Embroidery thread tension control system of embroidery machine

Abstract

The utility model discloses an embroidery thread tension control system of an embroidery machine, which is characterized in that a fixed wheel assembly, a plurality of movable wheel assemblies, a thread length measuring assembly and an embroidery thread pressing assembly are arranged in a matched manner, and the thread length measuring assembly detects the current consumption of embroidery threads with different colors in a pattern in real time and sends the current consumption to a control module; the control module judges the difference value between the current consumption of the embroidery threads of different colors in the same pattern and the preset consumption, the control module sends a control signal to the embroidery thread pressing assembly according to the difference value, and the embroidery thread pressing assembly drives the movable wheel assemblies corresponding to the embroidery threads of different colors to be close to or away from the fixed wheel assemblies at the corresponding positions; whether the tension of the embroidery thread at the time is appropriate or not can be judged according to the difference between the current consumption of the embroidery threads with different colors and the preset consumption, so that the tension of the embroidery thread is dynamically adjusted, and the embroidery quality of an embroidery product is ensured.

Description

Technical Field

[0001] This utility model relates to the technical field of embroidery machines, specifically to an embroidery thread tension control system for embroidery machines. Background Technology

[0002] With the rapid development of industrial computer embroidery machine technology, the types of embroidery threads and fabrics used for embroidery are increasing, and the requirements for embroidery quality are becoming more and more stringent. In particular, facing the diverse needs of personalized customers, how to ensure the high quality of embroidery products and have good stability and consistency is a huge challenge. One of the key factors affecting embroidery quality is the tension of the embroidery thread. Experienced embroidery workers will manually adjust the tension of the embroidery thread according to factors such as the type of embroidery thread, the thickness of the fabric, and the characteristics of the machine. However, this manual adjustment method has two disadvantages: (1) It requires a high level of skill from the workers. Because there are many parameters involved, and the quality of the embroidery must be correctly assessed, workers need to have long-term embroidery experience and be very familiar with the embroidery process and the characteristics of the machine; (2) It is difficult to meet the timeliness of quality control. When workers are monitoring multiple embroidery machines, it is difficult to ensure that they can detect changes in embroidery quality in a timely manner and make corresponding adjustments.

[0003] Currently, most automatic thread tension adjustment devices on the market use open-loop control, adjusting the machine and controlling the tension before embroidery based on a pre-set standard tension value. However, as the embroidery progresses, the thread tension changes, making it impossible to adjust the dynamic tension during the embroidery process to ensure the quality of the embroidery. Utility Model Content

[0004] Therefore, it is necessary to provide an embroidery thread tension control system for embroidery machines. This can solve the problem of poor embroidery quality caused by the inability to automatically adjust thread tension.

[0005] An embroidery thread tension control system for an embroidery machine includes a fixed plate, a support base, a fixed wheel assembly, several movable wheel assemblies, a thread length measuring assembly, and an embroidery thread pressing assembly;

[0006] The support base is mounted on the fixed plate, the fixed wheel assembly is disposed on the top surface of the fixed plate, the plurality of movable wheel assemblies are movably disposed on the support base in the vertical direction and correspond to the fixed wheel assembly, and the embroidery thread pressing assembly is mounted on the fixed plate and abuts against the bottom of at least one movable wheel assembly, for controlling the movable wheel assembly to move closer to or away from the fixed wheel assembly;

[0007] The line length measuring component includes at least one photoelectric turntable and at least one photoelectric sensor. The photoelectric turntable is mounted on a wheel and rotates synchronously with the rotation of the wheel. The photoelectric sensor is mounted on the fixed plate and is adapted to the position of the photoelectric turntable.

[0008] In one embodiment, the fixed wheel assembly includes a mounting base and a plurality of fixed wheels, the mounting base being fixedly disposed on the fixed plate, and the plurality of fixed wheels being rotatably disposed on the mounting base.

[0009] In one embodiment, the movable wheel assembly includes a base and a movable wheel, the base being movably disposed on the support in a vertical direction, and the movable wheel being rotatably disposed on the base.

[0010] In one embodiment, a plurality of guide posts are symmetrically arranged on both sides of the support base, and a plurality of guide members are symmetrically arranged on the base. The guide members have guide holes, and the guide posts pass through the guide holes. When the base moves in the vertical direction, the guide members slide along the guide posts. A spring is sleeved on the guide post, and the two ends of the spring abut against the support base and the guide members, respectively.

