Industrial sewing machine bottom line monitoring method and system

Abstract

The invention relates to the technical field of sewing machine bottom line monitoring, in particular to an industrial sewing machine bottom line monitoring method and system. A full-thread shuttle peg is used for teaching in an actual sewing environment, the dynamically measured full-capacity needle number truly reflects the actual sewing capacity under the combination of specific threads and cloth, systematic errors caused by inaccurate presetting are eliminated, and follow-up early warning is targeted; through the collaborative analysis of the comprehensive main shaft rotation angle, the needle pulse, the tension signal and the photoelectric signal, the system can distinguish effective sewing, needle skipping, thread breaking and normal operation pause in a high-precision mode, counting errors or teaching interruption caused by misjudgment of a sensor are avoided, and the purity of effective sewing needle number data is ensured. Based on a dynamic full-capacity needle number early warning mechanism, accurate needle replacement reminding can be provided before a bottom thread is really used up, the product quality and consistency are improved, meanwhile, unnecessary shutdown and production interruption are reduced, and the production efficiency and intelligent management level of industrial sewing are comprehensively improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sewing machine bobbin thread monitoring, in particular to an industrial sewing machine bobbin thread monitoring method and system. BACKGROUND

[0002] In the field of industrial sewing, whether the bobbin thread is sufficient directly relates to the quality and production efficiency of the sewn product. The traditional and existing bobbin thread monitoring methods mainly have several significant technical bottlenecks.

[0003] Firstly, most systems rely on presetting a fixed full capacity needle number as the threshold for early warning and depletion. This method ignores the influence of multiple variables in reality, such as bobbin thread type, thread diameter, winding tightness, and the thickness and material of the sewing fabric, resulting in a large deviation between the preset value and the actual sewable needle number. Either the early warning is too early, causing resource waste and production interruption, or the early warning is too late, resulting in defective products.

[0004] In addition, the existing technology lacks an evaluation mechanism for the reliability of the monitoring data itself. If the demonstration process used to establish the benchmark is of low quality due to frequent needle skipping and abnormal pauses, then precise and safe monitoring and management of the sewing machine cannot be implemented. SUMMARY

[0005] In view of the above shortcomings of the prior art, the present application provides an industrial sewing machine bobbin thread monitoring method and system, which can effectively solve the problem of inaccurate monitoring and early warning of the bobbin thread of the sewing machine in the prior art.

[0006] To achieve the above purpose, the present application is implemented by the following technical solutions: The present application provides an industrial sewing machine bobbin thread monitoring method and system, which at least includes: A sewing machine demonstration counting stage is constructed to measure the full capacity needle number of the bobbin; Needle counting is performed when valid needle pulses are detected; The sampling data of the demonstration process are subjected to abnormality identification and correction, including: A main shaft rotation angle is established to judge needle skipping abnormalities and limit pulse counting; A tension signal and a photoelectric signal are established to judge whether the thread is broken and trigger invalid pulse demonstration; A main shaft speed is established and the duration is collected to judge whether it is a normal pause operation and manage pulse counting; The demonstration counting stage is ended, and the final full capacity needle number is constructed according to the valid sewing needle number; A sewing machine system sewing early warning stage, presetting a safe early warning needle number, constructing a remaining sewing needle number according to the fixed full capacity needle number and the cumulative sewing needle number of the sewing machine system in the sewing process, and judging whether to trigger an audible and light early warning according to the remaining sewing needle number.

[0007] Further, the establishment of the sewing machine teaching counting stage includes: After the user presses the teaching function key, the following initialization operations are performed, including: Setting the teaching needle count counter to zero; Starting the spindle pulse collector, tension collector, and photoelectric broken thread detector.

[0008] Further, the establishment of the spindle rotation angle to determine the needle skipping abnormality and limit pulse counting is specifically: If the spindle rotation angle appears continuous increments but no needle pulse is detected, it means that the needle has not penetrated the fabric or has not completed the sewing action, so it is determined that the needle skipping abnormality is triggered and: Pausing the pulse counting for that time period; Marking the pulses of that time period as invalid data and not counting them into the needle count accumulated in the teaching counting stage; If the set threshold is exceeded, restart the teaching and re-establish the counting stage and insert the full thread bobbin.

