A method and system for intelligent embroidery stitch optimization and energy-saving control

Abstract

This invention discloses an intelligent embroidery stitch optimization and energy-saving control method and system, belonging to the field of intelligent manufacturing technology. The method includes the following steps: collecting the power level switching signal, drive current change curve, and image acquisition time record of the embroidery machine; generating an electromagnetic interference distribution map based on the collected data; extracting the interference concentration area from the electromagnetic interference distribution map; establishing an interference scale table; and outputting the interference scale results. This invention achieves temporal isolation and synchronous coordination between power switching and image acquisition through interference scale modeling and dynamic matching of the power quiet zone, eliminating the impact of electromagnetic interference on image acquisition and ensuring stable stitch recognition. Through the linkage update of illumination sampling and the interference control list, adaptive control of power, exposure, and illumination is achieved, effectively reducing energy consumption while improving embroidery accuracy.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, specifically to an intelligent embroidery stitch optimization and energy-saving control method and system. Background Technology

[0002] Intelligent embroidery stitch optimization and energy-saving control refers to the comprehensive analysis and dynamic adjustment of the stitch formation process, energy usage process, and motion path of the embroidery machine during the embroidery production process, relying on an industrial control system and utilizing computer vision, sensor perception, and intelligent control technologies. The system establishes a correlation model between stitch texture, light intensity, and energy consumption by real-time acquisition of stitch images, lighting conditions, and drive load signals. It automatically identifies problems such as stitch overlap, uneven stitch spacing, and light and shadow interference, and adjusts needle speed, step distance, lighting, and tension ratio at the control level to achieve automatic optimization of the stitch trajectory. Simultaneously, relying on the energy distribution strategy and rhythmic control mechanism of the industrial control system, it coordinates and manages the energy consumption of the motor drive, light source, and control unit, significantly reducing overall energy consumption while ensuring embroidery accuracy and consistency.

[0003] The existing technology has the following shortcomings: In existing technologies, embroidery machines typically regulate energy consumption by frequently switching power levels during energy-saving control. However, the rapid changes in drive current during this process can easily generate high-frequency electromagnetic echoes in the circuit. These electromagnetic echoes can easily propagate in the reverse direction along the control circuit and superimpose onto the image acquisition circuit, causing instantaneous interference to the acquired signal. When the interference signal strength is large, the data frames of the image acquisition system will be misaligned, the image update rhythm will be disrupted, and phenomena such as afterimage superposition and inter-frame jumps are likely to occur. Such problems are more easily amplified in scenarios involving dynamic lighting adjustment and high-speed stitch tracking. This can not only lead to the system misjudging stitch defects but may also cause control logic misalignment during the stitch optimization process, resulting in embroidery path deviation, recognition interruption, or even abnormal equipment shutdown, seriously affecting the stable operation of the intelligent embroidery system and the effectiveness of energy-saving control.

[0004] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide an intelligent embroidery stitch optimization and energy-saving control method and system to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for intelligent embroidery stitch optimization and energy-saving control, comprising the following steps: Collect the power level switching signal, drive current change curve and image acquisition time record of the embroidery machine, generate an electromagnetic interference distribution map based on the collected data, extract the interference concentration area from the electromagnetic interference distribution map, establish an interference scale table and output the interference scale results. Based on the interference scale, determine the power silence zones on both sides of the interference concentration zone, synchronously transmit the image acquisition reference signal within the power silence zone, record the acquisition time information corresponding to the power silence zone, generate a silence zone record table, and establish a synchronization control reference. Based on the synchronization control reference, adjust the image exposure order and polarized light supplementation period within the power quiet zone, superimpose incident delay sampling to form a multi-time sampling mechanism, generate an illumination sampling arrangement list and output illumination synchronization parameters. Based on the illumination sampling and arrangement list, the power switching process is dynamically controlled. By adjusting the drive switching rate, power transition amplitude and switching sequence, the current change is gradually distributed, an interference control list is generated and drive suppression parameters are established. Based on the interference control list, the interference scale is reviewed in real time. The power quiet zone width and exposure step interval are updated according to the latest interference distribution. The synchronization control reference is corrected and the light sampling rhythm is adjusted to form a stable operating rhythm and achieve dynamic self-adaptation for embroidery stitch optimization and energy-saving control.

[0007] Preferably, the steps for outputting the interference calibration results are as follows: By uniformly collecting the power level switching signal, drive current change curve and image acquisition time record during the operation of the embroidery machine, a synchronous sampling sequence is established, so that the power level switching signal, drive current change curve and image acquisition time record are associated on the same time axis. After completing synchronous acquisition, the power level switching signal and the drive current change curve are superimposed and analyzed to establish the correlation distribution between power switching behavior and current transient behavior, and the potential electromagnetic interference influence area is marked by the image acquisition time record. After constructing the temporal density data of the interference events, an electromagnetic interference distribution map is generated based on the data. The interference concentration area is identified by analyzing the interference intensity curve in the distribution map. After identifying the interference concentration area, an interference calibration table is established based on the interference peak range. The interference intensity value, interference duration, current change rate and power switching frequency are recorded and the interference calibration results are output for the construction of synchronous control reference and the determination of power quiet zone.

[0008] Preferably, the steps for establishing a synchronous control reference are as follows: The steps for determining the power quiet zone based on the interference scale table are as follows: By analyzing the location of the interference concentration area in the interference scale table, the interference boundary of the power switching event in the time dimension is determined, and the time interval with stable interference intensity before and after the interference concentration area is selected as the initial candidate area of ​​the power silence area. After the power quiet zone is determined, the time boundary of the power quiet zone is synchronized and a synchronization reference is set. Synchronization reference points are set at the start and end times of the power quiet zone, and image acquisition reference signals are synchronously transmitted within the power quiet zone. During the process of sending the image acquisition reference signal and performing the acquisition operation, the acquisition time information corresponding to the power quiet zone is recorded, and a quiet zone record table is generated. After the silent zone recording table is generated, a synchronization control reference is established based on the time distribution and acquisition timing characteristics of the silent zone. This allows the power switching scheduling to be adjusted according to the synchronization control reference, thereby achieving timing coordination between image acquisition and power switching.

