Control method and control system for preventing needle breakage of nest thread trimming mechanism on sewing machine

Abstract

The application provides a control method and a control system for preventing needle breakage of a bird nest thread trimming mechanism of a sewing machine. The method comprises: obtaining an upper needle position calibration angle parameter during use of an electric control of the sewing machine; comparing the upper needle position calibration angle parameter during use of the electric control with an upper needle position calibration angle parameter during factory shipment of the electric control to generate a comparison result; analyzing a deviation degree of the two upper needle position calibration angle parameters according to the comparison result; and generating a control instruction of a bird nest thread trimming stepping motor based on the deviation degree. The application can protect the electric control system of the sewing machine by analyzing the upper needle position calibration angle parameter generated during each actual operation, so as to prevent needle breakage and puncher collision.

Description

Technical Field

[0001] This application belongs to the technical field of sewing machine control, and relates to a control method and control system for preventing needle breakage in a sewing machine's thread-cutting mechanism with fewer bird nests. Background Technology

[0002] Modern sewing machines are equipped with thread-cutting mechanisms to automatically cut the top and bottom threads at the end of sewing. After each thread cut, a certain length of top thread remains on one side of the needle, forming the starting thread. During the next stitch, this starting thread easily forms a bird's nest pattern on the fabric, affecting the overall quality of the fabric and thus the garment. To ensure garment quality, manual trimming of these bird's nest-like thread ends is necessary, increasing worker workload and reducing production efficiency.

[0003] To address this issue, a thread-cutting mechanism with reduced stitches has been introduced to the market. This mechanism typically includes one or two rotatable starting cutters. Taking a two-cutter setup (moving cutter + auxiliary moving cutter) as an example, the principle behind this mechanism is as follows: during the initial stitch, the moving cutter's hook groove is positioned directly below the needle. As the main shaft rotates, the rotary hook brings the top thread end to below the needle plate. After the needle returns to its original position, the moving cutter and the pressure plate hold the top thread end down. After a certain number of stitches (achieving interlacing of the top and bottom threads while shortening the remaining top thread end), the moving cutter and auxiliary moving cutter move towards the needle to cut the thread, thus reducing or even eliminating stitches. "Reduced stitches" can be defined as the top thread end length being ≤4mm or other reasonably set length thresholds, preventing it from wrapping around the back of the fabric.

[0004] However, the timing of the above-mentioned thread-cutting and auxiliary knife movements places very high demands on the accuracy of the main spindle motor's mechanical angle (the sewing machine's main spindle is driven by the main motor). If the main spindle motor's mechanical angle deviates, such as if the upper needle stop angle is manually adjusted incorrectly, the thread-cutting and auxiliary knife movements may hit the needle, posing a risk of the needle breaking. Summary of the Invention

[0005] This application provides a control method and control system for preventing needle breakage in the thread-cutting mechanism of a sewing machine with a missing needle nest, which is used to solve the problem that the thread-cutting mechanism of the missing needle nest breaks the needle due to unreasonable adjustment of the needle stop angle on the sewing machine.

[0006] In a first aspect, this application provides a control method for preventing needle breakage in a thread-cutting mechanism with fewer bird nests on a sewing machine, comprising: acquiring the upper needle position calibration angle parameter when the sewing machine's electronic control is in use; comparing the upper needle position calibration angle parameter when the electronic control is in use with the upper needle position calibration angle parameter when the electronic control is manufactured, and generating a comparison result; analyzing the degree of deviation between the two upper needle position calibration angle parameters based on the comparison result; and generating a control command for the thread-cutting stepper motor with fewer bird nests based on the degree of deviation.

[0007] In one implementation of the first aspect, before the step of obtaining the upper needle position calibration angle parameter when using the sewing machine electronic control, the method further includes: writing the upper needle position calibration angle parameter when the sewing machine electronic control is manufactured.

[0008] In one implementation of the first aspect, the step of writing the needle position calibration angle parameter when using the sewing machine electronic control includes: obtaining the needle position calibration angle parameter generated by the manufacturer when the sewing machine electronic control is manufactured, and storing it in a first storage space; assigning the needle position calibration angle parameter in the first storage space to a second storage space; the needle position calibration angle parameter in the second storage space is the correct needle stop angle parameter when the sewing machine electronic control is manufactured, and cannot be modified.

[0009] In one implementation of the first aspect, the step of obtaining the upper needle position calibration angle parameter when using the sewing machine's electronic control includes: obtaining a handwheel rotation command generated during actual operation of the sewing machine's electronic control; determining the upper needle position calibration angle parameter based on the handwheel rotation command; obtaining a parameter writing command generated on the sewing machine's operation panel; and storing the upper needle position calibration angle parameter corresponding to each actual operation into the first storage space based on the parameter writing command.