[0009] Further, the establishment of the tension signal and the photoelectric signal to determine whether the thread is broken and trigger invalid pulse teaching is specifically: If the tension signal continuously falls below the lower limit and the photoelectric broken thread signal continuously does not light up, it is determined that the thread is broken early, and: Pausing the needle count and marking the pulses of that time period as invalid teaching; Prompting the user to replace the full thread bobbin and re-teach.

[0010] Further, if the spindle speed drops to zero and the duration is lower than the preset time threshold, it is determined that it is a normal pause operation, and the operation resumes to continue the teaching stage.

[0011] Further, the end of the teaching counting stage triggers: 1) The user actively ends the teaching counting stage; 2) When the following conditions are met simultaneously, the system automatically determines that the bottom thread is exhausted and triggers the end of the teaching counting stage: The tension signal continuously falls below the threshold, the photoelectric broken thread signal continuously does not light up, and the spindle load appears an empty bobbin characteristic change; Empty bobbin characteristic change: When the bobbin is almost empty or empty, the sewing resistance drops below the threshold; The spindle load current drops below the threshold; The motor appears to be shaking or idling.

[0012] An industrial sewing machine bottom thread monitoring system includes: A teaching stage module that establishes a sewing machine teaching counting stage and measures the full capacity of the bobbin; The needle count counting module performs needle count counting when a valid needle pulse is detected. The needle number correction module performs abnormality identification and correction on the sampling data of the teaching process, including: The main shaft rotation angle is established to judge the needle skipping abnormality and limit the pulse counting. The tension signal and the photoelectric signal are established to judge whether the thread is broken and trigger the invalid pulse teaching. The main shaft rotation speed is established and the duration is collected to judge whether it is a normal pause operation and manage the pulse counting. The teaching counting stage is ended, and the final full-capacity needle number is constructed according to the valid sewing needle number. The sewing early warning module presets a safety warning needle number, constructs a remaining sewing needle number according to the fixed full-capacity needle number and the cumulative sewing needle number of the sewing machine system in the sewing process, and judges whether to trigger the audible and light warning according to the remaining sewing needle number.

[0013] A computer device includes a memory and a processor, the memory stores a computer program, and the processor implements the steps of the method when executing the computer program.

[0014] A computer readable storage medium has a computer program stored thereon, and the computer program is executed by a processor to implement the steps of the method.

[0015] The technical scheme provided by the application has the following beneficial effects compared with the known prior art: By introducing the teaching counting stage and the multi-sensor information fusion mechanism, the accuracy and reliability of the bottom line monitoring are greatly improved. By teaching with a full-thread bobbin in the actual sewing environment, the full-capacity needle number measured dynamically truly reflects the actual sewing capacity under the combination of a specific thread and a cloth, completely eliminates the systematic error caused by inaccurate presetting, and makes the subsequent warning targeted.

[0016] Through comprehensive analysis of the main shaft rotation angle, needle pulse, tension signal and photoelectric signal, the system can accurately distinguish between effective sewing, needle skipping, thread breaking and normal operation pause, effectively avoid counting errors or teaching interruption caused by single sensor misjudgment, and ensure the purity of the effective sewing needle number data.

[0017] In addition, the teaching quality scoring mechanism can automatically identify and prompt low-quality teaching by quantitatively evaluating key indicators such as needle skipping rate and downtime frequency, thereby ensuring the effectiveness of the reference data from the source.