[0009] Preferably, during the establishment of the synchronous control reference, the start time, end time, and duration of each power quiet zone are time-matched with the image acquisition cycle. By aligning the time, the image acquisition process is completed within the power quiet zone, thereby avoiding the critical time period of image acquisition when switching power, and ensuring that the energy output of the embroidery machine during operation is stable and consistent with the synchronous control of image acquisition.

[0010] Preferably, the steps for adjusting the image exposure order and polarized light compensation period within the power quiet zone according to the synchronization control reference are as follows: The time distribution within the power quiet zone is divided according to the synchronous control reference to determine the timing arrangement of the image exposure sequence, and the exposure start time and exposure duration are allocated within the power stable output phase; After the exposure sequence is determined, the polarized light supplementation period is synchronously adjusted according to the time division results of the power silent zone, so that the supplementation period corresponds to the exposure period in time and maintains stable illumination. After synchronizing the exposure sequence and polarized light supplementation period, incident delayed sampling is superimposed in the power silent zone to form a multi-time-series sampling mechanism and obtain image data of illumination level differences. After completing the exposure sequence adjustment, polarized light compensation synchronization, and incident delay sampling, an illumination sampling arrangement list is generated based on the acquired illumination and sampling time information, and illumination synchronization parameters are output for subsequent illumination compensation and synchronization optimization.

[0011] Preferably, the trigger time of the incident delay sampling is determined based on the time base in the synchronization control reference and maintains a linear progressive relationship with the image exposure sequence, so that each frame sampling is completed within the power quiet zone. The illumination sampling arrangement list records the start and end times of the exposure cycle, the supplementary lighting cycle and the sampling cycle, as well as the illumination intensity distribution, thereby achieving time synchronization between illumination sampling and power output and ensuring continuous and stable image acquisition.

[0012] Preferably, the dynamic rhythm control steps for the power switching process based on the illumination sampling and arrangement list are as follows: Based on the exposure cycle, fill light cycle and sampling delay parameters recorded in the illumination sampling schedule, an initial time allocation scheme for the power switching process is established, and the power switching trigger point is repositioned to a time outside the range of image acquisition interference. After obtaining the initial time allocation scheme, the drive switching rate during the power switching process is dynamically adjusted so that the power transition process exhibits a continuously changing slow-release characteristic and a power switching rate control curve is formed. After the power switching rate adjustment is completed, the power transition amplitude and switching timing are dually regulated according to the illumination sampling arrangement list and the power switching rate control curve, so that the power switching behavior and the illumination sampling behavior complement each other in time. After completing the comprehensive control of drive switching rate, power transition amplitude and switching timing, an interference control list is generated based on the dynamic parameters of the entire power switching process, and drive suppression parameters are established to constrain subsequent power switching behavior.

[0013] Preferably, during the dynamic adjustment of the drive switching rate, the power switching rate is associated with the illumination stabilization stage in the illumination sampling catalog. When the illumination intensity curve is stable and the image acquisition interval is uniform, the drive switching rate is kept constantly increasing. When entering the exposure start-up stage, the drive switching rate is gradually slowed down to extend the current change time span and achieve a gradual distribution of current changes during the power switching process.

[0014] Preferably, the steps for real-time review of the interference scale table based on the interference control list are as follows: By reading the interference control list in real time and reviewing the time, the interference distribution in the interference scale table is updated and aligned, so that the time calibration of the interference scale table is consistent with the actual changes in power switching behavior. After the interference scale is updated, the width of the power quiet zone is corrected in real time according to the new interference distribution, so that the time interval of the power quiet zone matches the interference characteristics and maintains output stability. After the power quiet zone width is adjusted, the exposure step interval during the image acquisition process is updated according to the new interference distribution and quiet zone time structure, so that the image acquisition triggering rhythm avoids the interference peak area. After correcting the power quiet zone width and exposure step interval, the synchronization control reference is corrected according to the updated interference scale, and the illumination sampling rhythm is adjusted to form a stable rhythm and achieve dynamic adaptive control.

[0015] An intelligent embroidery stitch optimization and energy-saving control system includes an interference modeling module, a synchronization establishment module, an illumination coordination module, a rhythm control module, and an adaptive optimization module. The interference modeling module collects the power level switching signal, drive current change curve, and image acquisition time record of the embroidery machine. Based on the collected data, it generates an electromagnetic interference distribution map, extracts the interference concentration area from the electromagnetic interference distribution map, establishes an interference scale table, and outputs the interference scale results. The synchronous establishment module determines the power silence zone on both sides of the interference concentration zone based on the interference scale table, synchronously sends the image acquisition reference signal within the power silence zone, records the acquisition time information corresponding to the power silence zone, generates a silence zone record table, and establishes a synchronous control reference. The illumination coordination module adjusts the image exposure order and polarized light supplementation period within the power quiet zone according to the synchronization control reference, superimposes incident delay sampling to form a multi-time sequence sampling mechanism, generates an illumination sampling arrangement list and outputs illumination synchronization parameters. The rhythm control module dynamically controls the power switching process based on the illumination sampling and arrangement list. By adjusting the drive switching rate, power transition amplitude and switching sequence, it achieves a gradual distribution of current changes, generates an interference control list and establishes drive suppression parameters. The adaptive optimization module reviews the interference scale in real time based on the interference control list, updates the power quiet zone width and exposure step interval according to the latest interference distribution, corrects the synchronization control reference and adjusts the light sampling rhythm, forming a stable operating rhythm and realizing dynamic adaptation for embroidery stitch optimization and energy-saving control.

[0016] The technical effects and advantages provided by the present invention in the above technical solution are as follows: This invention achieves temporal isolation of electromagnetic interference and synchronous coordination of image acquisition rhythm by introducing interference scale modeling and dynamic matching of power quiet zones between power switching and image acquisition, thus mitigating power output fluctuations over time. This method prevents current changes from being concentrated within the image acquisition window, fundamentally eliminating electromagnetic echo interference to visual recognition. It maintains continuous and stable stitch texture acquisition, avoiding problems such as image frame errors, inter-frame jumps, and path drift, thereby improving the accuracy and operational reliability of embroidery stitch optimization.

