch count with the actual thread length for real-time dyeing decisions, the system automatically compensates for thread instability caused by factors such as upper and lower thread tension fluctuations and stitch length variations during the embroidery process, ensuring smooth transitions in gradient or multi-color patterns.

[0048] S300: Dyeing the current target wire section to be dyed with the color to be dyed using the preset nozzle.

[0049] It should be noted that the present application solution uses a high-precision preset nozzle to achieve real-time on-demand dyeing of the target wire.

[0050] Reference Figure 2 As shown, in some specific embodiments, determining the color to be dyed of the current segment of target wire to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery tape file includes: S210: Calculating the number of middle stitches corresponding to the actual middle thread length based on the pre-learned correspondence between the number of stitches and thread length; S220: Calculating the number of stitches corresponding to the target thread material in the current segment according to the number of intermediate stitches and the current number of embroidery stitches; S230: Determine the color to be dyed of the current segment of target thread from the electronic embroidery tape file according to the number of stitches corresponding to the current segment of target thread.

[0051] It should be noted that the present application solution can evaluate the correspondence between the number of needles and the thread length corresponding to the current embroidery pattern and the target thread based on the learning of the instant dyeing device, and then calculate the intermediate number of needles corresponding to the actual intermediate thread length based on the correspondence between the number of needles and the thread length, and then add the intermediate number of needles to the current number of embroidery needles to obtain the number of needles corresponding to the current segment of the target thread, and finally match the color corresponding to the number of needles corresponding to the current segment of the target thread from the electric embroidery plate file, and this color is the color to be dyed of the current segment of the target thread. Among them, the intermediate number of needles reflects the number of needles that can be embroidered with the target thread of the actual intermediate thread length, and the number of needles corresponding to the current segment of the target thread reflects the number of needles that the current segment of the target thread will be used for embroidery, that is, the number of needles used for embroidery. For example, assuming that the current number of embroidery needles is 150, and the intermediate number of needles is calculated to be 1000, then the number of needles corresponding to the current segment of the target thread is 1150.

[0052] In some specific embodiments, the correspondence between the number of stitches and thread length includes the thread length corresponding to each stitch. The number of intermediate stitches corresponding to the actual intermediate thread length can be calculated by dividing the actual intermediate thread length by the thread length corresponding to each stitch. It can be understood that the total thread usage = the sum of all stitch coordinate distances + the average thread length per stitch * the total number of stitches, where the average thread length per stitch is related to the thickness of the embroidery substrate and the stitch length. Based on the total thread usage, the corresponding length of each stitch of the target thread material on the embroidery substrate can be estimated.

[0053] In some specific embodiments, the calculating the number of intermediate stitches corresponding to the actual intermediate thread length based on the pre-learned correspondence between the number of stitches and thread length includes: The number of intermediate stitches corresponding to the actual intermediate thread length is calculated based on the pre-learned correspondence between the number of stitches and the thread length and the needle method and / or embroidery substrate currently used by the electric embroidery machine.

[0054] It should be noted that in the embodiments of the present application, the calculation model is adjusted in real time for different stitches and / or embroidery substrates to ensure that the calculated number of intermediate stitches corresponding to the actual intermediate line length is more accurate. For example, for elastic embroidery substrates, the calculated number of intermediate stitches can be optimized by enabling a strain compensation algorithm. For multi-layer composite embroidery substrates, its penetration resistance can be identified and the thread consumption coefficient can be set to participate in the calculation of the number of intermediate stitches. For different stitches, since the thread length may be different, it is necessary to add a thread consumption of about 0-2 / 3 of the stitch length to some stitches.

[0055] Furthermore, for special needle techniques (such as E-shaped needles, etc.), some thread length compensation (such as 3-5% thread length compensation, etc.) can be automatically added to the corners.