[0018] Based on the dynamic full capacity needle number early warning mechanism, accurate needle thread changing reminder can be provided before the bottom line is really exhausted, sufficient reaction time is reserved for the operator, the defective products caused by empty shuttle sewing are greatly reduced, the product quality and consistency are improved, unnecessary downtime and production interruption are reduced, and the production efficiency and intelligent management level of industrial sewing are comprehensively improved. BRIEF DESCRIPTION OF DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0020] Figure 1 The figure is a schematic diagram of the overall method of the present application. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be described clearly and completely below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are some embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0022] At present, in the industrial sewing production process, the accurate monitoring of the remaining amount of the bottom thread bobbin has always been a technical problem to be solved, and the existing methods have many limitations, which seriously restrict the further improvement of production efficiency and product quality. These problems mainly manifest in the following aspects: First of all, the most core problem is the irreconcilable contradiction between the static monitoring benchmark and the dynamic diversity of the actual situation. Most of the existing systems rely on a preset, fixed full capacity needle number as the monitoring and early warning benchmark.

[0023] However, in actual production, the number of needles that a bobbin can really sew is significantly affected by many variables: For example, different types and materials of thread (such as cotton, polyester, embroidery thread) have different diameters and friction coefficients, resulting in different winding densities and release resistances on the bobbin; different thicknesses and textures of fabrics (such as silk, denim, leather) have a huge impact on sewing resistance; even the tightness of the bobbin winding itself varies from batch to batch. Using a fixed value to deal with such complex and variable production conditions will inevitably result in a serious lack of monitoring accuracy, which leads to either premature triggering of the warning system, causing waste of thread and unnecessary frequent downtime, disrupting the production rhythm; or a serious lag in the warning, when the alarm goes off, the bottom thread has already run out, and the system has been producing a large number of irreversible defective products in an empty sewing state, causing direct losses of raw materials and labor hours.

[0024] Secondly, during the monitoring process, the sensing and recognition ability of complex sewing states is seriously insufficient, resulting in high misjudgment rate and poor reliability. This is specifically manifested in three aspects.

[0025] The needle skipping and sensor noise cannot be distinguished. The traditional needle skipping detection, if only relying on needle position pulses, is prone to false positives due to pulse loss caused by mechanical vibration or electromagnetic interference, and the system may incorrectly determine a normal sewing as a needle skipping and pause counting, disrupting the accurate needle count.

[0026] The real thread breakage and loose thread or sensor interference cannot be distinguished. Relying solely on a tension sensor, a loose thread may be misjudged as a broken thread; relying solely on a photoelectric sensor, the signal may be abnormal due to dust pollution or environmental light interference. This single and isolated judgment logic makes the system very fragile and weak in anti-interference ability, with poor stability in the actual noisy industrial environment.

[0027] In summary, the existing technology has three major core defects: rigid reference setting, extensive state recognition, and unreliable data source, which leads to the problems of low precision, frequent false positives, and poor reliability of the industrial sewing machine thread monitoring system.

[0028] Therefore, the technical solution aims to establish a precise reference through dynamic and adaptive demonstration counting, accurately distinguish various states through multi-sensor information fusion intelligent diagnosis, and ensure the reliability of the data source through the introduction of a demonstration quality scoring system, thereby building a truly intelligent, reliable, and practical industrial sewing machine thread monitoring system to improve product quality, reduce material waste, and optimize production processes.

[0029] The present application will be further described below in conjunction with the embodiments.

[0030] Embodiment 1 (see Figure 1 ): An industrial sewing machine thread monitoring method, at least comprising: Step 1, initial sewing machine teaching count stage (put in full thread bobbin, for measuring the full capacity of a bobbin needle number) After the user presses the teaching function key in the sewing machine system, the sewing machine system enters the teaching mode and performs the following initialization operations, including: Set the teaching needle count counter to zero, the counter is used to read the spindle encoder or needle pulse signal, each needle stroke corresponds to a pulse trigger counter increase, used to determine how many needles the current bobbin has sewn.