[0010] In one implementation of the first aspect, the step of comparing the upper needle position calibration angle parameter during the use of the electronic control with the upper needle position calibration angle parameter at the factory of the electronic control to generate a comparison result includes: subtracting the upper needle position calibration angle parameter during the use of the electronic control from the upper needle position calibration angle parameter at the factory of the electronic control to obtain the difference between the two; and using the difference as the comparison result.

[0011] In one implementation of the first aspect, the step of analyzing the degree of deviation of the calibration angle parameters of the two upper needle positions based on the comparison result includes: determining whether the difference is greater than a preset threshold; if the difference is greater than the preset threshold, it is determined that the degree of deviation of the calibration angle parameters of the two upper needle positions is large, which will lead to needle breakage; if the difference is less than or equal to the preset threshold, it is determined that the degree of deviation of the calibration angle parameters of the two upper needle positions is small and does not affect the operation of the stepper motor for cutting the wire in the bird's nest.

[0012] In one implementation of the first aspect, the step of generating control instructions for the "few bird nests" thread-cutting stepper motor based on the degree of deviation includes: in response to the analysis result indicating that the deviation of the two upper needle position calibration angle parameters is large and will lead to needle breakage, the control instruction is to not start the operation of the "few bird nests" thread-cutting stepper motor; in response to the analysis result indicating that the deviation of the two upper needle position calibration angle parameters is small and does not affect the operation of the "few bird nests" thread-cutting stepper motor, the control instruction is to start the operation of the "few bird nests" thread-cutting stepper motor.

[0013] In one implementation of the first aspect, in response to the control command to not start the operation of the thread-cutting stepper motor, a first motor drive command is generated based on the position information of the main spindle motor; the first motor drive command is used to control the operation of the sewing machine main spindle motor; in response to the control command to start the operation of the thread-cutting stepper motor, the first motor drive command is generated based on the position information of the main spindle motor, and a second motor drive command is generated based on the position information of the thread-cutting stepper motor; the second motor drive command is used to control the operation of the sewing machine thread-cutting stepper motor.

[0014] In one implementation of the first aspect, in response to the analysis result that the deviation between the calibration angle parameters of the two upper needle positions is large, which may lead to needle breakage, an alarm message is displayed; the alarm message is automatically cleared or manually cleared by pressing a button within a fixed time.

[0015] Secondly, this application provides a control system for preventing needle breakage in a sewing machine's thread-cutting mechanism with a reduced "bird's nest" feature, comprising: an operation panel configured to acquire and display the needle position calibration angle parameters during the use of the sewing machine's electronic control system based on user parameter modification operations; a control module configured to compare the needle position calibration angle parameters during electronic control use with the needle position calibration angle parameters at the factory setting of the electronic control system, and generate a comparison result; analyze the degree of deviation between the two needle position calibration angle parameters based on the comparison result; generate control commands for the thread-cutting stepper motor with reduced "bird's nest" feature based on the degree of deviation; a main spindle motor drive module and a main spindle motor; and a thread-cutting stepper motor drive module and a thread-cutting stepper motor. In response to the control command to not start the operation of the wire-cutting stepper motor, the control module generates a first motor drive command based on the position information of the spindle motor; the first motor drive command is used to control the operation of the spindle motor through the spindle motor drive module; in response to the control command to start the operation of the wire-cutting stepper motor, the control module generates the first motor drive command based on the position information of the spindle motor, and generates a second motor drive command based on the position information of the wire-cutting stepper motor; the second motor drive command is used to control the operation of the wire-cutting stepper motor through the wire-cutting stepper motor drive module.

[0016] As described above, the control method and control system for preventing needle breakage in the thread-cutting mechanism of a sewing machine with fewer bird nests as described in this application have the following beneficial effects:

[0017] This application analyzes the upper needle position calibration angle parameters generated under each actual operation. When the upper needle stop angle is incorrectly adjusted by human error, resulting in an incorrect upper needle stop angle, the operation of the bird's nest thread cutting mechanism can be stopped through the control logic to protect the sewing machine's electrical control system. This prevents problems such as the needle hitting and breaking the cutter of the bird's nest thread cutting mechanism, eliminates safety hazards, and also improves work efficiency. Attached Figure Description

[0018] Figure 1 This diagram shows a first application scenario of the control method for preventing needle breakage using a thread-cutting mechanism on a sewing machine, as described in an embodiment of this application.

[0019] Figure 2 This diagram shows a second application scenario of the control method for preventing needle breakage using a thread-cutting mechanism on a sewing machine, as described in an embodiment of this application.

