Sewing system

Abstract

A sewing system (500) has a plurality of sewing machines (1) that operate in a normal mode and a low-power standby mode that stands by at lower power consumption than the normal mode, and a control section (110) that is connected to the plurality of sewing machines (1) via a network (NW). The control section (110) acquires information related to operating states from the plurality of sewing machines (1), and transmits an instruction to switch to the low-power standby mode to a sewing machine (1) in which the operating state of the sewing machine (1) among the plurality of sewing machines (1) satisfies a mode switching condition.

Description

Technical Field

[0001] This invention relates to sewing systems. Background Technology

[0002] Electric sewing machines that use an electric motor as a power source are known. Patent Document 1 describes a stepper motor drive device for a sewing machine that controls the ON / OFF state of a switching element when the stepper motor is in a stopped state, so that the current flowing from the coil is returned to the coil itself through the self-inductance of the coil.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2009-095148 Summary of the Invention

[0004] Activities related to the Sustainable Development Goals (SDGs) have become more active, and there is room for improvement in reducing electricity consumption in existing sewing machines. In particular, there is a desire to reduce the electricity consumption of sewing machines in places such as sewing factories with multiple sewing machines.

[0005] The purpose of this invention is to reduce the power consumption of sewing machines.

[0006] According to the present invention, a sewing system includes: a plurality of sewing machines that operate in a normal mode and a low-power standby mode with lower power consumption than the normal mode; and a control unit that controls mode switching for the plurality of sewing machines, the control unit acquiring information related to the operating state of the plurality of sewing machines and sending an instruction to switch to the low-power standby mode to the sewing machine whose operating state meets the mode switching conditions.

[0007] The effects of the invention

[0008] According to the method of the present invention, the power consumption of the sewing machine can be reduced. Attached Figure Description

[0009] Figure 1 This is a structural diagram of the sewing system.

[0010] Figure 2 This is a perspective view of the sewing machine involved in the embodiment.

[0011] Figure 3 This is a perspective view showing a portion of the sewing machine involved in the embodiment.

[0012] Figure 4 This is a perspective view showing a portion of the sewing machine involved in the embodiment.

[0013] Figure 5 This is a block diagram illustrating an example of the functional structure of a sewing machine according to an embodiment.

[0014] Figure 6 This is a block diagram illustrating an example of the structure of a management device.

[0015] Figure 7 This is an illustrative diagram showing an example of switching from normal mode to low-power standby mode.

[0016] Figure 8 This is an explanatory diagram illustrating an example of operational performance information.

[0017] Figure 9 This is a flowchart illustrating an example of a switching process to a low-power standby mode performed via a sewing system.

[0018] Figure 10 This is a flowchart illustrating an example of a process for stopping the power supply to a sewing machine via a sewing system.

[0019] Figure 11 This is a structural diagram of the sewing system involved in other embodiments. Detailed Implementation

[0020] Below, refer to the appendix. Figure 1 The embodiments of the present invention will be described below, but the present invention is not limited to these embodiments. The structural elements of the embodiments described below can be appropriately combined. In addition, sometimes some structural elements are not used.

[0021] [Sewing System]

[0022] Figure 1 This is a structural diagram of sewing system 500. (For example...) Figure 1 As shown, the sewing system 500 includes multiple sewing machines 1 and a management device 400 for managing the multiple sewing machines 1. The multiple sewing machines 1 and the management device 400 are configured to communicate via a network NW. Figure 1 In one example shown, five sewing machines are illustrated: sewing machine 1A, sewing machine 1B, sewing machine 1C, sewing machine 1D, and sewing machine 1E. However, when describing the common features of these sewing machines, they are referred to as "sewing machine 1" and redundant descriptions are omitted.

[0023] The sewing system 500 is configured as a production equipment for sewn products in a sewing factory or the like. Multiple sewing machines 1 each perform sewing for manufacturing the same or other types of sewn products. A management device 400 communicates with the multiple sewing machines 1 via a network NW and manages each sewing machine 1.

[0024] exist Figure 1In this example, the sewing system 500 includes a power supply unit 300 that supplies power to multiple sewing machines 1. The power supply unit 300 may also be part of a power supply device (distribution panel, etc.) in a facility such as a sewing factory. The power supply unit 300, for example, supplies power from a commercial power source to each sewing machine 1. Furthermore, the power supply unit 300 can be communicatively connected to a management device 400 via a network (NW). Additionally, [further details to be added]. Figure 1 Solid lines connecting the various parts represent communication paths (wired or wireless) formed through the network NW, while dashed lines represent power supply paths from the power supply unit 300. The management device 400 can receive power from the power supply unit 300 or from other power sources.

[0025] [Sewing machine]

[0026] Next, a structural example of the sewing machine 1 will be described. A local coordinate system is defined in the sewing machine 1. In this embodiment, the local coordinate system defined in the sewing machine 1 will be appropriately referred to as the sewing machine coordinate system. The sewing machine coordinate system is defined using an XYZ orthogonal coordinate system. In this embodiment, the positional relationships of each part will be described based on the sewing machine coordinate system. The direction parallel to the X-axis within the defined plane is defined as the X-axis direction. The direction parallel to the Y-axis within the defined plane and orthogonal to the X-axis is defined as the Y-axis direction. The direction parallel to the Z-axis and orthogonal to the defined plane is defined as the Z-axis direction. The rotational or tilting direction centered on the X-axis is defined as the θX direction. The rotational or tilting direction centered on the Y-axis is defined as the θY direction. The rotational or tilting direction centered on the Z-axis is defined as the θZ direction. Furthermore, in this embodiment, the plane including the X-axis and Y-axis is appropriately referred to as the XY plane. The XY plane is parallel to the defined plane. In this embodiment, the XY plane is defined as being parallel to the horizontal plane. The Z-axis direction is the up-down direction. The +Z direction is the up direction, and the -Z direction is the down direction. In addition, the XY plane can also be tilted relative to the horizontal plane.