[0056] Reference Figure 3 As shown, in some specific embodiments, determining the color to be dyed of the current segment of target wire to be dyed based on the current embroidery needle count, the actual intermediate thread length, and the electronic embroidery plate tape file further includes: S210': Obtain the current pre-dyeing needle number, which is the number of needles corresponding to the dyed wire; S220': Calculating an estimated middle thread length according to the current number of embroidery stitches and the current number of pre-dyeing stitches; S230': Compare the estimated middle wire length with the actual middle wire length, and adjust the coloring of the current segment target wire according to the comparison result.

[0057] Understandably, electric embroidery thread typically consists of two parts: an upper thread, which is the target thread to be dyed immediately, and a bobbin thread, which is used for fixing and does not require dyeing. A small portion of the upper thread is typically pulled to the back, creating a tug-of-war between the two threads. The density, elasticity, and stitching of the embroidery substrate can all affect this balance, altering the tension of the upper thread and causing variations in thread usage.

[0058] To address the above problems, the present application solution adjusts the dyeing position according to the current number of embroidery needles and the current number of pre-dyeing needles, thereby reducing the error of traditional single needle number prediction and achieving real-time and precise control during the embroidery dyeing process.

[0059] In a specific embodiment, comparing the estimated intermediate wire length with the actual intermediate wire length and adjusting the coloring of the current target wire section according to the comparison result includes: If the estimated middle line length is greater than the actual middle line length, the length of the current section of wire dyed with the color to be dyed is increased by the difference between the estimated middle line length and the actual middle line length; or, If the estimated middle line length is less than the actual middle line length, the target wire material that has been dyed between the electric embroidery machine and the preset nozzle is reduced by the length of the difference between the estimated middle line length and the actual middle line length.

[0060] It is understandable that the actual middle thread length is relatively constant. An estimated middle thread length can be calculated based on the current number of embroidery stitches and the current number of pre-dye stitches. If the estimated middle thread length is greater than the actual middle thread length, this indicates that the thread used for the number of stitches already embroidered exceeds the estimated amount in the record. In this case, the instant dyeing device can increase the thread length corresponding to the current number of pre-dye stitches for correction, thereby increasing the length of the current segment of thread dyed with the color to be dyed to extend the length of the dyed segment. For example, the length of the current segment of thread dyed with the color to be dyed is increased by the difference between the estimated middle thread length and the actual middle thread length. If the estimated middle thread length is less than the actual middle thread length, this indicates that the middle thread length is excessive, exceeding the required amount. A thread winding device can be added to the electric embroidery system to remove the excess thread and cut off the extra dyed segment. For example, the already dyed target thread between the electric embroidery machine and the preset nozzle can be pulled by a length equal to the difference between the estimated middle thread length and the actual middle thread length. This method can improve color alignment accuracy and prevent color shift in the embroidery pattern.

[0061] Reference Figure 4 As shown, in some specific embodiments, the method further includes a pre-learning process of the correspondence between the number of needles and the thread length, including: S211: using the electric embroidery machine to embroider the target pattern using the target thread based on the electric embroidery pattern file to obtain an embroidery sample; S212: Calculating the target thread length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample; S213: Generate the correspondence between the number of needles and the wire length according to the length of the target wire corresponding to each needle.

[0062] It is understandable that, on the one hand, due to the high speed of electric embroidery, the thread usage may still vary between the same embroidery substrate and different target thread materials. On the other hand, parameters such as the thickness and elasticity of different embroidery substrates may also affect the thread usage. Based on this, in the embodiment of the present application, the target thread material can be used to embroider patterns on various embroidery substrates in advance for the software of the instant dyeing device to learn and evaluate the thread usage of the target thread material on each embroidery substrate.

[0063] In specific implementation, the target pattern is first embroidered using the target thread material on an electric embroidery machine based on the electric embroidery pattern tape file to obtain an embroidery sample. The target thread length corresponding to each needle is then calculated based on the total thread consumption and the total number of stitches in the embroidery sample. Finally, a needle count-thread length correspondence is generated based on the target thread length corresponding to each needle. Furthermore, based on the needle count-thread length correspondence for each embroidery sample, a needle count-thread length database based on actual production can be established to facilitate subsequent querying.