[0020] Figure 3 The diagram shown illustrates the principle of the control method for preventing needle breakage using the thread-cutting mechanism on a sewing machine according to an embodiment of this application.

[0021] Figure 4 This diagram illustrates the parameter settings for the control method of the anti-needle breakage mechanism for the thread-cutting mechanism on a sewing machine as described in this embodiment of the application.

[0022] Figure 5 The flowchart shown is a parameter acquisition flowchart of the control method for preventing needle breakage in the thread-cutting mechanism of a sewing machine as described in the embodiments of this application.

[0023] Figure 6 The diagram shows the parameter analysis flowchart of the control method for preventing needle breakage in the thread-cutting mechanism of a sewing machine as described in the embodiments of this application.

[0024] Figure 7 The diagram shown is a structural connection diagram of the control system for the needle-breaking prevention mechanism of the thread-cutting mechanism on the sewing machine described in this application embodiment.

[0025] Figure 8 The diagram shown is a schematic diagram of the control system for the needle-breaking prevention mechanism of the thread-cutting mechanism on the sewing machine described in this application embodiment.

[0026] Component designation explanation

[0027] 1 Operation panel 2 Control module 3 Spindle motor drive module 4 spindle motor 5 Wire-cutting stepper motor drive module 6 Wire cutting stepper motor S31~S34 step S311~S314 step Detailed Implementation

[0028] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, unless otherwise specified, the following embodiments and features in the embodiments can be combined with each other.

[0029] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. Therefore, the drawings only show the components related to this application and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0030] The following embodiments of this application provide a control method and control system for preventing needle breakage in a sewing machine's thread-cutting mechanism with fewer bird nests, including but not limited to applications in the main shaft sewing and thread-cutting structure of a sewing machine. The following description will use this application scenario as an example.

[0031] Please see Figure 1 and Figure 2 The diagrams shown are a first application scenario structural diagram of the control method for preventing needle breakage using a thread-cutting mechanism on a sewing machine according to embodiments of this application, and a second application scenario structural diagram of the same method. Figure 1 and Figure 2 As shown, Figure 1 The winning bids included the upper stop needle position, machine needle, movable knife, and auxiliary movable knife; Figure 2 The machine includes a lower stop needle position, a needle, a movable cutter, and an auxiliary cutter. The timing of the movements of the movable cutter and auxiliary cutter in the "bird's nest" thread-cutting mechanism places extremely high demands on the accuracy of the main spindle motor's mechanical angle (the sewing machine's main spindle is driven by the main motor). Normally, 0° on the main spindle motor corresponds to the upper stop needle position, and 176° corresponds to the lower stop needle position. The timing of the movements of the movable cutter and auxiliary cutter is based on the main spindle motor's mechanical angle. If the main spindle motor's mechanical angle deviates, such as by manually adjusting the upper stop needle angle (which is adjustable for easy correction) incorrectly, resulting in the needle being below the needle plate at 0°, the movable cutter and auxiliary cutter may hit the needle during their movement, or the needle may directly pierce the cutter, causing it to break. This poses a safety hazard, affects work efficiency, and can damage the machine. To address these issues, this application provides a control method for preventing needle breakage in the "bird's nest" thread-cutting mechanism of a sewing machine.

[0032] The technical solutions in the embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0033] Please see Figure 3 The diagram shows the principle flowchart of the control method for preventing needle breakage using the thread-cutting mechanism on a sewing machine according to an embodiment of this application. Figure 3 As shown, this embodiment provides a control method for preventing needle breakage in a sewing machine's thread-cutting mechanism with fewer bird nests, specifically including the following steps:

[0034] S31, obtain the upper needle position calibration angle parameter when using the sewing machine's electronic control.

[0035] Specifically, initially, the default value Y1 is assigned to the needle position calibration angle parameter PX1 used when the sewing machine electronic control is in operation. At the same time, after the default value Y1 is assigned to the needle position calibration angle parameter PX2 used when the sewing machine electronic control is manufactured, the value of PX2 remains fixed.

[0036] The default value Y1 is determined based on the actual position of the upper stop needle on the machine. The default value is 0°. By default, 0° corresponds to the actual position of the upper stop needle on the machine, but there will be deviations between different machines. Therefore, it can be fine-tuned when setting the factory default value.

[0037] S32 compares the upper needle position calibration angle parameter during the use of the electronic control with the upper needle position calibration angle parameter when the electronic control is manufactured, and generates a comparison result.

[0038] Specifically, the upper needle position calibration angle parameter PX1 during the use of the electronic control is compared with the upper needle position calibration angle parameter PX2 when the electronic control is manufactured, and a comparison result is generated, namely PX1-PX2.