[0027] Figure 2 This is a perspective view showing an example of the structure of sewing machine 1. Figure 3 and Figure 4 Each of these is a perspective view representing a portion of sewing machine 1. In this embodiment, sewing machine 1 is an electronic revolving sewing machine, but sewing machine 1 is not limited to this. The type of sewing machine 1 is not limited to... Figures 2 to 4 The example shown can also be any type of sewing machine 1. Sewing machine 1 has a worktable 2, a frame 3, a head 4, a head rotating device 5, a holding part 6, a holding part moving device 7, and a valve 8 (see reference). Figure 4 ), reactor rotation device 9 (refer to) Figure 4 ), power switch 10, start switch 11, temporary stop switch 12, emergency stop switch 13 and operation panel 14.

[0028] Workbench 2 is the base for assembling the various parts of sewing machine 1. The upper surface of workbench 2 is the working surface for sewing operations.

[0029] Frame 3 is supported on the upper surface of workbench 2. Frame 3 has: a first column portion 31, which is located at the corner of workbench 2 on the +X and +Y sides; a second column portion 32, which is located at the corner of workbench 2 on the -X and +Y sides; and a beam portion 30, which connects the upper ends of the first column portion 31 and the upper ends of the second column portion 32. Frame 3 is a so-called portal frame.

[0030] The head 4 is supported by the beam 30 of the frame 3. The head 4 is positioned above the retaining member 6. The head 4 is aligned with the needle bar 40 (see reference). Figure 3 The head 4 is supported by the needle bar 40. With the needle bar 40 supported, the head 4 can rotate about a rotation axis AX orthogonal to the upper surface of the worktable 2. In this embodiment, the rotation axis AX is substantially parallel to the Z-axis. A cover member 33 is arranged around the head 4.

[0031] like Figure 3 As shown, the needle bar 40 is supported on the head 4 and can reciprocate in the Z-axis direction. The needle bar 40 holds the sewing machine needle 41. The needle bar 40 holds the sewing machine needle 41 in a manner parallel to the Z-axis. In this embodiment, the sewing machine needle 41 is configured with a rotation axis AX (see reference AX). Figure 2 It is consistent with sewing machine needle 41.

[0032] like Figure 2 As shown, a winding device 16 is installed on the workbench 2. Figure 3 As shown, a bobbin holder device 17 is provided at the head 4. The upper thread is supplied from the winding device 16 to the sewing machine needle 41 via the bobbin holder device 17. The upper thread passes through the needle eye 42 of the sewing machine needle 41.

[0033] like Figure 2 As shown, the head rotation device 5 generates power to rotate the head 4 around the rotation axis AX. The head rotation device 5 includes, for example, an electric actuator such as a stepper motor.

[0034] The holding member 6 holds the sewing object 50. The holding member 6 is a frame-shaped component. The holding member 6 holds the sewing object 50 by sandwiching it between its upper and lower parts. The holding member 6 is movably supported on the upper surface of the worktable 2. The holding member 6 can move while holding the sewing object 50 on the upper surface of the worktable 2, including the sewing position directly below the sewing machine needle 41. The holding member 6 can move in the XY plane parallel to the upper surface of the worktable 2.

[0035] The retaining component moving device 7 generates power to move the retaining component 6 in the XY plane. The retaining component moving device 7 is disposed on the upper surface of the worktable 2. The retaining component moving device 7 includes: an X-axis moving device 7X, which moves the retaining component 6 in the X-axis direction; and a Y-axis moving device 7Y, which moves the retaining component 6 in the Y-axis direction. The X-axis moving device 7X includes: an X-axis guide member whose edge on the +Y side of the worktable 2 extends in the X-axis direction; and an X-axis drive unit, which includes a motor and a ball screw mechanism. The Y-axis moving device 7Y includes: a Y-axis guide member extending in the Y-axis direction; and a Y-axis drive unit, which includes a motor and a ball screw mechanism.

[0036] The head 4 has a presser foot 43 that presses down on the sewing object 50 from above (see reference). Figure 3 The presser foot 43 has an opening through which the sewing machine needle 41 passes. The presser foot 43 presses down on the workpiece 50 around the sewing machine needle 41. The sewing machine needle 41 reciprocates in the Z-axis direction. The presser foot 43 suppresses any lifting of the workpiece 50 caused by the movement of the sewing machine needle 41. The sewing machine needle 41 passes through the workpiece 50 pressed by the presser foot 43.

[0037] like Figure 3 As shown, a needle plate 20 is disposed below the needle bar 40. The needle plate 20 is fixed to the worktable 2. The needle plate 20 is disposed directly below the needle bar 40. An opening 26 is formed in the needle plate 20 for the sewing machine needle 41 to pass through.

[0038] like Figure 4 As shown, the pot 8 is positioned directly below the needle plate 20. A spool housing is housed within the pot 8. The spool housing holds the spool with the thread wound on it. The pot 8, by supplying the thread, works in conjunction with the sewing machine needle 41 to form a stitch on the object 50 being sewn. The pot 8 is supported by a support member 80. The support member 80 is configured to surround the pot 8.

[0039] The spool 8 rotates around the pivot axis CX, which is substantially parallel to the XY plane, as the sewing machine needle 41 reciprocates. As the sewing machine needle 41, which passes through the workpiece 50, rises, a loop of upper thread is formed. This loop is hooked by the tip of the rotating spool 8. The loop, hooked by the tip, expands with the rotation of the spool 8, passing over the surface of the spool housing. If the loop detaches from the tip, the upper thread is pulled by the workpiece 50 and intertwines with the lower thread. This intertwining of the upper and lower threads creates a stitch on the workpiece 50.