[0017] This invention achieves dynamic adaptive coordination of power control, exposure control, and illumination sampling over time by linking and updating the illumination sampling catalog and the interference control catalog. This mechanism enables the system to automatically adjust the power quiet zone width, exposure step size, and illumination rhythm based on real-time interference distribution. This ensures that the embroidery machine maintains optimal illumination balance and energy matching at different energy consumption stages, ultimately reducing overall energy consumption while maintaining stitch consistency. This achieves high-precision control and energy-saving operation of the embroidery process. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0019] Figure 1 This is a flowchart of a method for optimizing and controlling intelligent embroidery stitches according to the present invention.

[0020] Figure 2 This is a schematic diagram of a module of an intelligent embroidery stitch optimization and energy-saving control system according to the present invention. Detailed Implementation

[0021] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that the description of this disclosure will be more complete and fully convey the concept of the exemplary embodiments to those skilled in the art.

[0022] This invention provides, for example Figure 1 The method for intelligent embroidery stitch optimization and energy-saving control shown includes the following steps: Collect the power level switching signal, drive current change curve and image acquisition time record of the embroidery machine, generate an electromagnetic interference distribution map based on the collected data, extract the interference concentration area from the electromagnetic interference distribution map, establish an interference scale table and output the interference scale results. To achieve accurate identification and quantification of electromagnetic interference during the operation of the embroidery machine, the entire process can be implemented according to the following steps: A synchronized sampling time sequence was established by uniformly collecting power level switching signals, drive current variation curves, and image acquisition time records during the operation of the embroidery machine. The power level switching signal reflects the change process of the embroidery machine's power output state; its frequency and duration directly reflect the real-time state of the embroidery machine's energy control strategy. The drive current variation curve characterizes the instantaneous characteristics of current fluctuations in the motor drive unit at the moment of power switching. This curve continuously records the current's trajectory over time through a current sensor, thereby capturing the current abrupt changes that occur during power level switching. The image acquisition time record is automatically timestamped by the embroidery machine's visual acquisition device at the start of each image frame, forming acquisition time sequence information corresponding one-to-one with power output events. After acquisition, the three types of data are synchronized through a time reference signal, linking the power level switching signal, current variation curve, and image acquisition time record on the same time axis. This unified time-series acquisition method allows for a complete mapping of current changes and image acquisition moments at different power switching stages of the embroidery machine, laying the data foundation for the subsequent generation of electromagnetic interference distribution maps.

[0023] After synchronous acquisition, the power level switching signal and the drive current change curve are overlaid and analyzed to establish the correlation distribution between power switching behavior and current transient behavior. In this embodiment, the rising and falling segments of the power level switching signal represent the switching process of different power levels, and the abrupt change point of the current change curve corresponds to the moment of rapid current change. Through time correspondence, each power level switching event is mapped to its corresponding current change amplitude and duration, forming a multi-dimensional dataset containing time coordinates, power level status, and current change amplitude. Then, the image acquisition time record is introduced into this dataset, and the time intervals where the power level switching event overlaps with or is adjacent to the image acquisition time are marked as potential electromagnetic interference (EMI) influence areas. Through this mapping method, the influence range of each power switch on the image acquisition process can be clearly identified in the time series. The output of this stage is the temporal density distribution data of interference events, providing basic parameters for the subsequent construction of an EMI distribution map.

[0024] After constructing the temporal density data of interference events, an electromagnetic interference (EMI) distribution map is generated based on this data. This map uses time as the horizontal axis and interference intensity as the vertical axis, continuously mapping the combined characteristics of power switching and current changes to form an interference intensity curve within the embroidery machine's working cycle. This interference intensity curve reflects the superposition effect of current fluctuations and power switching frequency, while also incorporating the distribution of image acquisition times, allowing the EMI distribution map to intuitively show the overlap between power switching and image acquisition in the time dimension. In the distribution map, high interference intensity segments are represented by concentrated peak areas on the curve. These areas represent periods of frequent power switching and large current fluctuations, corresponding to intervals where the image acquisition signal is susceptible to interference. Through continuous analysis of the interference distribution curve, multiple interference intensity peak regions can be identified; these regions are the concentrated areas of EMI. To improve the temporal resolution of the interference distribution, this implementation method uniformly divides the sampling time window during the distribution map generation process, ensuring that the number and intensity of interference events within each unit of time are accurately recorded. The EMI distribution map generated in this way not only shows the temporal distribution characteristics of the interference but also reflects the coupling relationship between the power switching signal and the image acquisition signal.

[0025] After identifying the concentrated interference areas, an interference scale table is established based on the peak interference intervals in the electromagnetic interference distribution map, and the interference scale results are output. The interference scale table uses time periods as the base unit, recording the interference intensity, duration, current change rate, and power switching frequency for each time period, forming an interference scale sequence that can be used for subsequent control. In this scale table, each scale value represents the interference impact level of the embroidery machine within a specific time period. To ensure that the interference scale table can fully reflect the interference distribution characteristics of the embroidery machine's entire working cycle, the scale table generation process is divided according to the peak distribution intervals of the interference distribution map. More dense scale intervals are set for time periods with large interference intensity changes, while relatively wide intervals are set for time periods with stable interference changes. This non-uniform scale division method refines the recording accuracy of the dense interference areas in time, allowing the interference scale results to more accurately reflect the coupling degree between power switching behavior and image acquisition timing. After output, the interference scale results are used for subsequent synchronous control reference construction and power quiet zone determination, providing basic data support for the entire embroidery stitch optimization and energy-saving control process.