[0031] Start the spindle pulse collector (used to detect the rotation of the sewing machine spindle, convert mechanical motion into pulse signal, generate a pulse for each needle stroke, provide input signal for the counter), tension collector (based on wire tension sensor, get tension change, monitor bottom thread tension in real time, judge whether there is thread breakage, loose thread or abnormal sewing) and photoelectric thread breakage detector (detect whether there is thread breakage through photoelectric sensor or laser thread breakage detector); among the above, the spindle is the core drive shaft of the sewing machine, which drives the needle up and down movement and the bobbin rotation.

[0032] Voice prompt: teaching start, please continue to sew until the bottom thread is exhausted or press the end key.

[0033] Step 2, after the teaching count stage, perform needle count, the sewing machine system collects sensor data according to the set sampling period, and counts the number of needles according to the following rules: When a valid needle pulse is detected, perform:

[0034] Among them, represents the number of needles accumulated in the teaching count stage.

[0035] Further, to ensure that the full capacity of the needle number obtained in the teaching count stage is accurate, then: Step 3, abnormal identification and correction of sampling data of teaching process, including: 1) If the spindle rotation angle (refers to the angular increment of the spindle from a certain time position, unit: degree, collected by the spindle encoder installed on the spindle, generates a pulse every certain angle, and the change of the rotation angle can be obtained by accumulating these pulses) appears continuous increment (such as greater than 0) but no needle pulse is detected, it means that the needle does not penetrate the cloth or does not complete the sewing action, then it is determined as needle skipping abnormal and performs: Pause the pulse count in this time period; Mark the pulse in this time period as invalid data, which is not included in the number of needles accumulated in the teaching count stage ; If the set threshold is exceeded, prompt the user to start teaching again and reestablish the count stage, and reinsert the full thread bobbin.

[0036] In the above scheme, if only the needle pulse detection may misreport, because mechanical vibration or sensor noise may cause pulse loss, therefore the main shaft rotation angle is introduced as a reference signal, which can ensure that the main shaft indeed has movement when determining the needle jump, and improve the accuracy of needle jump detection.

[0037] 2) If the tension signal is continuously lower than the lower limit (the tension is lower than the threshold value), and the photoelectric broken line signal is continuously not bright (when the line exists, the light path is blocked, and a high level is output, which is usually normal sewing; when the line is broken, the light path is smooth, and the signal is continuously not blocked, indicating that the line is broken in advance, and the photoelectric sensor provides a fast and direct broken line signal), it is determined that the line is broken in advance, and the following is performed: pause the needle count and mark the pulses in this time period as invalid teaching; prompt the user to replace the full line bobbin and re-teach.

[0038] In the above scheme, only tension or photoelectric signal may misjudge, such as line loosening or light interference, and the combination of the two can greatly reduce the misjudgment rate.

[0039] 3) If the main shaft rotation speed is reduced to zero (there should be a certain rotation speed during normal sewing, for example, greater than 0) and the duration is lower than the preset time threshold, which can be set to 2S, and the specific embodiment of the present application can not be limited, it is determined that the normal pause operation is normal, which does not affect the needle count (this period of time will not be recorded as an invalid teaching time period, and will not affect the final full capacity needle count), and only the statistics are paused (during the main shaft stop, the teaching needle count is paused, which avoids the empty rotation statistics), and the operation is continued (after the main shaft resumes rotation, the counter continues to accumulate the needle count, and the teaching is normally performed). It should be noted that during the teaching stage of the industrial sewing machine, the user may have a short pause, for example: adjusting the position of the cloth, observing the sewing situation, and taking a short break, if these short pauses are considered as exceptions, such as needle jump or broken line, the needle count statistics will be paused or the teaching will be considered invalid, therefore a normal pause operation judgment and analysis method is needed.

[0040] Then, according to the above established rules, the effective sewing needle count obtained in the teaching count stage is only contains the effective sewing needle count.

[0041] Step 4, the end trigger of the teaching count stage, according to establish the final full capacity needle count: The end trigger of the teaching count stage includes two: 1) The user actively ends, that is, the user presses the end key, and the system immediately ends the teaching count stage.