[0040] The vessel 8 and the head 4 rotate synchronously around the rotation axis AX. That is, the head 4 and the vessel 8 rotate together around the rotation axis AX. The vessel 8 and the support component 80 rotate together around the rotation axis AX. The relative positions of the vessel 8 and the support component 80 are constant.

[0041] The vessel rotation device 9 generates power to rotate the vessel 8 around the rotation axis AX. The vessel rotation device 9 includes, for example, an electric actuator such as a stepper motor. The vessel rotation device 9 is driven so that the head 4 and the vessel 8 rotate together around the rotation axis AX.

[0042] like Figure 2 As shown, the power switch 10, start switch 11, temporary stop switch 12, emergency stop switch 13, and operation panel 14 are each located on the edge of the workbench 2 and operated by the operator. Operating the power switch 10 starts the sewing machine 1. Operating the start switch 11 starts the sewing machine 1, initiating the sewing process. The sewing process involves forming stitches on the sewing object 50. In this embodiment, the sewing machine 1 forms stitches on the sewing object 50 based on pre-created sewing data. With the sewing object 50 held by the holding member 6, the machine moves within the XY plane, including the sewing position, based on the sewing data, thereby forming stitches on the sewing object 50. Operating the temporary stop switch 12 stops the sewing machine 1. Operating the emergency stop switch 13 forcibly stops the sewing machine 1.

[0043] The operation panel 14 is mounted on the upper surface of the worktable 2. The operation panel 14 displays various information related to the sewing machine 1 and receives various information related to the operation of the sewing machine 1. The operation panel 14 has an input device 18 and a display device 19. The input device 18 is configured as a touchscreen for specifying input positions and coordinates on the display surface of the display device 19. The display device 19 is, for example, a liquid crystal display or an organic EL display.

[0044] [Functional Structure of a Sewing Machine]

[0045] Figure 5 This is a block diagram illustrating an example of the functional structure of the sewing machine 1 according to the embodiment. For example... Figure 5As shown, the sewing machine 1 includes a control unit 110, a storage unit 120 connected to the control unit 110, a communication unit 130, the aforementioned operation panel 14, a power supply circuit 150, and a sewing machine motor 160. The control unit 110 includes a central processing unit such as a CPU (Central Processing Unit). The storage unit 120 stores the programs executed by the control unit 110 and functions as the working area of ​​the control unit 110. The control unit 110 controls the functional units of the sewing machine 1 in accordance with data and commands, thereby enabling various functions to be realized. In this embodiment, the functional units include, for example, the operation panel 14, the communication unit 130, and the sewing machine motor 160, but are not limited to these examples.

[0046] The storage unit 120 can store various information such as program 121, sewing machine information 122, and sewn product information 123. Program 121 is a program that causes the control unit 110 to execute functions related to various actions of the sewing machine 1. Sewing machine information 122 includes information such as the sewing machine ID assigned to the sewing machine 1. Sewn product information 123 is information about the sewn products sewed (manufactured) by the sewing machine 1, obtained from the management device 400. Sewn product information 123 includes the ID information (product number) of the sewn product. Sewn product information 123 may include design data for the sewing parts of the sewing object 50. By sewing according to the design data, sewn products are manufactured.

[0047] The communication unit 130 communicates with other communication devices, for example. The communication unit 130 supports various communication standards. The communication unit 130 sends and receives various information, for example, via wired or wireless networks. The communication unit 130 supplies received information to the control unit 110. The communication unit 130 sends information to the transmission target indicated by the control unit 110.

[0048] The operation panel 14 includes an input device 18 and a display device 19. The input device 18 receives input from the operator or others and supplies the input information to the control unit 110. The display device 19 displays various information under the control of the control unit 110.

[0049] The power supply circuit 150 supplies power from the power supply unit 300 to each functional unit of the sewing machine 1, including the control unit 110 and the storage unit 120. Power is supplied to the power supply circuit 150 from the power supply unit 300 by turning on the power switch 10. Power is cut off from the power supply unit 300 by turning off the power switch 10. The power supply circuit 150 may include a power converter, which converts the power supplied from the power supply unit 300 into a predetermined voltage and current to be supplied to the functional units. The power supply circuit 150 may include circuitry for measuring the voltage and current of each functional unit.

[0050] The sewing machine motor 160 is the drive source for various mechanisms of the sewing machine 1. The sewing machine motor 160 includes, for example, a stepper motor or a servo motor. The sewing machine motor 160 generates power for the reciprocating movement mechanism of the sewing machine needle 41 using electricity from the power supply circuit 150. The operation of the sewing machine motor 160 is controlled by the control unit 110. The sewing machine motor 160 includes motors for the head rotating device 5, the holding component moving device 7, and the kettle rotating device 9, as described above.

[0051] The control unit 110 is a computer that controls the following functional units, which operate using power supplied by the power supply circuit 150. The control unit 110 transmits information related to the operating state of the sewing machine 1 to the management device 400 via the communication unit 130. The information related to the operating state is not particularly limited as long as it allows identification of whether the sewing machine 1 is in an operating or non-operating state. In this embodiment, the control unit 110 transmits the operating state of the sewing machine 1 itself (i.e., whether it is in an operating or non-operating state). In this specification, the operating state is the state in which the needle bar 40 (sewing machine needle 41) is reciprocated by the sewing machine motor 160, and the non-operating state is the state in which the needle bar 40 (sewing machine needle 41) is stopped. The control unit 110 obtains the operating state based on the operation of the sewing machine motor 160.

[0052] The sewing machine 1 according to this embodiment operates in a normal mode and a low-power standby mode, which consumes less power than the normal mode. The control unit 110 controls the switching between the normal mode and the low-power standby mode. The control unit 110 switches from the normal mode to the low-power standby mode in response to an instruction received from the management device 400. The control unit 110 also switches from the low-power standby mode to the normal mode in response to a reset instruction from the management device 400, an input operation from the operation panel 14, or the start switch 11.