[0064] It should be noted that, in order to improve the accuracy of the generated correspondence between the number of needles and the thread length, for each target thread material and embroidery base material, multiple embroidery samples can be embroidered for the instant dyeing device to learn.

[0065] In some specific embodiments, calculating the target thread length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample includes: Obtaining the thread amount and number of stitches corresponding to different stitches, and calculating the target wire length corresponding to each stitch of each stitch according to the thread amount and number of stitches corresponding to different stitches; Generating the correspondence between the number of needles and the wire length according to the length of the target wire corresponding to each needle includes: The correspondence between the number of stitches and the wire length is generated according to the length of the target wire corresponding to each stitch of the various stitches.

[0066] It should be noted that the total amount of thread used will vary depending on the stitching method (such as flat stitch, chain stitch, toothbrush stitch, towel stitch, etc.). Figure 5 As shown, Figure 5Two stitches are shown: conventional stitch 01 and terry stitch 02. Conventional stitch 01 has the thread tucked tightly against the surface of the embroidery base, while terry stitch 02 uses an electric embroidery machine to extend the needle bar, preventing the thread from being tucked tightly against the surface, forming loops. To address this issue, the present invention reduces thread length prediction errors by identifying thread differences associated with different stitches.

[0067] In specific implementation, since the instant dyeing device dyes the target thread based on the electronic embroidery pattern file, the thread usage of the embroidery pattern can be segmented during the learning process, such as dividing the thread usage limit of each needle method according to different needle methods, so as to provide segmented learning for the instant dyeing device. Figure 5 The two stitches shown can be used to divide the embroidery pattern into segment 1 and segment 2 according to the stitches, where segment 1 corresponds to conventional stitch 01 and segment 2 corresponds to towel stitch 02. The thread usage and stitch count corresponding to segment 1 and segment 2 are obtained, and the thread usage and stitch count corresponding to segment 1 and segment 2 are respectively calculated to obtain the target thread length corresponding to each stitch of conventional stitch 01 and towel stitch 02. Then, a corresponding relationship between the stitch count and thread length corresponding to conventional stitch 01 and towel stitch 02 is established based on the target thread length corresponding to each stitch of conventional stitch 01 and towel stitch 02.

[0068] Figure 6a-6c The diagram shows toothbrush embroidery, a new type of embroidery technique. It is named for its upright threads, resembling the bristles of a toothbrush. It is also known as vertical thread embroidery. Toothbrush embroidery has a strong three-dimensional effect, is soft and washable, and can be combined with sequin embroidery, towel embroidery, flat embroidery, and other techniques to create a variety of techniques. For further reference, Figure 6a-6c As shown in the figure, the embroidery base material of toothbrush embroidery is usually composed of surface auxiliary material 03, middle auxiliary material 04 and base material 05. After the electric embroidery is completed, it is cut from the middle (such as along the Figure 6b Cut along the dotted line in the figure) and remove the middle auxiliary material 04, leaving the base material 05 and the embroidery thread 06 (i.e. the target thread 06), and you can create a whole-surface standing bristle effect, such as Figure 6c In the process of learning toothbrush embroidery, the surface auxiliary material 03, the middle auxiliary material 04 and the base material 05 can be considered as a whole for learning.

[0069] In some specific embodiments, the model can also be dynamically adjusted during the learning process, such as automatically optimizing model parameters every 5,000 stitches or compensating for nonlinear errors in real time. It should be noted that the embodiments of this application do not specifically limit the specific method of dynamic parameter adjustment, and can be selected according to actual needs without violating the inventive concept of this application.

[0070] In some specific embodiments, the current embroidery stitch count includes: Using a sensor to identify the number of driving rotations of the electric embroidery machine, and calculating the number based on the number of driving rotations; or, The electric embroidery machine identifies the real-time needle number.