[0042] 2) When the following conditions are met at the same time, the system automatically determines that the bottom line is exhausted, and triggers the end of the teaching count stage: Tension signal continuously below threshold, photoelectric broken thread signal continuously no light, spindle load appears empty shuttle characteristic change (normal sewing, spindle load is stable, current or power fluctuation is within normal range; empty shuttle characteristic change: ① when the bobbin is almost used up or empty, the sewing resistance drops below the threshold; ② the spindle load current drops below the threshold; ③ the motor appears jitter or idling).

[0043] After meeting the above three conditions, the teaching counting phase is automatically triggered to end, and the effective sewing needle number is obtained according to the effective sewing needle number The final full-capacity needle number is obtained, that is, the maximum needle number upper limit that the sewing machine system can sew when the full-line bobbin is placed.

[0044] Further, in the present embodiment, a teaching quality scoring stage is also provided for real-time monitoring and evaluation of the quality of the teaching counting stage, to determine whether to re-perform the teaching counting stage, and to improve the effective sewing needle number Corresponding to the accuracy of the full-capacity needle number, then: The teaching counting stage process is monitored from start to end, and the following feature data is continuously recorded during the teaching counting stage process, including: Number of skipped stitches Obtained from the above spindle angle and needle pulse mismatch detection; Total number of original teaching needles The total number of needles counted during the entire teaching process, including the number of needles before the abnormal period is excluded, and the number of skipped stitches is usually counted once per time, so the number of skipped stitches and the total number of original teaching needles are dimensionally consistent; Effective sewing needle number The final teaching needle number excluding the abnormal period (the duration of the skipped stitch that does not exceed the threshold); Average sewing speed Time average of spindle speed; Number of stop times The number of times the spindle speed drops to zero and exceeds the threshold value, such as 2 seconds; Abnormal segment length ratio Abnormal duration / total teaching time, total teaching time is from start to end time, and abnormal duration can be the duration of skipped stitch that does not exceed the threshold.

[0045] Establish a teaching quality scoring formula:

[0046] Among them, Reflects the relative proportion of skipped stitches during the teaching process, and is used to evaluate the continuity of sewing, Reflects the proportion of operational shutdowns during the teaching process, , , , respectively represent the corresponding weight coefficient, represents the teaching quality score; Then, the score level is determined: If , it indicates that the teaching effectiveness is high; If , it indicates that the teaching effectiveness is medium; If , it indicates that the teaching effectiveness is low.

[0047] Then when in , it prompts to suggest re-teaching, which can ensure the accuracy of the teaching counting stage, so as to build an accurate maximum needle upper limit and implement the sewing safety supervision operation of the sewing machine, reducing the defective and poor rate of sewing.

[0048] Further, it also includes: Step 5, sewing machine system sewing warning stage: In order to avoid sudden sewing to empty shuttle and produce defective products during the sewing process, a certain number of available needles must be reserved as a buffer zone before the bottom thread is truly exhausted. Therefore, the sewing machine system is pre-set with a safety warning needle number, which is usually a preset value, such as 80-50 needles, etc. Then: If the subsequent user operation of the sewing machine system is based on the remaining sewing needle number obtained by subtracting the cumulative sewing needle number of the sewing machine system during the sewing process from the fixed full capacity needle number after accumulating the sewing needle number, the remaining sewing needle number is less than or equal to the safety warning needle number, the sewing machine system will trigger a warning, for example: Acoustic and optical warning + voice broadcast: "Please note that the bottom thread is about to run out, please prepare to replace it", by prompting the user to replace the full thread bobbin, the early warning mechanism provides sufficient replacement time for the operator, reducing the probability of defective products.

[0049] If the remaining sewing needle number is greater than the safety warning needle number, it reflects that it is still safe to sew at this time, and no voice prompt is triggered.

[0050] It should be noted that if the user does not replace it in time, the sewing machine system detects that the bottom thread is exhausted, triggering a secondary alarm: forced shutdown + full screen alarm, to avoid causing equipment failure or safety hazards.