[0053] The normal mode is the mode in which the machine operates by means of power supplied from the power supply unit 300, and it is a mode in which power consumption reduction control as in the low-power standby mode is not performed. In the normal mode, the operation of the sewing machine motor 160, the operation of the power circuit 150 which controls the voltage and current to the sewing machine motor 160, and the operation of the control unit 110 which controls each functional unit are implemented. In the normal mode, the sewing machine 1 can perform sewing operations (can be in an operating state). In the normal mode, even when the sewing machine 1 is not in an operating state, the control unit 110 performs the holding control of the sewing machine motor 160, the control of the power circuit 150, and the operation control of each functional unit implemented by the control unit 110. The holding control refers to the control that maintains the control position of each motor and actuator of the sewing machine 1 without changing the position of the needle bar 40, the position of the head rotating device 5, the position of the holding component moving device 7, the position of the pot rotating device 9, etc. Therefore, in the normal mode, the sewing operation that has been temporarily stopped can be directly restarted.

[0054] The low-power standby mode is a mode that operates by supplying power from the power supply unit 300, and reduces power consumption by setting each functional unit to an off or standby state. Since the low-power standby mode is a standby mode for sewing operations, it is only executed when not in operation. In the low-power standby mode, the control unit 110 disconnects the power supply to the sewing machine motor 160 and does not perform hold control. Therefore, the power consumption required for hold control is reduced compared to the normal mode. In the low-power standby mode, the control unit 110 does not perform current and voltage control of the sewing machine motor 160 implemented through the power circuit 150. Therefore, the power consumption in the power circuit 150 is reduced compared to the normal mode. In the low-power standby mode, the control unit 110 can also stop a portion of the power generation operation of the power circuit 150. Specifically, the control unit 110 can also stop the operation of the power generation circuit in the power circuit 150 that drives the sewing machine motor 160. In low-power standby mode, the control unit 110 switches to standby mode or disconnects the power supply, maintaining only the minimum required functions. Therefore, the power consumption of the control unit 110 is reduced compared to the normal mode. On the other hand, in low-power standby mode, for example, the power supply can be maintained for functions used in preparation for the next sewing operation (such as the holding member moving device 7 related to the setting of the sewing object 50, and lighting, etc., not shown).

[0055] [Management Device]

[0056] The management device 400 is, for example, a computer, a server device, etc. Figure 6 This is a block diagram illustrating an example of the structure of the management device 400. For example... Figure 6As shown, the management device 400 includes a display unit 410, an operation unit 420, a communication unit 430, a storage unit 440, and a control unit 450. The control unit 450 is electrically connected to the display unit 410, the operation unit 420, the communication unit 430, and the storage unit 440.

[0057] The display unit 410 can display various information under the control of the control unit 450. The display unit 410 has a display panel such as a liquid crystal display or an organic EL display. The display unit 410 displays various information in response to signals input from the control unit 450.

[0058] The operation unit 420 includes one or more devices for receiving user operations. These devices include, for example, keys, buttons, touchscreens, mice, etc. The operation unit 420 can supply signals corresponding to the received operations to the control unit 450.

[0059] The communication unit 430 can communicate with, for example, the sewing machine 1, the power supply unit 300, and other communication devices. The communication unit 430 supports various communication standards. The communication unit 430 can send and receive various information, for example, via a wired or wireless network NW. The communication unit 430 supplies received information to the control unit 450. The communication unit 430 transmits information to the transmission target indicated by the control unit 450.

[0060] The storage unit 440 is capable of storing programs and data. The storage unit 440 is also used as a work area for temporarily storing the processing results of the control unit 450. The storage unit 440 can store various information such as program 441, management information 442, and operational performance information 443. Program 441 enables the control unit 450 to perform functions such as managing multiple sewing machines 1. Management information 442 includes information such as the operating status of each sewing machine 1, the current mode (normal mode or low-power standby mode), and information on the sewn products 123 during sewing operations. Operational performance information 443 will be described later.

[0061] The control unit 450 is an arithmetic processing device. The control unit 450 can refer to information stored in the storage unit 440 as needed and execute commands contained in the program 441 stored in the storage unit 440. Furthermore, the control unit 450 controls the structure of the sewing machine 1 in accordance with data and commands, thereby realizing various functions.

[0062] By executing program 441, control unit 450 is able to provide the function of managing the operating state of each of the multiple sewing machines 1, particularly controlling the switching between normal mode and low-power standby mode. In other words, control unit 450 controls the mode switching of the multiple sewing machines 1.

[0063] Specifically, the control unit 450 obtains information related to the operating state from the sewing machine 1 and sends an instruction to the sewing machine 1 to switch to a low-power standby mode when the operating state meets the mode switching conditions. Thus, the control unit 450 controls the sewing machine 1 to switch from the normal mode to the low-power standby mode in accordance with the operating state of the sewing machine 1.

[0064] In this embodiment, the mode switching condition includes the case where the continuous non-operation time of the sewing machine 1 exceeds a set value V. The control unit 450 obtains the continuous non-operation time based on information related to the operating state periodically obtained from the sewing machine 1. The continuous non-operation time is the length of time that remains in the non-operation state after transitioning from the operating state to the non-operation state. That is, the continuous non-operation time is the length of time that the needle bar 40 of the sewing machine 1 remains stopped. If the sewing machine 1 becomes in the non-operation state, the control unit 450 counts the continuous non-operation time of the sewing machine 1. When the count value of the continuous non-operation time reaches the set value V (threshold), the control unit 450 determines that the sewing machine 1 meets the mode switching condition and switches the sewing machine 1 to a low-power standby mode.