[0071] It should be noted that the embodiments of this application do not limit the specific method for obtaining the current number of embroidery stitches of the electric embroidery machine. This method can be selected based on actual needs without violating the inventive concept of this application. It is understood that the needle raising and lowering of an electric embroidery machine is typically based on a rotational drive. Therefore, a sensor can be added to the electric embroidery machine to identify the number of rotations of the electric embroidery machine drive, and then the current number of embroidery stitches of the electric embroidery machine can be calculated based on the number of rotations of the electric embroidery machine drive detected by the sensor. For example, in some specific embodiments, the motion transmission ratio of the electric embroidery machine is 1:1. Therefore, every complete rotation (360°) of the electric embroidery machine main shaft is converted into a complete raising and lowering motion of the needle bar through the eccentric wheel or cam mechanism, that is, 1 rotation = 1 stitch.

[0072] In addition to the above methods, some electric embroidery machines can recognize the real-time needle number themselves. Therefore, it is only necessary to transmit the real-time needle number recognized by the electric embroidery machine itself as the current embroidery needle number to the instant dyeing device through a data cable or other means.

[0073] In some specific embodiments, the target wire material includes yarn or a rope for cord embroidery.

[0074] It should be noted that yarns include but are not limited to cotton yarns, polyester yarns, and silk yarns. The method provided in the embodiments of the present application can improve the compatibility of the yarns to be dyed, meet the full spectrum of needs from fine calligraphy and painting embroidery to rough rope art decoration, and achieve precise dyeing control for all types of embroidery media.

[0075] It's understood that cord embroidery (including both standard and simplified cord embroidery) refers to a decorative embroidery technique using cord or similar materials, widely used in clothing, home accessories, and other fields. Cord embroidery uses thicker cord (such as cotton, hemp, or metal-core cord) as the primary embroidery material, creating a three-dimensional pattern by coiling, securing, or sewing it onto fabric. Cord embroidery typically uses cord with a diameter of 1-5 mm and made from cotton, hemp, polyester, or blended yarns. The cord is partially embedded in the fabric, while other portions are raised, creating a distinct concave-convex effect. Cord embroidery is typically secured to the fabric using the cord guide holes and presser foot mechanism of a dedicated cord embroidery machine. For example, ordinary thread (undyed) is used, and various stitching techniques are used to sew the cord back and forth on both sides to secure it. Simple cord embroidery is a simplified version of cord embroidery, typically using finer thread or simplified techniques. It's suitable for quickly creating decorative lines or basic patterns. The materials for simple cord embroidery are usually thin cords (such as lace thread, embroidery thread ropes) or directly replaced with thick thread.

[0076] When dyeing a rope using the method provided in the embodiments of this application, since the rope itself is extremely resistant to stretching, the thread usage is essentially constant: the total thread usage of the rope = the sum of the stitch coordinate distances. Furthermore, the method provided in the embodiments of this application enables continuous color transitions on a single rope, breaking through the single-color limitations of traditional rope embroidery and enabling segmented dyeing. Compared to traditional rope-changing methods, this significantly improves the craftsmanship and production efficiency of rope embroidery.

[0077] Example 2 Corresponding to the above embodiment 1, the present application also provides an electric embroidery method based on instant dyeing, wherein, in this embodiment, the same or similar contents as those in the above embodiment 1 can be referred to the above introduction and will not be described in detail later. Figure 7 As shown, the method includes the following steps: S400: dyeing a target wire using an instant dyeing device based on the instant dyeing method for an electric embroidery machine as described in any one of the first embodiments, and conveying the dyed target wire to the electric embroidery machine; S500: Embroidering a target pattern using the dyed target thread material based on the embroidery plate tape file using an electric embroidery machine.