[0051] Industrial sewing machine bottom thread monitoring system, comprising: Teaching stage module, building a sewing machine teaching counting stage, measuring the full capacity needle number of the bobbin; Needle counting module, performing needle counting when detecting valid needle pulses; The number of needles correction module performs abnormality identification and correction on the sampling data of the teaching process, including: The main shaft rotation angle is established to judge needle skipping abnormality and limit pulse counting; The tension signal and the photoelectric signal are established to judge whether the thread is broken and trigger invalid pulse teaching; The main shaft rotation speed is established and the duration is collected to judge whether it is a normal pause operation and manage pulse counting; The teaching counting stage is ended, and the final full-capacity needle number is constructed according to the effective sewing needle number; The sewing early warning module presets a safety early warning needle number, constructs a remaining sewing needle number according to the fixed full-capacity needle number and the cumulative sewing needle number of the sewing machine system in the sewing process, and judges whether to trigger an audible and light early warning according to the remaining sewing needle number.

[0052] Furthermore, the functions can be stored in a computer-readable storage medium if the functions are realized in the form of software function units and sold or used as independent products. Based on such understanding, the technical solutions of the present application can be embodied in the form of software products, and the computer software products are stored in a storage medium, including a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present application. The aforementioned storage medium includes: a U disk, a mobile hard disk, a read-only memory (ROM, Read-Only Memory), a random access memory (RAM, Random Access Memory), a magnetic disk or an optical disk, and various media that can store program codes.

[0053] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered a list of executable instructions for implementing logic functions, and can be specifically embodied in any computer-readable medium for use by an instruction execution system, device or apparatus, such as a computer-based system, a system including a processor, or other system that can fetch and execute instructions from the instruction execution system, device or apparatus, or in conjunction with these instruction execution systems, devices or apparatus. For the purpose of this specification, the "computer-readable medium" can be any device that can contain, store, communicate, propagate or transport programs for use by an instruction execution system, device or apparatus, or in conjunction with these instruction execution systems, devices or apparatus.

[0054] More specific examples (a non-exhaustive list) of the computer-readable medium include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber device, and a portable compact disc read-only memory (CDROM). Additionally, the computer readable medium can be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, for instance via an optical scanner, then compiled, interpreted, or otherwise processed, using an appropriate medium, into a computer readable medium.

[0055] Furthermore, in order to provide a concise description of exemplary embodiments, all features of an actual implementation can not be described (i.e., those unrelated to the best method currently contemplated of carrying out the application, or those unrelated to enabling the application).

[0056] It should be understood that numerous specific implementations can be made within the scope of the present application. The applications are not limited to the embodiments described above, but can be used in any number of applications, including, for example, the following:

[0057] The above examples should only be considered as being illustrative of the technical solutions of the present application, and not as limiting thereof; even though the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacements to some of the technical features; and these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for monitoring the bottom thread of an industrial sewing machine, characterized in that, include: Construct a teaching counting stage for the sewing machine and measure the full-capacity stitch count of the bobbin; Perform a needle count; when a valid needle pulse is detected, the needle count is performed. Anomaly identification and correction are performed on the sampled data during the teaching process, including: Establish a spindle rotation angle to detect skipped needle abnormalities and limit pulse counting; Establish tension and photoelectric signals to determine if the wire is broken and trigger invalid pulse teaching. Establish spindle speed and collect duration, determine whether it is a normal pause operation and manage pulse counting; After the teaching and counting phase ends, the final full-capacity stitch count is constructed based on the effective stitch count. During the sewing warning phase of the sewing machine system, a preset safety warning stitch count is established. The remaining stitch count is calculated based on the fixed full capacity stitch count and the cumulative stitch count during the sewing process. The remaining stitch count is then used to determine whether to trigger an audible and visual warning.

2. The industrial sewing machine bottom thread monitoring method according to claim 1, characterized in that, The construction of the sewing machine teaching counting phase includes: After the user presses the teach function key, the following initialization operations are performed, including: Set the teaching pin counter to zero; Start the spindle pulse acquisition unit, tension acquisition unit, and photoelectric wire breakage detector.