[0065] Figure 7 This is an illustrative diagram showing an example of switching from normal mode to low-power standby mode. Figure 7 The graph illustrates the changes in the operating state of sewing machine 1. The vertical axis represents the operating state, and the horizontal axis represents the elapsed time. The operating state is a binary value: "operating" or "not operating."

[0066] exist Figure 7 In this context, the periods from time t0 to time t1, from time t2 to time t3, from time t4 to time t5, and after time t6 represent continuous non-operational times, respectively. Figure 7 In the example, after time t4, when the set value V is reached during a continuous non-operation period (time tc), the control unit 450 determines that the mode switching condition is met. At time tc, the control unit 450 sends an instruction to the sewing machine 1 to switch to low-power standby mode. Therefore, the sewing machine 1 begins operation in low-power standby mode from time tc. Figure 7 At time t5, for example, the operator inputs the start switch 11 to start sewing, thereby resetting the sewing machine 1 from the low-power standby mode to the normal mode. The control unit 450 can also send a reset instruction to the sewing machine 1 from the low-power standby mode to the normal mode in response to an operation input, for example, to the operation unit 420.

[0067] Furthermore, the lengths of the non-operation time from time t0 to time t1 and from time t2 to time t3 are shorter than the set value V. Therefore, the control unit 450 does not switch to low-power standby mode during these continuous non-operation times. Figure 7 In the example, during the period from time t0 to time tc and after time t5, sewing machine 1 operates in the normal mode.

[0068] The set value V (threshold) for continuous non-operation time can be manually set by users such as the administrator of the sewing system 500 through the operation unit 420. Alternatively, the control unit 450 can also set the set value V for continuous non-operation time itself. For example, the control unit 450 can set the set value V based on the operation performance information 443 (see reference). Figure 6 The set value V for continuous non-operation time is calculated.

[0069] Specifically, the control unit 450 obtains the actual operating performance information 443 of the sewing machine 1 (refer to...). Figure 6 The data is recorded in the storage unit 440. The operation performance information 443 is information indicating the change of the operating status of the sewing machine 1 over time, and is log data obtained by accumulating and recording the operating status in association with time information. Based on the operation performance information 443, the control unit 450 calculates representative values ​​of multiple consecutive non-operating times in the past performance, and calculates the set value V (i.e., mode switching condition) of the consecutive non-operating time accordingly.

[0070] Figure 8 This is an explanatory diagram illustrating an example of operational performance information 443. Figure 8 The operational performance information 443 is displayed graphically, with the vertical axis representing the operational status and the horizontal axis representing the elapsed time.

[0071] In this embodiment, operational performance information 443 is obtained through a teaching operation for measuring operational performance. When manufacturing sewn products in a sewing factory, operating time and non-operating time fluctuate due to various external factors. The teaching operation referred to here means actually performing sewing operations on the sewing machine 1 by eliminating irregular external factors as much as possible, following standard sewing content and procedures, and measuring the changes in the operating state during this time.

[0072] exist Figure 8 In the example shown, the sewing operation for the first sewn item is performed during the operating time from time t11 to time t12. The sewing operation for the second sewn item is performed during the operating time from time t13 to time t14. The sewing operation for the third sewn item is performed during the operating time from time t15 to time t16. The sewing operation for the fourth sewn item is performed during the operating time from time t17 to time t18.

[0073] like Figure 8As shown, the control unit 450 calculates the maximum (longest) continuous non-operation time from the operational performance information 443 over a certain period. Figure 8 In the example, the continuous non-operation time from time t14 to time t15 becomes the maximum. The control unit 450 calculates the length of time obtained by adding a certain margin (surplus time) relative to the maximum continuous non-operation time and uses it as the setting value V for the mode switching condition.

[0074] Furthermore, the non-operating time of sewing machine 1 may include the time for moving the produced sewn item, the time for operator rest or to deal with malfunctions, and the time for preparation work before and after sewing. The length of the non-operating time required for preparation work before and after sewing varies depending on the type of sewn item. That is, sometimes the preparation work before sewing may take a long time or be completed in a short time, depending on the type of sewn item. Therefore, Figure 8 The length of the operating time and the maximum length of the non-operating time in the operating performance information 443 shown may vary depending on the type of sewn product.

[0075] Therefore, the control unit 450 can record the operating performance information 443 of the sewing machine 1 for each sewing product. For example, the product number of the sewing product included in the management information 442 and the operating performance information 443 when manufacturing the sewing product with that product number are recorded together. Moreover, the control unit 450 calculates the set value V for the continuous non-operating time corresponding to the sewing product based on the operating performance information 443. In this case, the set value V(A) corresponding to product number (A) is applied when sewing is performed on product number (A), and the set value V(B) corresponding to product number (B) is applied when sewing is performed on product number (B). As described above, the set value V is changed for each sewing product. As a result, the switching to the power-saving standby mode can be optimized for each sewing product.

[0076] The mode switching condition can also be any condition other than the continuous non-operation time of sewing machine 1.

[0077] For example, mode switching conditions include at least one of the following: the arrival of a predetermined time and the occurrence of a predetermined event. For instance, in a sewing factory equipped with a sewing system 500, the overall rest time is set in the control unit 450. If the start time of the rest time arrives, the control unit 450 determines that the mode switching conditions are met; if the end time of the rest time arrives, it determines that the mode switching conditions are no longer met. Alternatively, the rest time can be specified as a rest time event instead of a predetermined time, and recorded in the control unit 450 as such. If a rest event occurs, the control unit 450 determines that the mode switching conditions are met; if the rest event ends, it determines that the mode switching conditions are no longer met.

[0078] [Collaboration with the Power Supply Department]

[0079] In addition to switching to the aforementioned power-saving standby mode, power consumption can be further reduced by switching the power supply to each sewing machine 1 on and off. For example... Figure 1 As shown, the power supply unit 300 connects to the control unit 450 of the management device 400 via the network NW (see reference). Figure 6 The control unit 450 is connected to the power supply unit 300 to the plurality of sewing machines 1.