[0026] Based on the interference scale, determine the power silence zones on both sides of the interference concentration zone, synchronously transmit the image acquisition reference signal within the power silence zone, record the acquisition time information corresponding to the power silence zone, generate a silence zone record table, and establish a synchronization control reference. To achieve time-sequence isolation between image acquisition and power switching during embroidery machine operation, ensuring that the image acquisition process occurs within a low-interference zone, the specific implementation steps are as follows: By analyzing the location of concentrated interference areas in the interference scale table, the interference boundaries of power switching events in the time dimension are determined. The interference scale table records the interference intensity values, interference durations, and corresponding power switching amplitudes and current change rates for different time periods. By analyzing the duration of the peak interference intensity, the start and end points of each concentrated interference area can be identified. When determining the boundaries of concentrated interference areas, the continuous trend of the interference intensity value is used as the dividing criterion; when the interference intensity exceeds a set threshold within a continuous time period, it is determined to be a concentrated interference area. After the concentrated interference areas are identified, a relatively stable time interval of interference intensity is selected before and after each concentrated interference area as the initial candidate areas for the power silence area. The power silence area is used to temporarily delay the output of the power switching signal, allowing the embroidery machine to maintain a stable energy output state within this interval, providing a relatively stable interference environment for image acquisition. In this way, the power silence area and the concentrated interference area are mutually isolated in time. The boundary of the power silence area is determined based on the width of the concentrated interference area and the recovery time of the current change, thereby achieving dynamic pairing of the interference area and the silence area.

[0027] After the power quiet zone is determined, synchronization references are established for the time boundaries at both ends of the power quiet zone. To ensure precise correspondence between the image acquisition process and the time distribution of the power quiet zone, synchronization reference points are set at the start and end times of the power quiet zone. These synchronization reference points establish a unified time reference between the power switching signal and the image acquisition signal through the main control unit, enabling the image acquisition process to start and complete within the power quiet zone. Within the power quiet zone, an image acquisition reference signal is synchronously transmitted. This signal is generated by the main control unit based on the power switching control timing and transmitted in advance before the power quiet zone opens. Upon receiving the image acquisition reference signal, the image acquisition device initiates the exposure and data acquisition process, ensuring complete overlap between the image acquisition and power quiet zone time windows. Through this time synchronization method, power switching and image acquisition are strictly isolated on the time axis, preventing interference from sudden power switching current changes. The establishment of the synchronization reference signal not only ensures the temporal independence of image acquisition but also provides a time reference for subsequent synchronization control.

[0028] During the image acquisition reference signal transmission and acquisition operation, the acquisition time information corresponding to the power quiet zone is recorded in real time, forming quiet zone operation data. This acquisition time information includes the start time of image acquisition, exposure duration, data transmission time, and image frame completion time within the quiet zone. By continuously recording this time information, the temporal distribution characteristics of image acquisition behavior within the power quiet zone can be formed. Simultaneously, the start and end times, duration, power stability value, and current fluctuation amplitude of the power quiet zone are matched with the image acquisition time information to generate a quiet zone record table. The quiet zone record table completely records the temporal distribution, power stability, and the correspondence between image acquisition behavior within the power quiet zone, ensuring that each quiet zone has independent acquisition timing and power status information. In subsequent control processes, the quiet zone record table serves as a reference for power switching management and image acquisition synchronization, providing the system with basic time-related data.

[0029] After generating the silent zone record table, a synchronization control reference is established based on the time distribution and acquisition timing characteristics of the silent zones. The synchronization control reference analyzes the correspondence between the image acquisition time distribution and power output status within different silent zones to describe the synchronization relationship between the power silent zones and image acquisition. When establishing the synchronization control reference, the start time, end time, and duration of each silent zone are time-fitted with the image acquisition cycle, enabling subsequent power switching scheduling to automatically adjust based on this reference. The role of the synchronization control reference is to provide a unified time coordinate for subsequent exposure sequence adjustment, illumination compensation control, and rhythm optimization, ensuring that power switching during energy-saving control of the embroidery machine always avoids the critical time period of image acquisition. In this way, the image acquisition process can be stably completed within the time range of the power silent zone, thereby avoiding the influence of electromagnetic interference on the acquired signal and achieving timing coordination between embroidery stitch recognition and energy-saving control.

[0030] Based on the synchronization control reference, adjust the image exposure order and polarized light supplementation period within the power quiet zone, superimpose incident delay sampling to form a multi-time sampling mechanism, generate an illumination sampling arrangement list and output illumination synchronization parameters. To achieve temporal coordination between image acquisition and illumination control within the power quiet zone, ensuring that exposure and fill light actions are completed within the interference stability window, thereby improving the illumination uniformity and temporal stability of line texture acquisition, the specific implementation steps are as follows: The time distribution within the power quiet zone is divided based on a synchronization control reference to determine the timing of image exposure. The synchronization control reference includes the start and end times, duration, and corresponding image acquisition timing parameters of the power quiet zone. Analysis of the reference's time data reveals multiple sampling windows suitable for exposure operations within the power quiet zone. Within each sampling window, the exposure start time and duration are allocated based on the image acquisition device's exposure cycle and data transmission delay, ensuring the exposure process is completed within a stable power output phase and avoiding overlap with power switching or current adjustment phases. In determining the exposure sequence, the image frames are captured according to time periods with low power fluctuations in the interference scale table, ensuring each exposure corresponds to a relatively stable interference interval. This approach creates a time-based exposure sequence structure, providing a foundation for arranging the polarized light compensation cycle.

[0031] After the exposure sequence is determined, the polarized light supplementary illumination period is synchronously adjusted based on the time division of the power quiet zone. The supplementary illumination period is set based on the exposure sequence, with polarized light supplementary illumination periods set before and after each exposure. The supplementary light source uses a stable output mode, with its illumination time corresponding to the exposure start and end times, ensuring the image sensor receives uniform incident light intensity during exposure. The direction of the polarized light maintains a fixed relationship with the needle movement direction, allowing the supplementary light to form a uniform distribution of reflected light on the embroidery stitch surface. Within the power quiet zone, the supplementary illumination period is strictly aligned with the power fluctuation time interval, ensuring that no light signal changes superimposed on power fluctuations occur during illumination compensation. The duration of the supplementary illumination period is set based on the exposure duration and image acquisition delay, ensuring that the end of exposure and the end of supplementary illumination converge at the same time, forming a time sequence structure where exposure and illumination are completed synchronously. Through this synchronous control method, the illumination environment for image acquisition is stabilized within the power quiet zone, allowing the detailed texture of the embroidery stitches to be accurately recorded under stable illumination conditions.