[0039] S33, based on the comparison results, analyze the degree of deviation of the calibration angle parameters of the two upper needle positions.

[0040] Specifically, assuming the preset threshold is Y2, the degree of deviation of the calibration angle parameters of the two upper needle positions is analyzed based on the comparison results PX1-PX2 and the relationship between Y2.

[0041] S34, Based on the degree of deviation, generate control instructions for the stepper motor that cuts the wire in the bird's nest.

[0042] In one embodiment, before the step of obtaining the upper needle position calibration angle parameter during the use of the sewing machine's electronic control, the method further includes:

[0043] Write the needle position calibration angle parameters that were set at the factory when the sewing machine's electronic control system is manufactured.

[0044] Furthermore, the steps for writing the upper needle position calibration angle parameters when using the sewing machine's electronic control system include:

[0045] (1) Obtain the upper needle position calibration angle parameters generated by the manufacturer when the sewing machine is manufactured and store them in the first storage space.

[0046] Specifically, the first storage space refers to the storage space corresponding to the needle position calibration angle parameter PX1 when the electronic control is used. After assigning the initial default value Y1 and the Y1 generated in each subsequent actual operation to the needle position calibration angle parameter PX1 when the sewing machine electronic control is used, the latest Y1 value updates and overwrites the previously stored Y1 value and is stored in the first storage space.

[0047] (2) Assign the upper needle position calibration angle parameter of the first storage space to the second storage space; the upper needle position calibration angle parameter of the second storage space is the correct upper stop needle angle parameter when the sewing machine electronic control is manufactured and cannot be modified.

[0048] Specifically, the second storage space refers to the storage space corresponding to the needle position calibration angle parameter PX2 when the electronic control is manufactured. After assigning the default value Y1 from the initial manufacturing process to the needle position calibration angle parameter PX2 when the sewing machine's electronic control is manufactured, Y1 is stored in the second storage space and cannot be modified.

[0049] Please see Figure 4 This diagram illustrates the parameter settings for the control method of the anti-needle breakage mechanism for the thread-cutting mechanism on a sewing machine as described in this embodiment of the application. Figure 4 As shown, the needle position calibration angle parameters generated by the manufacturer during the factory operation of the sewing machine's electronic control system are obtained and stored in the first storage space. The parameter values ​​in the first storage space are refreshed in real time according to each actual operation. The needle position calibration angle parameters initially stored in the first storage space are assigned to the second storage space; the needle position calibration angle parameters in the second storage space are the correct needle stop angle parameters generated during the factory operation of the sewing machine's electronic control system and cannot be modified.

[0050] Please see Figure 5 The diagram shows a flowchart of parameter acquisition for the control method of the anti-needle breakage control method of the thread-cutting mechanism on a sewing machine as described in the embodiments of this application. Figure 5 As shown, step S31, which obtains the upper needle position calibration angle parameter during the use of the sewing machine's electronic control, includes:

[0051] S311, Obtain the handwheel rotation command generated during the actual operation of the sewing machine's electronic control.

[0052] Specifically, in actual operation, an interface for quickly calibrating the needle stop position is provided. On the sewing machine monitoring display screen, turning the handwheel generates the handwheel rotation command. The sewing machine monitoring display screen also shows the monitoring number associated with the current sewing machine.

[0053] S312, determine the upper needle position calibration angle parameter according to the handwheel rotation command.

[0054] Specifically, in response to the handwheel rotation of the sewing machine, the monitoring display screen shows the mechanical angle of the main spindle motor in real time until it rotates to the actual upper stop needle angle of the machine.

[0055] S313, retrieve the parameter writing command generated on the sewing machine operation panel.

[0056] Specifically, in response to the handwheel rotating to the actual upper stop needle angle of the machine, pressing and holding the assignment write key generates the parameter write command, which assigns the current angle to PX1. For example, the assignment write key is the P key on the operation panel.

[0057] S314, according to the parameter writing instruction, store the upper needle position calibration angle parameter corresponding to each actual operation into the first storage space.

[0058] Specifically, according to the parameter writing instruction, the initial default value Y1 and the Y1 generated in each subsequent actual operation are assigned to the needle position calibration angle parameter PX1 when the sewing machine electronic control is used, and then stored in the first storage space.

[0059] In one embodiment, the step of comparing the upper needle position calibration angle parameter during the use of the electronic control with the upper needle position calibration angle parameter at the factory of the electronic control, and generating a comparison result, includes:

[0060] (1) The difference between the upper needle position calibration angle parameter when the electronic control is used and the upper needle position calibration angle parameter when the electronic control is manufactured is obtained.