[0080] When the sewing machine 1, which has switched to low-power standby mode, meets the power-stop condition, the control unit 450 sends an instruction to the power supply unit 300 to stop the power supply to the sewing machine 1 that meets the power-stop condition.

[0081] like Figure 1 As shown, upon receiving the instruction, the power supply unit 300 stops supplying power to the corresponding sewing machine 1. Thus, the power supply to the sewing machine 1 is stopped, thereby reducing power consumption (so-called standby power) generated in low-power standby mode.

[0082] Power-off conditions include, for example, situations where all sewing machines 1 belonging to a designated group are switched to low-power standby mode. The designated group consists of two or more pre-defined sewing machines 1 from among the multiple sewing machines 1 included in the sewing system 500. For example, it is possible to... Figure 1 Sewing machines 1A, 1B, and 1C of the five sewing machines 1 shown are grouped into one group, while sewing machines 1D and 1E are grouped into another. The specified group may also include all the sewing machines 1 present in the sewing system 500. That is, in Figure 1 In the example, all sewing machines 1A to 1E can also be grouped together as one group.

[0083] The number of sewing machines 1 belonging to a designated group can be appropriately set according to the scale of the sewing system 500 (the total number of sewing machines 1). In the case of multiple production lines that produce sewn products, each sewing machine 1 belonging to one production line can also be grouped together. The power supply unit 300 can switch the power supply on and off for each sewing machine 1 individually or on a group basis.

[0084] The control unit 450 sends an instruction to the power supply unit 300 to stop the power supply to all sewing machines 1 belonging to the group that meets the power stop conditions. Upon receiving the instruction, the power supply unit 300 stops the power supply to all sewing machines 1 belonging to the corresponding group at the same time.

[0085] Especially when switching to low-power standby mode based on a predetermined time or the occurrence of an event, it is preferable to stop the power supply to the power supply unit 300. This is because, for example, during designated time periods such as lunch breaks in sewing factories, the sewing machines 1 belonging to the group simultaneously become inactive. Therefore, by simply setting a time period in advance, the power can be simultaneously disconnected via the management device 400 (control unit 450) without the operator needing to individually operate the power switch 10 of the sewing machines 1 belonging to the group.

[0086] Furthermore, if the sewing machines 1 belonging to the group whose power supply has stopped no longer meet the power stop conditions, or in accordance with the input operation performed through the operation unit 420, the control unit 450 sends an instruction to restart the power supply to the power supply unit 300. Upon receiving the instruction, the power supply unit 300 restarts the power supply to all sewing machines 1 belonging to the corresponding group.

[0087] [The operation of the sewing system]

[0088] Next, an example of the operation of the sewing system 500 will be explained. Figure 9 This is a flowchart illustrating an example of the switching process to a low-power standby mode performed by the sewing system 500. Figure 9 The processing sequence shown is achieved through the coordinated operation of the control unit 450 of the management device 400 and the control units 110 of each sewing machine 1. Figure 9 The processing sequence shown is repeated.

[0089] like Figure 9 As shown, after each sewing machine 1 is started, the control unit 110 begins operation in normal mode (step S1). The control unit 450 of the management device 400 begins to acquire information related to the operating status of each sewing machine 1 (step S2A). That is, the control unit 110 of each sewing machine 1 begins to send information related to the operating status to the management device 400 via the communication unit 130 (step S2B). The control unit 450 of the management device 400 receives the operating status sent from each sewing machine 1 via the network NW via the communication unit 430.

[0090] The control unit 450 of the management device 400 determines, based on information related to the operating status obtained from each sewing machine 1, whether the mode switching condition is met for each sewing machine 1 (step S3). Specifically, the control unit 450 determines whether the continuous non-operation time of the sewing machine 1 exceeds a set value. If a switching time or event is set as a mode switching condition, the control unit 450 determines whether the time has arrived or whether the event has occurred. If the control unit 450 determines that the mode switching condition has not yet been met, it repeats the determination in step S3, thereby monitoring the changes in the operating status of each sewing machine 1 over time, the arrival of the predetermined time, and whether the event has occurred.

[0091] When the control unit 450 of the management device 400 determines that the mode switching conditions are met, it sends an instruction to switch to a low-power standby mode via the communication unit 430 for the sewing machine 1 that meets the mode switching conditions (step S4A). When multiple sewing machines 1 meet the mode switching conditions, the control unit 450 sends instructions to switch to a low-power standby mode to each of the multiple sewing machines 1. Furthermore, if the control unit 110 of each sewing machine 1 receives an instruction to switch to a low-power standby mode via the communication unit 130, it switches the operating mode from the normal mode to the low-power consumption mode (step S4B).

[0092] Figure 10 This is a flowchart illustrating an example of a process for stopping the power supply to the sewing machine 1 via the sewing system 500. Figure 10 The processing sequence shown is implemented by the control unit 450 of the management device 400. Figure 10 The processing sequence shown is repeated.

[0093] The power supply unit 300 begins supplying power to each sewing machine 1 (step S11). The control unit 450 of the management device 400 determines whether there is a group that meets the power stop condition (step S12). That is, the control unit 450 determines whether all sewing machines 1 belonging to the same group have switched to low power standby mode. When there are multiple groups in the sewing system 500, the control unit 450 determines whether the power stop condition is met for each group. If the control unit 450 determines that the power stop condition has not been met, it repeats the determination in step S12, thereby monitoring the operating mode (normal mode or low power standby mode) of each sewing machine 1 belonging to the group over time.