[0032] After synchronizing the exposure sequence and polarized light compensation period, incident delayed sampling is superimposed within the power quiet zone to form a multi-temporal sampling mechanism. Incident delayed sampling fine-tunes the temporal distribution of the illumination signal, enabling the image acquisition device to capture image frames with slight illumination differences at different time points, thus creating differences in illumination levels across multiple frames. This delayed sampling mechanism allows the system to acquire multiple spatially consistent image data with different temporal distributions within a single power quiet zone, thereby enhancing the contrast and depth of subsequent line trace texture recognition. In practice, the trigger time of incident delayed sampling is determined based on the time reference in the synchronization control reference, maintaining a linear progression with the exposure sequence. For example, after the first frame exposure is completed, delayed sampling will start after a fixed time offset to ensure that each frame sampling is completed within the power stabilization zone. In this way, the power quiet zone not only serves as a time buffer for illumination stabilization but also acts as a temporal container for sampling illumination changes. The introduction of incident delay sampling enables multi-temporal illumination sampling to be realized within a single power quiescent zone, forming image data with diverse illumination levels, and providing rich raw information for subsequent illumination sampling and arrangement.

[0033] After completing exposure sequence adjustment, polarized light illumination synchronization, and incident delay sampling, an illumination sampling schedule is generated based on the acquired illumination and sampling time information, and illumination synchronization parameters are output. The illumination sampling schedule is organized by power quiet zone, recording the start and end times, duration, and corresponding illumination intensity distribution for each exposure cycle, illumination cycle, and delay sampling cycle. This schedule forms a complete timetable of illumination behavior within the power quiet zone, establishing a one-to-one correspondence between illumination changes, exposure rhythm, and power state on the time axis. Illumination synchronization parameters are extracted from the illumination sampling schedule and include control elements such as illumination intensity, polarization angle, sampling delay, and exposure rhythm, guiding subsequent illumination compensation and synchronization optimization operations. Through the generation of the illumination sampling schedule and the output of illumination synchronization parameters, continuous illumination control can be achieved between different power quiet zones, ensuring traceable control in both time and illumination for each image acquisition. This process not only ensures the continuity of illumination acquisition, but also achieves rich capture of stitch texture information through multi-time-series sampling, enabling the embroidery image to be acquired with high consistency within the energy stable region.

[0034] Based on the illumination sampling and arrangement list, the power switching process is dynamically controlled. By adjusting the drive switching rate, power transition amplitude and switching sequence, the current change is gradually distributed, an interference control list is generated and drive suppression parameters are established. To ensure that the dynamic changes during power switching are coordinated with the timing structure defined in the illumination sampling orchestration list, and to achieve a smooth distribution of current changes during power switching, thereby effectively suppressing electromagnetic interference and maintaining synchronous stability between image acquisition and drive operation, the specific implementation steps are as follows: Based on the exposure cycle, fill light cycle, and sampling delay parameters recorded in the illumination sampling orchestration list, an initial time allocation scheme for the power switching process is established. The illumination sampling orchestration list details the time slice distribution, exposure trigger point, and fill light duration within the power quiet zone; these time parameters reflect the tolerance range of image acquisition for power fluctuations. By reading the illumination sampling orchestration list, the time periods in each work cycle of the embroidery machine with relatively stable illumination and intensive exposure activity can be identified. Using these time periods as time references for power scheduling, the trigger point for power switching operations is repositioned to a time with lower risk of image acquisition interference. This process creates a time isolation zone between the power switching behavior and the illumination sampling process, avoiding triggering power level switching events during the highly sensitive phase of illumination sampling. The time distribution information provided by the illumination sampling orchestration list allows for the initial construction of a temporal distribution framework for power switching, providing a time reference for subsequent rhythm control.

[0035] After obtaining the initial time allocation scheme, the drive switching rate is dynamically adjusted during power switching to make the power transition process exhibit a continuously changing, gradual release characteristic. The power switching rate determines the steepness of the current change, and there is a direct correlation between the rate of current change and the intensity of electromagnetic interference. To ensure that the current change is evenly distributed over time, this implementation correlates the power switching rate with the illumination stabilization phase in the illumination sampling schedule. When the illumination intensity curve in the illumination sampling schedule is stable and the image acquisition interval is uniform, the drive switching rate maintains a constant increase; when the illumination sampling cycle enters the exposure start phase, the drive switching rate gradually slows down to extend the time span of current change, thereby reducing the energy concentration at the moment of power switching. Through this continuous adjustment method, the dynamic rhythm of power switching can be coordinated with the time rhythm of illumination sampling, so that the energy distribution of current change is evenly diffused over time. The output of this stage is the power switching rate control curve, which serves as a reference for adjusting the power transition amplitude and switching sequence in subsequent steps.

[0036] After the power switching rate is adjusted, the power transition amplitude and switching timing are dually controlled according to the illumination sampling schedule and the power switching rate control curve. The power transition amplitude reflects the difference in power output between different levels, while the switching timing defines the trigger point for power level changes on the time axis. To make current changes smoother over time, this implementation controls the power transition amplitude in segments according to the exposure interval distribution in the illumination sampling schedule. When the illumination sampling schedule shows dense exposure intervals, the change in power transition amplitude between adjacent levels decreases, resulting in a stepped, gradual increase in power output. When the illumination sampling intervals are relatively loose, the power transition amplitude increases proportionally to maintain overall energy output efficiency. At the same time, the trigger timing for power switching is dynamically adjusted according to the sampling delay in the illumination sampling schedule, ensuring that the switching trigger point avoids the incident delay sampling stage and the critical exposure stage, thereby preventing current transients from affecting the illumination stability of image acquisition. By coordinating the power transition amplitude and switching timing in both directions, the timing complementarity between power switching behavior and illumination sampling behavior is achieved, enabling the embroidery machine to achieve a dynamic balance between energy consumption control and visual acquisition.