[0061] Specifically, the difference between the upper pin position calibration angle parameter PX1 when the electronic control is in use and the upper pin position calibration angle parameter PX2 when the electronic control is manufactured is obtained as PX1-PX2.

[0062] (2) The difference is taken as the comparison result.

[0063] Specifically, the difference PX1 - PX2 is taken as the comparison result.

[0064] In one embodiment, the step of analyzing the degree of deviation of the calibration angle parameters of the two upper needle positions based on the comparison results includes:

[0065] (1) Determine whether the difference is greater than a preset threshold.

[0066] Specifically, a preset threshold is set as Y2, and it is determined whether the absolute value of the difference PX1-PX2 is greater than the preset threshold Y2.

[0067] (2) If the difference is greater than the preset threshold, it is determined that the deviation of the calibration angle parameters of the two upper needle positions is large, which will lead to needle breakage; if the difference is less than or equal to the preset threshold, it is determined that the deviation of the calibration angle parameters of the two upper needle positions is small and will not affect the operation of the stepper motor for cutting the wire in the bird's nest.

[0068] In one embodiment, the step of generating control commands for the stepper motor that cuts the bird's nest wire based on the degree of deviation includes:

[0069] In response to the deviation results of the analysis, the deviation of the calibration angle parameters of the two upper needle positions is relatively large, which will lead to needle breakage. The control command is to not start the operation of the stepper motor for cutting the bird's nest thread.

[0070] In response to the deviation analysis results, the deviation of the two upper needle position calibration angle parameters is small and does not affect the operation of the bird nest trimming stepper motor. The control command is to start the operation of the bird nest trimming stepper motor.

[0071] Specifically, assuming PX2 = 0°, the preset threshold for deviation is 10°. If PX1 is modified to 40° in actual operation, the sewing machine will stop at 40° after each thread cut. When starting to sew again, the difference between PX1 and PX2 (40°) will be greater than 10°, and the thread-cutting mechanism will not be executed.

[0072] Furthermore, depending on the control commands, the driving and operation of each motor are as follows:

[0073] In response to the control command to not start the operation of the stepper motor for cutting the thread in the bird's nest, a first motor drive command is generated based on the position information of the main spindle motor; the first motor drive command is used to control the operation of the sewing machine main spindle motor.

[0074] In response to the control command to start the operation of the thread-cutting stepper motor, a first motor drive command is generated based on the position information of the main spindle motor, and a second motor drive command is generated based on the position information of the thread-cutting stepper motor; the second motor drive command is used to control the operation of the sewing machine thread-cutting stepper motor.

[0075] In one embodiment, in response to the analysis result that the deviation of the calibration angle parameters of the two upper needle positions is too large, which may lead to needle breakage, an alarm message is displayed; the alarm message can be automatically cleared within a fixed time or manually cleared by pressing a button.

[0076] Specifically, the purpose and function of the alarm is to remind you that the angle setting of the stop needle is too far off, and the "few bird nests" function cannot be executed. Please check whether the PX1 angle setting is correct.

[0077] Please see Figure 6 The diagram shows the parameter analysis flowchart of the control method for preventing needle breakage in the thread-cutting mechanism of a sewing machine according to an embodiment of this application. Figure 6As shown, assuming the current upper needle stop angle setting parameter is PX1, and the default value is Y1; that is, PX1=Y1 when the electronic control is manufactured. The upper needle position calibration angle parameter PX2 is preset in the electronic control, and its default value is the same as PX1. When the electronic control is installed on the sewing machine at the factory, the employee will calibrate the upper needle stop position of the sewing machine, that is, set the mechanical angle of the spindle motor corresponding to the actual mechanical upper needle stop position to the PX1 parameter. In actual operation, there is a quick calibration interface for the needle stop position. In the monitoring display, turning the handwheel will display the mechanical angle of the spindle motor in real time. When it reaches the actual mechanical upper needle stop angle, pressing and holding the P key will assign the current angle to PX1. Afterwards, each time the machine stops, it will stop at the angle set in PX1, which is the actual upper needle stop position. This application assigns the upper needle stop angle to PX1 and PX2 simultaneously during the first operation, ensuring that the value of PX2 at the factory is the correct upper needle stop angle value. PX2 can only be modified once at the factory using this method. It cannot be modified or restored afterward. It can only be modified by entering the manufacturer's password to ensure its correctness.