[0094] When the control unit 450 of the management device 400 determines that the power stop condition has been met, it sends an instruction to the power supply unit 300 to stop the power supply to the group that meets the power stop condition via the communication unit 430 (step S13A). If the power supply unit 300 receives the instruction to stop the power supply to the group that meets the power stop condition, it stops the power supply to all sewing machines 1 belonging to that group (step S13B).

[0095] Furthermore, when a group has stopped receiving power, the control unit 450 of the management device 400 determines whether to remove the power supply to that group. The control unit 450 sends an instruction to the power supply unit 300 to remove the power supply to that group when a time period set for mode switching conditions (e.g., a rest period) has elapsed, a preset event has ended, or an instruction to restart power supply is received via the operation unit 420. Upon receiving the instruction to remove the power supply, the power supply unit 300 restarts power supply to all sewing machines 1 belonging to that group.

[0096] The functional structure of the sewing system 500 according to this embodiment has been described above. However, the above structure is merely an example, and the functional structure of the sewing system 500 according to this embodiment is not limited to this example. The functional structure of the sewing system 500 according to this embodiment can be flexibly modified according to specifications or applications.

[0097] [Effect]

[0098] As described above, according to this embodiment, the control unit 450 acquires information related to the operating states of the multiple sewing machines 1 and sends an instruction to the sewing machine 1 whose operating state meets the mode switching conditions to switch to a low-power standby mode. Thus, the sewing machine 1 receiving the instruction to switch to the low-power standby mode switches from the normal mode to the low-power standby mode, achieving a state with reduced power consumption. As a result, the power consumption of the sewing machine 1 can be reduced. Furthermore, in this embodiment, the control unit 450 sends the switching instruction to the low-power standby mode to each sewing machine 1 via the network NW, so it is not necessary to set mode switching conditions individually for each control unit 110 of the multiple sewing machines 1. Therefore, the workload of the manager can be reduced. The number of sewing machines 1 in the sewing system 500 of this embodiment is not particularly limited; the more sewing machines 1 there are, the greater the effect of reducing power consumption and workload, thus making it effective.

[0099] Furthermore, the mode switching condition includes situations where the continuous non-operation time of sewing machine 1 exceeds a set value V. Therefore, in situations where the operator of sewing machine 1 needs to adjust production, handle malfunctions, or leave the machine without requiring manual mode switching, power consumption can be appropriately reduced. Additionally, the mode switching condition includes at least one of the following: the arrival of a predetermined time or the occurrence of a predetermined event. This allows for the simultaneous switching of multiple sewing machines 1 to a low-power standby mode according to the sewing factory's schedule.

[0100] Furthermore, the control unit 450 acquires operating performance information 443, which indicates the changing operating status of the sewing machine 1 over time, and calculates a set value for continuous non-operating time based on the operating performance information 443. This allows for the setting of appropriate mode switching conditions (set values ​​for continuous non-operating time) corresponding to the operating performance. Moreover, the control unit 450 acquires the operating performance information 443 of the sewing machine 1 for each sewing product and calculates a set value V for continuous non-operating time corresponding to that product. This allows for the optimization of mode switching conditions (set values ​​for continuous non-operating time) for each sewing product, taking into account differences in preparation time related to the type of sewing product. As a result, the power consumption reduction effect can be improved.

[0101] Furthermore, when the sewing machine 1, which has switched to low-power standby mode, meets the power-stop condition, the control unit 450 sends an instruction to the power supply unit 300 to stop the power supply to the sewing machine 1. Thus, by stopping the power supply to the sewing machine 1 itself when the power-stop condition is met, power consumption can be further reduced. In this case, since the control unit 450 controls the power supply unit 300 of the facilities such as the sewing factory, there is no workload requiring the manager to operate the power supply unit 300.

[0102] The power stop condition includes the situation where all sewing machines 1 belonging to a designated group of multiple sewing machines 1 switch to a low-power standby mode. Therefore, in cases where multiple sewing machines 1 are collectively inactive due to rest periods or temporary production line shutdowns, the power supply can be stopped simultaneously via the control unit 450. This contributes to both effectively reducing power consumption and minimizing the increase in the manager's workload.

[0103] [Other Implementation Methods]

[0104] In the above embodiments, examples of mode switching conditions for transitioning to low-power standby mode include continuous non-operation time exceeding a set value, the arrival of a predetermined time, and the occurrence of a predetermined event. However, other conditions besides those described above can also be set as mode switching conditions. Similarly, an example of all sewing machines 1 belonging to the group switching to low-power standby mode is shown as a power-off condition. However, other conditions besides those described above can also be set as power-off conditions.

[0105] in addition, Figures 2 to 5 The structure of the sewing machine 1 shown is just an example. The sewing machine 1 can be any type or construction. Furthermore, the sewing machine 1 is not limited to using a sewing machine needle 41 and thread; it can also be an ultrasonic sewing machine that welds fabric by applying ultrasonic vibrations, etc.

[0106] Furthermore, in the above embodiment, an example is shown where the control unit 450 of the management device 400 determines the mode switching conditions and sends an instruction to switch to a low-power standby mode, but it is not limited to this. For example, any one of a plurality of sewing machines 1 may perform the same management functions as the management device 400. In this case, the control unit 110 of the sewing machine 1 performing the management function may determine the mode switching conditions related to other sewing machines 1 connected via the network NW and send an instruction to switch to a low-power standby mode.

[0107] Furthermore, in the above embodiment, an example is shown where the control unit 450 of the management device 400 obtains information related to the operating status of each sewing machine 1 (control unit 110), but it is not limited to this. Figure 11 This is a structural diagram of the sewing system involved in other embodiments. For example, in Figure 11 In the example shown, the management device 400 (control unit 450) obtains information related to the operating status of the sewing machine 1 from the operation information acquisition device 90, which detects information related to the operating status of the sewing machine 1.