[0078] This application solution, through the collaborative work of the instant dyeing device and the electric embroidery machine, realizes the integrated automatic operation from thread dyeing to pattern embroidery, significantly improving production efficiency and process consistency. The dyeing process is directly controlled based on the electric embroidery plate file to ensure that the color of the dyed thread is highly matched with the design pattern, solving the color difference problem that may exist in traditional pre-dyed thread, and can break through the color limitations of traditional embroidery thread, supporting any complex color combination and gradient effect, providing a broader space for embroidery art creation. In addition, by replacing the traditional multi-needle bar thread changing or pre-dyed yarn process with instant dyeing, the number of thread cutting and thread changing is greatly reduced, and production efficiency is improved, while reducing equipment complexity and maintenance costs.

[0079] In some specific embodiments, the electric embroidery method further comprises: The electric embroidery machine obtains the current number of embroidery needles and sends the current number of embroidery needles to the instant dyeing device.

[0080] Specifically, during the operation of the electric embroidery machine, the electric embroidery machine sends the acquired current embroidery stitch count to the instant dyeing device, so that the instant dyeing device determines the color to be dyed of the current segment of the target wire based on the current embroidery stitch count, the actual middle thread length and the electric embroidery plate tape file.

[0081] In some specific embodiments, each set of needles of the electric embroidery machine corresponds to one of the instant dyeing devices; The method of using the electric embroidery machine to embroider the target pattern based on the electric embroidery plate tape file by using the dyed target wire comprises: The target pattern is embroidered on the target wire dyed by the electric embroidery machine using a plurality of the instant dyeing devices based on the electric embroidery plate tape file.

[0082] It should be noted that, in the method provided in the embodiment of the present application, each group of needles of the electric embroidery machine can correspond to an instant dyeing device respectively, and the electric embroidery machine can use the target wire dyed by multiple instant dyeing devices simultaneously or separately to embroider the target pattern based on the electric embroidery plate tape file.

[0083] In some specific embodiments, when each group of needles of the electric embroidery machine corresponds to an instant dyeing device (that is, one electric embroidery machine corresponds to multiple instant dyeing devices), only the instant dyeing device serving as the host needs to perform pattern learning and identify the number of stitches of the electric embroidery machine, and the other instant dyeing devices are connected through line communication. However, since the actual middle length of the target thread between different instant dyeing devices and the needles of the electric embroidery machine may be different, each instant dyeing device will individually calibrate the dyeing of the current segment of the target thread according to the current number of pre-dyeing stitches and the current number of embroidery stitches.

[0084] In other specific embodiments, different instant dyeing devices perform pattern learning and recognize the stitch count of the electric embroidery machine based on the stitches performed by their connected needles. For example, an instant dyeing device connected to a needle performing conventional stitching performs conventional stitch pattern learning and recognizes the stitch count of the electric embroidery machine, while an instant dyeing device connected to a needle performing towel stitching performs towel stitch pattern learning and recognizes the stitch count of the electric embroidery machine, and so on. Detailed descriptions are omitted here.

[0085] Example 3 Corresponding to the above-mentioned embodiments 1 and 2, the present application also provides an electric embroidery system based on instant dyeing, wherein, in this embodiment, the same or similar contents as those in the above-mentioned embodiments 1 and 2 can be referred to the above introduction and will not be described in detail later. Figure 8 As shown, the system at least includes: The instant dyeing device 10 is configured to dye the target thread based on the instant thread dyeing method for the electric embroidery machine as described in any one of the first embodiments; The electric embroidery machine 20 is configured to be in communication connection with the instant dyeing device, and to embroider a target pattern based on the electric embroidery pattern tape file using the dyed target thread according to the instant dyeing-based electric embroidery method as described in any one of the second embodiments.

[0086] Further references Figure 8 As shown, in some specific embodiments, one electric embroidery machine corresponds to one instant dyeing device.