[0078] Afterwards, each time the "few bird's nest" thread cutting action is executed, the difference between PX1 and PX2, PX1-PX2, is first determined. When the difference between PX1 and PX2 is greater than Y2, the value of Y2 is set according to the mechanical deviation at which angle will cause needle breakage. When the difference is greater than Y2, all other functions of the system are normal, but the "few bird's nest" thread cutting action is no longer executed when starting the sewing. That is, the moving knife and auxiliary knife in the "few bird's nest" thread cutting mechanism do not move and remain in the initial position (this position does not interfere with the needle) to prevent abnormal needle breakage or the needle hitting the knife.

[0079] Additionally, when the difference between PX1 and PX2 is greater than Y2, the electronic control can also issue an alarm. This alarm can be automatically cleared after a fixed time, or it can be cleared manually by pressing a button, without affecting the normal use of the sewing machine.

[0080] The protection scope of the control method for preventing needle breakage by the thread-cutting mechanism on a sewing machine with fewer bird nests as described in the embodiments of this application is not limited to the execution order of the steps listed in this embodiment. Any solution implemented by adding, subtracting, or replacing steps in the prior art based on the principles of this application is included within the protection scope of this application.

[0081] This application also provides a control system for preventing needle breakage using a thread-cutting mechanism with fewer bird nests on a sewing machine. This control system can implement the control method for preventing needle breakage using a thread-cutting mechanism with fewer bird nests on a sewing machine described in this application. However, the implementation device for the control method for preventing needle breakage using a thread-cutting mechanism with fewer bird nests on a sewing machine described in this application includes, but is not limited to, the structure of the control system for preventing needle breakage using a thread-cutting mechanism with fewer bird nests on a sewing machine listed in this embodiment. Any structural modifications and substitutions made based on the principles of this application are included within the protection scope of this application.

[0082] Please see Figure 7 The diagram shows the structural connection of the control system for the anti-needle breakage mechanism of the thread-cutting mechanism on a sewing machine as described in this embodiment of the application. Figure 7 As shown, this embodiment provides a control system for preventing needle breakage by using a thread-cutting mechanism on a sewing machine with fewer bird nests, specifically including: an operation panel 1, a control module 2, a spindle motor drive module 3 and a spindle motor 4, a thread-cutting stepper motor drive module 5 and a thread-cutting stepper motor 6.

[0083] The operation panel 1 is configured to acquire and display the needle position calibration angle parameters when the sewing machine's electronic control is in use, based on the user's parameter modification operation.

[0084] The control module 2 is configured to compare the upper needle position calibration angle parameter when the electronic control is in use with the upper needle position calibration angle parameter when the electronic control is manufactured, and generate a comparison result; analyze the degree of deviation between the two upper needle position calibration angle parameters based on the comparison result; and generate control commands for the stepper motor for cutting the wire in the bird's nest based on the degree of deviation.

[0085] In response to the control command to not start the operation of the stepper motor for cutting the wire in the bird's nest, the control module 2 generates a first motor drive command based on the position information of the spindle motor 4; the first motor drive command is used to control the operation of the spindle motor 4 through the spindle motor drive module 3;

[0086] In response to the control command to start the operation of the wire-cutting stepper motor 6, the control module 2 generates the first motor drive command based on the position information of the spindle motor 4, and generates the second motor drive command based on the position information of the wire-cutting stepper motor 6; the second motor drive command is used to control the operation of the wire-cutting stepper motor 6 through the wire-cutting stepper motor drive module 5.

[0087] In one embodiment, before obtaining the needle position calibration angle parameters when using the sewing machine electronic control, the method further includes: writing the needle position calibration angle parameters when the sewing machine electronic control was manufactured.

[0088] In one embodiment, writing the needle position calibration angle parameter when using the sewing machine electronic control includes: obtaining the needle position calibration angle parameter generated by the manufacturer when the sewing machine electronic control is manufactured, and storing it in a first storage space; assigning the needle position calibration angle parameter in the first storage space to a second storage space; the needle position calibration angle parameter in the second storage space is the correct needle stop angle parameter when the sewing machine electronic control is manufactured, and cannot be modified.

[0089] In one embodiment, obtaining the upper needle position calibration angle parameter during the use of the sewing machine's electronic control system includes: obtaining a handwheel rotation command generated during actual operation of the sewing machine's electronic control system; determining the upper needle position calibration angle parameter based on the handwheel rotation command; obtaining a parameter writing command generated on the sewing machine's operation panel; and storing the upper needle position calibration angle parameter corresponding to each actual operation into the first storage space according to the parameter writing command.

[0090] In one embodiment, comparing the upper needle position calibration angle parameter during the use of the electronic control with the upper needle position calibration angle parameter at the factory of the electronic control to generate a comparison result includes: subtracting the upper needle position calibration angle parameter during the use of the electronic control from the upper needle position calibration angle parameter at the factory of the electronic control to obtain the difference between the two; and using the difference as the comparison result.