3. The industrial sewing machine bottom thread monitoring method according to claim 1, characterized in that, Following the teaching and counting phase, the following characteristic data will be continuously recorded for the teaching and counting phase process, including: Number of skipped stitches, total number of stitches in the original teaching demonstration, number of effective stitches, average sewing speed, average spindle speed and time, number of downtimes, and percentage of abnormal period duration; Establish the teaching quality scoring formula Q: To determine the rating level: like This indicates that the teaching is highly effective; like If the value is 0, it indicates that the teaching effectiveness is moderate. like If the result is negative, it indicates that the teaching effectiveness is low. So in the state of If the time is right, a prompt will be made suggesting that the lesson be repeated.

4. The method for monitoring the bottom thread of an industrial sewing machine according to claim 1, characterized in that, The specific steps for establishing the spindle rotation angle to determine skipped needle abnormalities and restricting pulse counting are as follows: If the spindle angle shows continuous increments but no needle pulse is detected, it indicates that the needle has not penetrated the fabric or has not completed the sewing action. In this case, it is determined to be a skipped stitch abnormality and the following steps are taken: Pause pulse counting for this time period; The pulses during this time period are marked as invalid data and are not included in the cumulative needle count during the teaching counting phase; If the set threshold is exceeded, the teaching process restarts, and the counting phase and full-line bobbin insertion are re-established.

5. The method for monitoring the bottom thread of an industrial sewing machine according to claim 1, characterized in that, The establishment of tension signal and photoelectric signal, determining whether the wire is broken and triggering invalid pulse teaching, specifically involves: If the tension signal remains below the lower limit and the photoelectric disconnection signal remains off, it is determined to be an early disconnection, and the following actions are taken: Pause the needle count and mark the pulses during that time period as invalid teaching; The user is prompted to replace the full-length bobbin and re-teach the program.

6. The method for monitoring the bottom thread of an industrial sewing machine according to claim 1, characterized in that, If the spindle speed drops to zero and the duration is less than the preset time threshold, it is determined to be a normal pause operation, and the teaching phase will continue after the operation is resumed.

7. The method for monitoring the bottom thread of an industrial sewing machine according to claim 1, characterized in that, The end trigger of the teaching counting phase includes: 1) The user actively ends the teaching and counting phase; 2) When the following conditions are met simultaneously, the system automatically determines that the baseline has been exhausted and triggers the end of the teaching counting phase: The tension signal remains below the threshold, the photoelectric disconnection signal remains unlit, and the spindle load exhibits empty shuttle characteristics. Changes in the characteristics of the empty shuttle: When the bobbin is almost used up or the bobbin is empty, the sewing resistance drops below the threshold. The spindle load current drops below the threshold. The motor is vibrating or running idle.

8. An industrial sewing machine bottom thread monitoring system, applied to the industrial sewing machine bottom thread monitoring method according to any one of claims 1-7, characterized in that, include: The teaching phase module constructs the teaching and counting phase of the sewing machine to measure the full capacity needle count of the bobbin; The needle counting module performs needle counting; it counts the number of needles when a valid needle pulse is detected. The needle count correction module identifies and corrects anomalies in the sampled data during the teaching process, including: Establish a spindle rotation angle to detect skipped needle abnormalities and limit pulse counting; Establish tension and photoelectric signals to determine if the wire is broken and trigger invalid pulse teaching. Establish spindle speed and collect duration, determine whether it is a normal pause operation and manage pulse counting; After the teaching and counting phase ends, the final full-capacity stitch count is constructed based on the effective stitch count. The sewing warning module presets a safety warning stitch count. It constructs the remaining sewing stitch count based on a fixed full capacity stitch count and the cumulative sewing stitch count of the sewing machine system during the sewing process. It then determines whether to trigger an audible and visual warning based on the remaining sewing stitch count.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 7.

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