[0087] Reference Figure 9As shown, in other specific embodiments, one electric embroidery machine corresponds to multiple instant dyeing devices. Specifically, each set of needles on the electric embroidery machine corresponds to an instant dyeing device. The electric embroidery machine can simultaneously or separately use the target thread dyed by multiple instant dyeing devices to embroider the target pattern based on the electric embroidery pattern tape file. For example, one electric embroidery machine can correspond to two, three, four, etc. instant dyeing devices, and these examples are not listed here one by one.

[0088] In some specific embodiments, the instant dyeing device 10 includes, but is not limited to, a Coloreel yarn dyeing machine. The Coloreel yarn dyeing machine is a device capable of instantly dyeing textile yarn. It combines Ricoh's inkjet technology with its own dyeing technology to provide high-quality, instant dyeing for textile yarn during production. This technology is compatible with all currently available embroidery machines. By instantly and synchronously dyeing raw white yarn, it eliminates any restrictions on color usage during the embroidery production process, ensuring manufacturers have full freedom in color selection, especially for specialized embroidery products.

[0089] Reference Figure 10a-Figure 10d As shown, in some specific implementations, the instant dyeing device 10 includes but is not limited to the following components: Multiple spools and thread clamps A, the spools are configured to wind the target thread and serve as the source of the target thread supply to ensure that the target thread is continuously supplied during continuous embroidery. The thread clamps are configured to ensure that the target thread has moderate tension during transportation by adjusting the pressure of the thread clamps to avoid being too loose (loose stitches, floating threads) or too tight (broken threads, wrinkled fabrics).

[0090] Multiple thread feeding devices B are configured to smoothly pull the target thread on the spool to the dyeing / embroidery area through components such as yarn guide wheels and tension wheels to avoid thread breakage, entanglement or accumulation, and work in conjunction with the thread clamp to dynamically adjust the tightness of the thread.

[0091] Print engine C is configured to parse the electronic embroidery plate file (such as DST format) through software, convert it into printing instructions, and control the preset print head to accurately reproduce the corresponding color on the target wire.

[0092] Air filter D is configured to filter flying catkins and lint in the air (especially when processing short-fiber yarns) to avoid clogging of nozzles, sensors or guide rails of moving parts, as well as clean air to reduce friction loss caused by particles in components such as cylinders and bearings.

[0093] The fixing module E is configured to fix the target yarn through a pneumatic / mechanical clamp to prevent displacement during the dyeing process, and to provide real-time feedback and adjust the yarn tension to avoid uneven dyeing caused by relaxation or over-stretching.

[0094] Carbon filter F is configured to efficiently adsorb organic pollutants and chemical gases, ensuring process environment safety, stable equipment operation and emission compliance.

[0095] The particle filter G is configured to intercept fiber debris and dust, preventing short fibers, cotton wool, etc. that fall off during target wire processing from entering the pneumatic system (such as cylinders, solenoid valves) or moving parts (such as guide rails, bearings), thereby reducing mechanical wear.

[0096] The cleaning module H is configured to pre-treat the target yarn, remove impurities such as spinning oil, wax or cottonseed hulls (especially for natural fibers) on the surface of the target yarn, ensure uniform penetration of the dye solution, and decompose the starch or PVA slurry on the fabric (through enzyme washing or hot water washing) to avoid dyeing spots.

[0097] Lubrication module and wire outlet device I: The lubrication module is configured to automatically inject lubricant (such as lithium-based grease or synthetic oil) into moving parts such as guide rails, bearings, and gears to reduce the friction coefficient and extend the life of the equipment. The wire outlet device is configured to ensure that the target wire enters the dyeing tank or printing area at a constant angle and position through components such as yarn guide porcelain eyes and tension wheels.

[0098] Double-control switch J is configured for safety interlock, operation mode switching and equipment start and stop management.

[0099] The stitch sensor port K is configured as a key sensing interface for real-time monitoring and control of the position of sewing / embroidery stitches or yarn guide needles, which directly affects sewing accuracy, dyeing uniformity and equipment automation level.