[0091] In one embodiment, the degree of deviation of the calibration angle parameters of the two upper needle positions is analyzed based on the comparison results, including: determining whether the difference is greater than a preset threshold; if the difference is greater than the preset threshold, it is determined that the degree of deviation of the calibration angle parameters of the two upper needle positions is large, which will lead to needle breakage; if the difference is less than or equal to the preset threshold, it is determined that the degree of deviation of the calibration angle parameters of the two upper needle positions is small and does not affect the operation of the stepper motor for cutting the wire in the bird's nest.

[0092] In one embodiment, a control command for the "few bird nests" thread-cutting stepper motor is generated based on the degree of deviation, including: in response to the analysis result indicating that the deviation of the two upper needle position calibration angle parameters is large and will lead to needle breakage, the control command is to not start the operation of the "few bird nests" thread-cutting stepper motor; in response to the analysis result indicating that the deviation of the two upper needle position calibration angle parameters is small and does not affect the operation of the "few bird nests" thread-cutting stepper motor, the control command is to start the operation of the "few bird nests" thread-cutting stepper motor.

[0093] In one embodiment, in response to the control command to not start the operation of the thread-cutting stepper motor, a first motor drive command is generated based on the position information of the main spindle motor; the first motor drive command is used to control the operation of the sewing machine main spindle motor; in response to the control command to start the operation of the thread-cutting stepper motor, the first motor drive command is generated based on the position information of the main spindle motor, and a second motor drive command is generated based on the position information of the thread-cutting stepper motor; the second motor drive command is used to control the operation of the sewing machine thread-cutting stepper motor.

[0094] In one embodiment, in response to the analysis result that the deviation of the calibration angle parameters of the two upper needle positions is too large, which may lead to needle breakage, an alarm message is displayed; the alarm message is automatically cleared within a fixed time or manually cleared by pressing a button.

[0095] Please see Figure 8The diagram shows the structural principle of the control system for the anti-needle breakage mechanism of the thread-cutting mechanism on a sewing machine as described in this embodiment of the application. Figure 8 As shown, the control system for the anti-needle breakage mechanism of the thread-cutting mechanism on the sewing machine includes an operation panel and a control module. The control module includes a controller, which controls the main spindle motor and the thread-cutting stepper motor of the thread-cutting mechanism. Figure 8 The information in the system connection diagram includes: the operation panel 1 is communicatively connected to the control module 2, sending the acquired needle position calibration angle parameters obtained during the actual operation of the sewing machine's electronic control to the control module 2. The control module 2 analyzes the deviation between the actual needle position calibration angle parameters and the factory-set needle position calibration angle parameters, and then generates a first motor drive command or a second motor drive command. The first motor drive command acts on the spindle motor drive module 3, thereby driving the spindle motor 4; the second motor drive command acts on the thread trimming stepper motor drive module 5, thereby driving the thread trimming stepper motor 6. The spindle motor 4 feeds back the first position information to the control module 2, and the thread trimming stepper motor 6 feeds back the second position information to the control module 2.

[0096] In the embodiments provided in this application, it should be understood that the disclosed systems or methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For instance, the division of modules / units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or units may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection through some interfaces, devices, or modules or units, and may be electrical, mechanical, or other forms.

[0097] The modules / units described as separate components may or may not be physically separate. The components shown as modules / units may or may not be physical modules; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules / units can be selected to achieve the objectives of the embodiments of this application, depending on actual needs. For example, the functional modules / units in the various embodiments of this application may be integrated into one processing module, or each module / unit may exist physically separately, or two or more modules / units may be integrated into one module / unit.

[0098] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0099] The descriptions of the processes or structures corresponding to the above figures each have their own emphasis. For parts of a process or structure that are not described in detail, please refer to the relevant descriptions of other processes or structures.

[0100] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A control method for preventing needle breakage in a thread-cutting mechanism with fewer bird nests on a sewing machine, characterized in that, include: Obtain the upper needle position calibration angle parameters when using the sewing machine's electronic control system; Compare the upper needle position calibration angle parameters during the use of the electronic control with the upper needle position calibration angle parameters when the electronic control is manufactured, and generate comparison results; The degree of deviation of the calibration angle parameters of the two upper needle positions is analyzed based on the comparison results; Based on the degree of deviation, control commands are generated for the stepper motor that cuts the wire in the bird's nest.

2. The method according to claim 1, characterized in that, Before the step of obtaining the upper needle position calibration angle parameters when using the sewing machine's electronic control, the following steps are also included: Write the needle position calibration angle parameters that were set at the factory when the sewing machine's electronic control system is manufactured.