[0037] After comprehensively regulating the drive switching rate, power transition amplitude, and switching timing, an interference control list is generated based on the dynamic parameters of the entire power switching process, and drive suppression parameters are established. The interference control list records the start time, duration, power transition amplitude, current fluctuation characteristics, and corresponding illumination sampling window information for each power switching event. This list reflects the impact of power switching on the illumination sampling process in a time-series format, making interference behavior traceable in the time dimension. Analysis of the interference control list allows for the extraction of current variation patterns and interference distribution characteristics at different power switching stages, thereby generating drive suppression parameters. These parameters include a power switching rate limit threshold, a transition amplitude compensation coefficient, and a switching delay period, used to constrain subsequent power switching behavior, ensuring that each power change process follows the principles of time mitigation and balanced energy distribution. Once established, the drive suppression parameters are output along with the interference control list, providing fundamental data support for subsequent adaptive optimization. In this way, the power switching process transitions from passive response to active regulation, enabling current changes to form a mitigated distribution structure within the power switching cycle, reducing interference propagation intensity at the source.

[0038] Based on the interference control list, the interference scale is reviewed in real time. The power quiet zone width and exposure step interval are updated according to the latest interference distribution. The synchronization control reference is corrected and the light sampling rhythm is adjusted to form a stable operating rhythm and realize dynamic self-adaptation of embroidery stitch optimization and energy-saving control. To achieve continuous dynamic adjustment of the embroidery machine's operating status, ensuring long-term stability and coordination of power control, image acquisition, and lighting distribution, and thus automatically adapting embroidery stitch optimization and energy-saving control to constantly changing operating conditions, the specific implementation steps are as follows: By real-time reading and time-review of the interference control list, the interference distribution in the interference scale table is updated and aligned. The interference control list records the trigger time, current fluctuation characteristics, interference duration, and their distribution on the time axis during power switching. Comparing this information with historical interference data in the interference scale table allows identification of the changing trends in interference characteristics at different operating stages of the embroidery machine. When the peak interference position in the interference control list for a certain period deviates from the boundary of the interference concentration area recorded in the interference scale table, the system adjusts the corresponding interval of the interference scale table based on the time record in the interference control list, ensuring that the interference intensity curve in the scale table is consistent with the actual operating state. This real-time review method ensures that the time calibration in the interference scale table always matches the actual changes in power switching behavior, thus maintaining the dynamic accuracy of the interference scale distribution. During this process, the update of the interference scale table not only adjusts the interference intensity values ​​but also simultaneously corrects the start and end times and duration of the interference concentration area, providing the latest reference for setting the boundary of the subsequent power silence zone.

[0039] After the interference scale is updated, the width of the power quiet zone is adjusted in real time according to the new interference distribution. The width of the power quiet zone directly determines the degree of time isolation between the image acquisition process and the power switching process, and its size depends on the extent of the interference concentration area and the duration of current recovery. In actual operation, when the interference control list shows that the fluctuation duration of the current change curve in a certain segment is prolonged, the width of the power quiet zone needs to be expanded accordingly to ensure that image acquisition starts after the interference has completely attenuated; conversely, when the interference control list shows that the current waveform after power switching recovers to a stable state earlier, the width of the power quiet zone can be appropriately reduced to improve energy utilization efficiency. By dynamically adjusting the width of the quiet zone according to the changes in interference distribution, the power quiet zone always maintains a time interval that matches the actual interference characteristics, thereby maintaining the synchronous stability of the embroidery machine's power output and image acquisition under different operating conditions. This correction process uses the updated interference scale as a time reference and resets the rear boundary of the quiet zone by accurately locating the end time point of the interference concentration area, thus forming a continuous matching mechanism between interference suppression and image acquisition timing.

[0040] After adjusting the width of the power quiet zone, the exposure step interval during image acquisition is updated based on the new interference distribution and the time structure of the quiet zone. The exposure step interval defines the exposure trigger time interval between consecutive image frames, and its value directly affects the illumination sampling density and the temporal balance of image frames. When the interference scale shows an increase in the temporal density of interference events, the exposure step interval is correspondingly extended on the time axis to avoid overlap between image acquisition and interference fluctuations, ensuring that the triggering rhythm of image acquisition avoids the interference peak area. When the interference scale shows a decrease in interference density, the exposure step interval can be shortened, making the image acquisition frequency closer to the power output rhythm, thereby improving sampling efficiency. The adjustment of the exposure step interval and the correction of the width of the power quiet zone are interrelated, and the two together determine the timing relationship between image acquisition and power switching. At this stage, the exposure step interval not only serves as a control parameter for the acquisition rhythm but also achieves illumination synchronization by aligning with the start and end times of the power quiet zone. In this way, the exposure action of each image frame can be completed within a period of stable power output, ensuring the image clarity and acquisition stability of the embroidery stitches. This process ensures that the timing of power switching and image acquisition is continuously coordinated under varying interference conditions, thereby avoiding image frame errors and trajectory deviations caused by interference drift during system operation.

[0041] After completing the dual correction of the power quiet zone width and exposure step interval, the synchronization control reference is modified based on the updated interference scale and exposure time distribution, and the illumination sampling rhythm is adjusted accordingly to form a stable operating rhythm. The synchronization control reference, serving as the time coordination benchmark for power control and image acquisition, includes key parameters such as power switching nodes, image exposure start points, illumination supplementation cycles, and incident delay sampling times. Based on the latest feedback provided by the interference control list, the time nodes in the synchronization control reference are re-optimized to allow the illumination sampling rhythm to automatically adapt to changes in interference distribution. When interference is dense, the illumination sampling rhythm is adjusted to a sparse mode to extend the sampling interval and ensure the stability of the acquired illumination; when interference is sparse, the illumination sampling rhythm is adjusted to a continuous mode to increase the sampling time density and ensure a smooth transition of illumination changes. Through this dynamic rhythm adjustment, the time step of illumination sampling is synchronized with the energy rhythm of power switching, forming a closed-loop complementary relationship between image acquisition, power control, and illumination adjustment in time. The resulting stable operating rhythm enables the embroidery machine to maintain the uniformity of the stitch formation process and the balance of energy consumption control under different loads, speeds, and lighting conditions.