[0100] The display L is configured to provide human-computer interaction services.

[0101] USB interface M is configured for design file transfer and update, production data interaction, peripheral expansion, etc.

[0102] The standby button N is configured to reduce device energy consumption and maintain system status during non-production periods or temporary interruptions, while avoiding the time-consuming restart problem caused by a complete shutdown.

[0103] It should be noted that the specific implementation of the electric embroidery machine is not limited in the embodiments of the present application. Without violating the inventive concept of the present application, any known electric embroidery machine can be used as the electric embroidery machine in the present application.

[0104] Example 4 Corresponding to the above-mentioned embodiment 2 or 3, the present application also provides an electric embroidery product, which is prepared based on the electric embroidery method based on instant dyeing as described in any one of the embodiments 2 or prepared using the electric embroidery system based on instant dyeing as described in the embodiment 3. In this embodiment, the same or similar contents as those in the above-mentioned embodiment 2 or 3 can be referred to the above introduction and will not be repeated later.

[0105] Each embodiment in this specification is described in a progressive manner. The same or similar parts between the embodiments can be referred to each other. Each embodiment focuses on the differences from other embodiments. In particular, for system or system embodiments, since they are basically similar to method embodiments, the description is relatively simple. For relevant parts, refer to the partial description of the method embodiment. The system and system embodiments described above are merely schematic, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment. A person of ordinary skill in the art can understand and implement it without expending creative work.

[0106] The technical solutions provided by the present invention have been described in detail above. Specific examples have been used herein to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is intended only to help understand the method and core concept of the present invention. At the same time, those skilled in the art will appreciate that the specific implementation methods and application scopes may vary based on the concepts of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A method for instant dyeing of thread for an electric embroidery machine, characterized in that: The method comprises: During the process of conveying the target thread material dyed by the preset nozzle to the electric embroidery machine, obtaining the current embroidery needle count of the electric embroidery machine, the actual middle length of the target thread material between the electric embroidery machine and the preset nozzle, and the electric embroidery stencil file, wherein the electric embroidery stencil file is an embroidery pattern file for instructing the electric embroidery machine; Determining the color to be dyed of the current segment of target thread to be dyed based on the current number of embroidery stitches, the actual middle thread length, and the electronic embroidery plate tape file; The preset nozzle is used to dye the current section of the target wire material to be dyed with the color to be dyed.

2. The instant thread dyeing method for an electric embroidery machine according to claim 1, characterized in that: The step of determining the color of the target wire of the current segment to be dyed based on the current number of embroidery needles, the actual middle thread length, and the electronic embroidery tape file includes: Calculating the number of intermediate stitches corresponding to the actual intermediate thread length based on a pre-learned correspondence between the number of stitches and thread length; The number of stitches corresponding to the target thread of the current segment is calculated according to the number of intermediate stitches and the current number of embroidery stitches; The color to be dyed of the current segment target wire is determined from the electronic embroidery tape file according to the number of stitches corresponding to the current segment target wire.

3. The instant thread dyeing method for an electric embroidery machine according to claim 2, characterized in that: The calculating of the number of intermediate stitches corresponding to the actual intermediate thread length based on the pre-learned correspondence between the number of stitches and thread length includes: The number of intermediate stitches corresponding to the actual intermediate thread length is calculated based on the pre-learned correspondence between the number of stitches and the thread length and the needle method and / or embroidery substrate currently used by the electric embroidery machine.

4. The instant thread dyeing method for an electric embroidery machine according to claim 2, characterized in that: The step of determining the color of the target wire of the current segment to be dyed based on the current number of embroidery needles, the actual middle thread length, and the electronic embroidery tape file further includes: Obtain the current pre-dyeing needle number, which is the number of needles corresponding to the dyed wire; Calculating an estimated middle thread length according to the current number of embroidery needles and the current number of pre-dyeing needles; The estimated middle wire length is compared with the actual middle wire length, and the coloring of the target wire of the current segment is adjusted according to the comparison result.