3. The method according to claim 2, characterized in that, The steps for writing the upper needle position calibration angle parameters when using the sewing machine's electronic control system include: Obtain the upper needle position calibration angle parameters generated by the manufacturer when the sewing machine's electronic control is manufactured, and store them in the first storage space; Assign the upper needle position calibration angle parameter of the first storage space to the second storage space; the upper needle position calibration angle parameter of the second storage space is the correct upper stop needle angle parameter when the sewing machine electronic control is manufactured, and cannot be modified.

4. The method according to claim 3, characterized in that, The steps for obtaining the upper needle position calibration angle parameters when using the sewing machine's electronic control system include: Obtain the handwheel rotation commands generated during actual operation of the sewing machine's electronic control system; The upper needle position calibration angle parameter is determined according to the handwheel rotation command; Obtain the parameter writing command generated on the sewing machine control panel; According to the parameter writing instruction, the upper needle position calibration angle parameter corresponding to each actual operation is stored in the first storage space.

5. The method according to claim 1, characterized in that, The steps for comparing the upper needle position calibration angle parameters during the use of the electronic control unit with the upper needle position calibration angle parameters at the factory of the electronic control unit, and generating comparison results, include: The difference between the upper pin position calibration angle parameter during the use of the electronic control and the upper pin position calibration angle parameter at the factory is obtained. The difference is taken as the comparison result.

6. The method according to claim 5, characterized in that, The steps for analyzing the degree of deviation of the calibration angle parameters of the two upper needle positions based on the comparison results include: Determine whether the difference is greater than a preset threshold; If the difference is greater than the preset threshold, it is determined that the deviation of the calibration angle parameters of the two upper needle positions is large, which will lead to needle breakage; if the difference is less than or equal to the preset threshold, it is determined that the deviation of the calibration angle parameters of the two upper needle positions is small and will not affect the operation of the stepper motor for cutting the wire in the bird's nest.

7. The method according to claim 6, characterized in that, The steps for generating control commands for the stepper motor that cuts wires in the bird's nest based on the degree of deviation include: In response to the deviation analysis results, the deviation of the calibration angle parameters of the two upper needle positions is relatively large, which will lead to needle breakage. The control command is to not start the operation of the stepper motor for cutting the bird's nest thread. In response to the deviation analysis results, the deviation of the two upper needle position calibration angle parameters is small and does not affect the operation of the bird nest trimming stepper motor. The control command is to start the operation of the bird nest trimming stepper motor.

8. The method according to claim 7, characterized in that: In response to the control command to not start the operation of the bird nest thread-cutting stepper motor, a first motor drive command is generated based on the position information of the main spindle motor; the first motor drive command is used to control the operation of the sewing machine main spindle motor. In response to the control command to start the operation of the thread-cutting stepper motor, a first motor drive command is generated based on the position information of the main spindle motor, and a second motor drive command is generated based on the position information of the thread-cutting stepper motor; the second motor drive command is used to control the operation of the sewing machine thread-cutting stepper motor.

9. The method according to claim 6, characterized in that: If the deviation result of the analysis shows that the deviation of the calibration angle parameters of the two upper needle positions is large, it will lead to needle breakage and display an alarm message; the alarm message will be automatically cleared within a fixed time or manually cleared by pressing a button.

10. A control system for preventing needle breakage using a thread-cutting mechanism with fewer bird nests on a sewing machine, characterized in that, include: The operation panel is configured to acquire and display the needle position calibration angle parameters when the sewing machine's electronic control is in use, based on user parameter modification operations. The control module is configured to compare the upper needle position calibration angle parameter during the use of the electronic control with the upper needle position calibration angle parameter at the factory of the electronic control, and generate a comparison result; analyze the degree of deviation between the two upper needle position calibration angle parameters based on the comparison result; and generate control instructions for the stepper motor for cutting the wire in the bird's nest based on the degree of deviation. Spindle motor drive module and spindle motor; Wire-cutting stepper motor drive module and wire-cutting stepper motor; In response to the control command to not start the operation of the stepper motor for cutting the wire in the bird's nest, the control module generates a first motor drive command based on the position information of the spindle motor; the first motor drive command is used to control the operation of the spindle motor through the spindle motor drive module; In response to the control command to start the operation of the wire-cutting stepper motor, the control module generates the first motor drive command based on the position information of the spindle motor, and generates the second motor drive command based on the position information of the wire-cutting stepper motor. The second motor drive command is used to control the operation of the wire-cutting stepper motor through the wire-cutting stepper motor drive module.

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