[0042] This invention achieves temporal isolation of electromagnetic interference and synchronous coordination of image acquisition rhythm by introducing interference scale modeling and dynamic matching of power quiet zones between power switching and image acquisition, thus mitigating power output fluctuations over time. This method prevents current changes from being concentrated within the image acquisition window, fundamentally eliminating electromagnetic echo interference to visual recognition. It maintains continuous and stable stitch texture acquisition, avoiding problems such as image frame errors, inter-frame jumps, and path drift, thereby improving the accuracy and operational reliability of embroidery stitch optimization.

[0043] This invention achieves dynamic adaptive coordination of power control, exposure control, and illumination sampling over time by linking and updating the illumination sampling catalog and the interference control catalog. This mechanism enables the system to automatically adjust the power quiet zone width, exposure step size, and illumination rhythm based on real-time interference distribution. This ensures that the embroidery machine maintains optimal illumination balance and energy matching at different energy consumption stages, ultimately reducing overall energy consumption while maintaining stitch consistency. This achieves high-precision control and energy-saving operation of the embroidery process.

[0044] This invention provides, for example Figure 2 The intelligent embroidery stitch optimization and energy-saving control system shown includes an interference modeling module, a synchronization establishment module, an illumination coordination module, a rhythm control module, and an adaptive optimization module. The interference modeling module collects the power level switching signal, drive current change curve, and image acquisition time record of the embroidery machine. Based on the collected data, it generates an electromagnetic interference distribution map, extracts the interference concentration area from the electromagnetic interference distribution map, establishes an interference scale table, and outputs the interference scale results. The synchronous establishment module determines the power silence zone on both sides of the interference concentration zone based on the interference scale table, synchronously sends the image acquisition reference signal within the power silence zone, records the acquisition time information corresponding to the power silence zone, generates a silence zone record table, and establishes a synchronous control reference. The illumination coordination module adjusts the image exposure order and polarized light supplementation period within the power quiet zone according to the synchronization control reference, superimposes incident delay sampling to form a multi-time sequence sampling mechanism, generates an illumination sampling arrangement list and outputs illumination synchronization parameters. The rhythm control module dynamically controls the power switching process based on the illumination sampling and arrangement list. By adjusting the drive switching rate, power transition amplitude and switching sequence, it achieves a gradual distribution of current changes, generates an interference control list and establishes drive suppression parameters. The adaptive optimization module reviews the interference scale in real time based on the interference control list, updates the power quiet zone width and exposure step interval according to the latest interference distribution, corrects the synchronization control reference and adjusts the light sampling rhythm, forming a stable operating rhythm and realizing dynamic adaptation for embroidery stitch optimization and energy-saving control.

[0045] The present invention provides an intelligent embroidery stitch optimization and energy-saving control method, which is implemented through the above-mentioned intelligent embroidery stitch optimization and energy-saving control system. For details of the specific method and process of the intelligent embroidery stitch optimization and energy-saving control system, please refer to the embodiment of the above-mentioned intelligent embroidery stitch optimization and energy-saving control method, which will not be repeated here.

[0046] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A method for optimizing and controlling energy-saving embroidery stitches, characterized in that, Includes the following steps: Collect the power level switching signal, drive current change curve and image acquisition time record of the embroidery machine, generate an electromagnetic interference distribution map based on the collected data, extract the interference concentration area from the electromagnetic interference distribution map, establish an interference scale table and output the interference scale results. Based on the interference scale, determine the power silence zones on both sides of the interference concentration zone, synchronously transmit the image acquisition reference signal within the power silence zone, record the acquisition time information corresponding to the power silence zone, generate a silence zone record table, and establish a synchronization control reference. Based on the synchronization control reference, adjust the image exposure order and polarized light supplementation period within the power quiet zone, superimpose incident delay sampling to form a multi-time sampling mechanism, generate an illumination sampling arrangement list and output illumination synchronization parameters. Based on the illumination sampling and arrangement list, the power switching process is dynamically controlled. By adjusting the drive switching rate, power transition amplitude and switching sequence, the current change is gradually distributed, an interference control list is generated and drive suppression parameters are established. Based on the interference control list, the interference scale is reviewed in real time. The power quiet zone width and exposure step interval are updated according to the latest interference distribution. The synchronization control reference is corrected and the illumination sampling rhythm is adjusted to form a stable operating rhythm.

2. The intelligent embroidery stitch optimization and energy-saving control method according to claim 1, characterized in that, The steps for outputting interference calibration results are as follows: By uniformly collecting the power level switching signal, drive current change curve and image acquisition time record during the operation of the embroidery machine, a synchronous sampling sequence is established, so that the power level switching signal, drive current change curve and image acquisition time record are associated on the same time axis. After completing synchronous acquisition, the power level switching signal and the drive current change curve are superimposed and analyzed to establish the correlation distribution between power switching behavior and current transient behavior, and the potential electromagnetic interference influence area is marked by the image acquisition time record. After constructing the temporal density data of the interference events, an electromagnetic interference distribution map is generated based on the data. The interference concentration area is identified by analyzing the interference intensity curve in the distribution map. After identifying the concentrated interference area, an interference scale table is established based on the interference peak interval. The interference intensity value, interference duration, current change rate and power switching frequency are recorded and the interference scale results are output.

3. The intelligent embroidery stitch optimization and energy-saving control method according to claim 2, characterized in that, The steps for establishing a synchronous control reference are as follows: The steps for determining the power quiet zone based on the interference scale table are as follows: By analyzing the location of the interference concentration area in the interference scale table, the interference boundary of the power switching event in the time dimension is determined, and the time interval with stable interference intensity before and after the interference concentration area is selected as the initial candidate area of ​​the power silence area. After the power quiet zone is determined, the time boundary of the power quiet zone is synchronized and a synchronization reference is set. Synchronization reference points are set at the start and end times of the power quiet zone, and image acquisition reference signals are synchronously transmitted within the power quiet zone. During the process of sending the image acquisition reference signal and performing the acquisition operation, the acquisition time information corresponding to the power quiet zone is recorded, and a quiet zone record table is generated. After the silent zone record table is generated, a synchronization control reference is established based on the time distribution and acquisition timing characteristics of the silent zone, so that the power switching scheduling is adjusted according to the synchronization control reference.