5. The instant thread dyeing method for an electric embroidery machine according to claim 4, characterized in that: The comparing the estimated intermediate wire length with the actual intermediate wire length and adjusting the coloring of the current target wire according to the comparison result includes: If the estimated middle line length is greater than the actual middle line length, the length of the current section of wire dyed with the color to be dyed is increased by the difference between the estimated middle line length and the actual middle line length; or, If the estimated middle line length is less than the actual middle line length, the target wire material that has been dyed between the electric embroidery machine and the preset nozzle is reduced by the length of the difference between the estimated middle line length and the actual middle line length.

6. The instant thread dyeing method for an electric embroidery machine according to any one of claims 2 to 5, characterized in that: The method further includes a pre-learning process of the correspondence between the number of needles and the thread length, including: Using the target thread material and the target pattern on the basis of the embroidery pattern tape file, the target pattern is embroidered by the embroidery machine to obtain an embroidery sample; Calculating the target thread length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample; The correspondence between the number of needles and the wire length is generated according to the length of the target wire corresponding to each needle.

7. The instant thread dyeing method for an electric embroidery machine according to claim 6, characterized in that: Calculating the target wire length corresponding to each stitch according to the total thread consumption of the embroidery sample and the total number of stitches of the embroidery sample includes: Obtaining the thread amount and number of stitches corresponding to different stitches, and calculating the target wire length corresponding to each stitch of each stitch according to the thread amount and number of stitches corresponding to different stitches; Generating the correspondence between the number of needles and the wire length according to the length of the target wire corresponding to each needle includes: The correspondence between the number of stitches and the wire length is generated according to the length of the target wire corresponding to each stitch of the various stitches.

8. The instant thread dyeing method for an electric embroidery machine according to any one of claims 1 to 4, characterized in that: The current embroidery stitch count includes: Using a sensor to identify the number of driving rotations of the electric embroidery machine, and calculating the number based on the number of driving rotations; or, The electric embroidery machine identifies the real-time needle number.

9. The instant thread dyeing method for an electric embroidery machine according to any one of claims 1 to 4, characterized in that: The target wire material includes yarn or a rope for cord embroidery.

10. An electric embroidery method based on instant dyeing, characterized in that: The method comprises: Based on the instant dyeing method for wire for electric embroidery machine according to any one of claims 1 to 9, a target wire is dyed by using an instant dyeing device and the dyed target wire is conveyed to the electric embroidery machine; The target pattern is embroidered by using the dyed target thread material on an electric embroidery machine based on the electric embroidery plate tape file.

11. The electric embroidery method based on instant dyeing according to claim 10, characterized in that: The electric embroidery method further comprises: The electric embroidery machine obtains the current number of embroidery needles and sends the current number of embroidery needles to the instant dyeing device.

12. The electric embroidery method based on instant dyeing according to claim 10 or 11, characterized in that: Each set of needles of the electric embroidery machine corresponds to one instant dyeing device; The method of using the electric embroidery machine to embroider the target pattern based on the electric embroidery plate tape file by using the dyed target wire comprises: The target pattern is embroidered on the target wire dyed by the electric embroidery machine using a plurality of the instant dyeing devices based on the electric embroidery plate tape file.

13. An electric embroidery system based on instant dyeing, characterized in that: The system comprises: An instant dyeing device configured to dye a target wire based on the instant wire dyeing method for an electric embroidery machine according to any one of claims 1 to 9; The electric embroidery machine is configured to be communicatively connected with the instant dyeing device, and embroiders a target pattern based on an electric embroidery plate tape file using the dyed target thread according to the instant dyeing electric embroidery method according to any one of claims 10 to 12.

14. An electric embroidery product, characterized in that: The electric embroidery product is prepared based on the electric embroidery method based on instant dyeing according to any one of claims 10 to 12 or is prepared using the electric embroidery system based on instant dyeing according to claim 13.

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