[0108] Depending on the type of sewing machine 1, there are also models that do not have the function of outputting information related to the operating status. The operation information acquisition device 90 is attached to the sewing machine 1 that does not have the function of outputting information related to the operating status, and acquires information related to the operating status from outside the sewing machine 1. The operation information acquisition device 90 includes: a detection device having a sensor class that detects detection information for acquiring information related to the operating status of the sewing machine 1; a control device that processes the detection information to acquire information related to the operating status; and a communication device that transmits the information related to the operating status to the management device 400. The operation information acquisition device 90 can communicate with the management device 400 via the communication device through a network NW. The sensor class of the detection device includes, for example, a sensor that detects the state changes of a moving part that performs periodic movements with the same cycle as the up-and-down movement of the needle bar 40. Such a sensor is, for example, a photoelectric sensor that detects the rotation of a pulley connected to the main shaft that transmits driving force to the needle bar 40. The pulley is used when the needle bar 40 is driven by hand cranking, and it also rotates integrally with the main shaft when driven by the sewing machine motor 160. The control device determines whether the pulley is rotating or stationary based on the detection information from the photoelectric sensor. Thus, the control device generates information related to the operating state of the sewing machine 1, indicating whether the sewing machine 1 is in an operating state or not.

[0109] The control unit 450 of the management device 400 obtains information related to the operating status of the sewing machine 1 from the operation information acquisition device 90. Therefore, in Figure 11 In the embodiment shown, by Figure 9 The acquisition of information related to the operating status of sewing machine 1, performed in steps S2A and S2B, is conducted through communication between the management device 400 and the operating information acquisition device 90. Figure 9 In step S4A, the control unit 450 of the management device 400 can directly send an instruction to the sewing machine 1 to switch to the low power standby mode if the mode switching conditions are met. If the operation information acquisition device 90 can communicate with the control unit 110 of the sewing machine 1, the control unit 450 can also send an instruction to the sewing machine 1 to switch to the low power standby mode via the operation information acquisition device 90.

[0110] Similarly, based on the acquisition of operating status-related information from the operating information acquisition device 90, it is possible to perform [operational procedures]. Figure 10 Step S12 involves determining whether there is a group that meets the power outage conditions.

[0111] A sewing machine 1 with the function of outputting information related to its operating status and a sewing machine 1 without this function can coexist. Figure 11In the example, sewing machines 1F, 1G, and 1H do not have the function of outputting information related to their operating status. Sewing machines 1D and 1E do have the function of outputting information related to their operating status. The control unit 450 of the management device 400 can obtain information related to the operating status of sewing machines 1F, 1G, and 1H from the operating information acquisition devices 90 attached to each of them, and can directly obtain information related to the operating status of sewing machines 1D and 1E from each of them.

[0112] This application claims priority based on Japanese Patent Application No. 2023-184666, filed on October 27, 2023, the entire contents of which are incorporated herein by reference.

[0113] Explanation of the label

[0114] 1, 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H… Sewing machine, 2… Workbench, 3… Frame, 4… Head, 5… Head rotating device, 6… Holding component, 7… Holding component moving device, 7X… X-axis moving device, 7Y… Y-axis moving device, 8… Kettle, 9… Kettle rotating device, 10… Power switch, 11… Start switch, 12… Temporary stop switch, 13… Emergency stop switch, 14… Control panel, 16… Winding device, 17… Bollard device, 18… Input device, 19… Display device, 20… Needle plate, 26… Opening, 30… Beam, 31… First column, 32… Second column, 33… Cover component, 40… Needle bar, 41… …Sewing machine needle, 42…Needle eye, 43…Pressing foot, 50…Sewing object, 80…Support component, 90…Operating information acquisition device, 110…Control unit, 120…Storage unit, 121…Program, 122…Sewing machine information, 123…Sewing product information, 130…Communication unit, 150…Power circuit, 160…Sewing machine motor, 300…Power supply unit, 400…Management device, 410…Display unit, 420…Operating unit, 430…Communication unit, 440…Storage unit, 441…Program, 442…Management information, 443…Operating performance information, 450…Control unit, 500…Sewing system, NW…Network, V…Set value for continuous non-operating time.

Claims

1. A sewing system comprising: Multiple sewing machines, which operate in a normal mode and a low-power standby mode with lower power consumption than the normal mode; and The control unit controls the mode switching of the plurality of sewing machines. The control unit acquires information related to the operating status of the plurality of sewing machines. An instruction is sent to the sewing machine whose operating state meets the mode switching conditions to switch to the low power standby mode.

2. The sewing system according to claim 1, wherein, The mode switching conditions include situations where the sewing machine's continuous non-operation time exceeds a set value.

3. The sewing system according to claim 2, wherein, The control unit acquires operational performance information representing the changing operating status of the sewing machine over time. The set value for the continuous non-operation time is calculated based on the operational performance information.

4. The sewing system according to claim 3, wherein, The control unit obtains the actual operating performance information of the sewing machine for each sewn product. Based on the operational performance information, the set value of the continuous non-operation time corresponding to the sewn product is calculated.

5. The sewing system according to any one of claims 1 to 4, wherein, The mode switching conditions include at least one of the following: the arrival of a predetermined time and the occurrence of a predetermined event.

6. The sewing system according to any one of claims 1 to 5, wherein, It also includes a power supply unit, which is connected to the control unit via a network to supply power to the plurality of sewing machines. When the sewing machine, which has switched to the low-power standby mode, meets the power-stop condition, the control unit sends an instruction to the power supply unit to stop the power supply to the sewing machine that meets the power-stop condition.

7. The sewing system according to claim 6, wherein, The power-off condition includes the situation where all the sewing machines belonging to a specified group among the plurality of sewing machines switch to the low-power standby mode. The control unit sends an instruction to the power supply unit to stop the power supply to all the sewing machines in the group that meet the power stop condition.

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