4. The intelligent embroidery stitch optimization and energy-saving control method according to claim 3, characterized in that, In the process of establishing a synchronous control reference, the start time, end time, and duration of each power quiet zone are time-matched with the image acquisition cycle. Through time alignment, the image acquisition process is completed within the power quiet zone, thereby allowing power switching to avoid the critical time period of image acquisition.

5. The intelligent embroidery stitch optimization and energy-saving control method according to claim 3, characterized in that, The steps for adjusting the image exposure sequence and polarized light compensation period within the power quiet zone based on the synchronization control reference are as follows: The time distribution within the power quiet zone is divided according to the synchronous control reference to determine the timing arrangement of the image exposure sequence, and the exposure start time and exposure duration are allocated within the power stable output phase; After the exposure sequence is determined, the polarized light supplementation period is synchronously adjusted according to the time division results of the power silent zone, so that the supplementation period corresponds to the exposure period in time and maintains stable illumination. After synchronizing the exposure sequence and polarized light supplementation period, incident delayed sampling is superimposed in the power silent zone to form a multi-time-series sampling mechanism and obtain image data of illumination level differences. After completing the exposure order adjustment, polarized light supplementary lighting synchronization, and incident delay sampling, an illumination sampling arrangement list is generated based on the collected illumination and sampling time information, and illumination synchronization parameters are output.

6. The intelligent embroidery stitch optimization and energy-saving control method according to claim 5, characterized in that, The trigger time for incident delayed sampling is determined based on the time base in the synchronization control reference and maintains a linear progressive relationship with the image exposure sequence, so that each frame sampling is completed within the power quiet zone. The illumination sampling catalog records the start and end times of the exposure cycle, the fill light cycle, and the sampling cycle, as well as the illumination intensity distribution.

7. The intelligent embroidery stitch optimization and energy-saving control method according to claim 5, characterized in that, The steps for dynamic rhythm control of the power switching process based on the illumination sampling and orchestration list are as follows: Based on the exposure cycle, fill light cycle and sampling delay parameters recorded in the illumination sampling schedule, an initial time allocation scheme for the power switching process is established, and the power switching trigger point is repositioned to a time outside the range of image acquisition interference. After obtaining the initial time allocation scheme, the drive switching rate during the power switching process is dynamically adjusted so that the power transition process exhibits a continuously changing slow-release characteristic and forms a power switching rate control curve. After the power switching rate adjustment is completed, the power transition amplitude and switching timing are dually regulated according to the illumination sampling arrangement list and the power switching rate control curve, so that the power switching behavior and the illumination sampling behavior complement each other in time. After completing the comprehensive control of drive switching rate, power transition amplitude and switching timing, an interference control list is generated based on the dynamic parameters of the entire power switching process, and drive suppression parameters are established.

8. The intelligent embroidery stitch optimization and energy-saving control method according to claim 7, characterized in that, During the dynamic adjustment of the drive switching rate, the power switching rate is correlated with the illumination stabilization stage in the illumination sampling schedule. When the illumination intensity curve is stable and the image acquisition interval is uniform, the drive switching rate is kept to rise constantly. When entering the exposure start-up stage, the drive switching rate is gradually slowed down to extend the current change time span.

9. The intelligent embroidery stitch optimization and energy saving control method according to claim 7, characterized in that, The steps for real-time review of the interference scale based on the interference control list are as follows: By reading the interference control list in real time and reviewing the time, the interference distribution in the interference scale table is updated and aligned, so that the time calibration of the interference scale table is consistent with the actual changes in power switching behavior. After the interference scale is updated, the width of the power quiet zone is corrected in real time according to the new interference distribution, so that the time interval of the power quiet zone matches the interference characteristics and maintains output stability. After the power quiet zone width is adjusted, the exposure step interval during the image acquisition process is updated according to the new interference distribution and quiet zone time structure, so that the image acquisition triggering rhythm avoids the interference peak area. After correcting the power quiet zone width and exposure step interval, the synchronization control reference is corrected according to the updated interference scale, and the illumination sampling rhythm is adjusted to form a stable rhythm and achieve dynamic adaptive control.

10. An intelligent embroidery stitch optimization and energy saving control system for implementing the intelligent embroidery stitch optimization and energy saving control method of any one of claims 1-9, characterized in that, It includes an interference modeling module, a synchronization establishment module, an illumination coordination module, a rhythm control module, and an adaptive optimization module: The interference modeling module collects the power level switching signal, drive current change curve, and image acquisition time record of the embroidery machine. Based on the collected data, it generates an electromagnetic interference distribution map, extracts the interference concentration area from the electromagnetic interference distribution map, establishes an interference scale table, and outputs the interference scale results. The synchronous establishment module determines the power silence zone on both sides of the interference concentration zone based on the interference scale table, synchronously sends the image acquisition reference signal within the power silence zone, records the acquisition time information corresponding to the power silence zone, generates a silence zone record table, and establishes a synchronous control reference. The illumination coordination module adjusts the image exposure order and polarized light supplementation period within the power quiet zone according to the synchronization control reference, superimposes incident delay sampling to form a multi-time sequence sampling mechanism, generates an illumination sampling arrangement list and outputs illumination synchronization parameters. The rhythm control module dynamically controls the power switching process based on the illumination sampling and arrangement list. By adjusting the drive switching rate, power transition amplitude and switching sequence, it achieves a gradual distribution of current changes, generates an interference control list and establishes drive suppression parameters. The adaptive optimization module reviews the interference scale in real time based on the interference control list, updates the power quiet zone width and exposure step interval according to the latest interference distribution, corrects the synchronization control reference and adjusts the illumination sampling rhythm to form a stable operating rhythm.

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