[0011] In one embodiment, the embroidery thread clamping assembly includes a motor mounting base, a motor, a drive wheel, a driven wheel, a lead screw, a lead screw nut, and a pressure block. The motor mounting base is mounted on the fixed plate, the motor is fixedly mounted on the motor mounting base, the drive wheel is rotatably mounted on the motor, the driven wheel is rotatably mounted on the motor mounting base and meshes with the drive wheel, one end of the lead screw is mounted on the driven wheel, and the other end is rotatably mounted on the motor mounting base, the lead screw nut is mounted on the lead screw, and the pressure block is fixedly mounted on the lead screw nut and abuts against the bottom of the base.

[0012] In one embodiment, the top surface of the pressure block has a symmetrically arranged inclined surface structure.

[0013] A method for controlling the tension of embroidery thread in an embroidery machine, applied to the control method of the embroidery thread tension control system of the embroidery machine, the method comprising:

[0014] The thread length measurement component detects the current consumption of different colors of embroidery thread in a pattern in real time and sends it to the control module.

[0015] The control module determines the difference between the current consumption and the preset consumption of different colored embroidery threads in the same pattern.

[0016] The control module sends a control signal to the embroidery thread clamping component based on the difference;

[0017] The embroidery thread clamping component drives the movable wheel component corresponding to different colored embroidery threads to move closer to or away from the fixed wheel component at the corresponding position.

[0018] In one embodiment, the method by which the thread length measuring component detects the current consumption of different colored embroidery threads in a pattern in real time and sends it to the control module is as follows:

[0019] The embroidery thread drives the photoelectric turntable to rotate via a wheel;

[0020] The marks on the photoelectric turntable pass through the photoelectric sensor in sequence;

[0021] Each time the photoelectric sensor detects a tag, it outputs a pulse signal.

[0022] The photoelectric sensor records the number and direction of the pulse signal and calculates the rotation angle or number of revolutions of the wheel;

[0023] The current consumption of different colored embroidery threads in a pattern is obtained by rotating the roulette wheel at its angle and by the number of rotations.

[0024] In one embodiment, the current consumption of one color of embroidery thread for a pattern is: L = N × C + θ / 360 × C, where L is the current consumption of one color of embroidery thread for a pattern, N is the number of rotations of the roulette wheel, C is the circumference of the roulette wheel, and θ is the angle of rotation of the roulette wheel.

[0025] In one embodiment, the method for obtaining the preset consumption amount of different colors of embroidery thread for the same pattern is as follows:

[0026] Calculate in advance the basic consumption of embroidery thread for each step of the embroidery process for different colors of the same pattern;

[0027] Obtain the embroidery speed coefficient for the same pattern using different colored embroidery threads;

[0028] Obtain the material coefficient of different colors of embroidery thread for the same pattern;

[0029] Using a pre-defined embroidery thread consumption model, the consumption of different colors of embroidery thread in each embroidery step is predicted based on the basic consumption of different colors of embroidery thread in each embroidery step, the embroidery speed coefficient, and the embroidery thread material coefficient.

[0030] The aforementioned embroidery thread tension control system, through the coordinated arrangement of a fixed wheel assembly, several movable wheel assemblies, a thread length measuring assembly, and an embroidery thread pressing assembly, allows the thread length measuring assembly to detect the current consumption of different colored embroidery threads in a pattern in real time and send it to the control module. The control module then determines the difference between the current consumption of different colored embroidery threads in the same pattern and the preset consumption. Based on this difference, the control module sends a control signal to the embroidery thread pressing assembly. The embroidery thread pressing assembly drives the movable wheel assemblies corresponding to different colored embroidery threads to move closer to or further away from the fixed wheel assembly at the corresponding position. By determining whether the tension of the embroidery thread is appropriate based on the difference between the current consumption of different colored embroidery threads and the preset consumption, the embroidery thread tension can be dynamically adjusted to ensure the quality of the embroidery. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the assembly structure of the embroidery thread tension control system of an embroidery machine according to an embodiment of the present invention;

[0032] Figure 2 for Figure 1 A bottom view of the embroidery thread tension control system of an embroidery machine according to an embodiment of the present invention;

[0033] Figure 3 for Figure 1 A schematic diagram of the assembly structure of the fixed wheel assembly and several movable wheel assemblies of the embroidery thread tension control system of an embroidery machine according to an embodiment of the present invention;

[0034] Figure 4 for Figure 1 A schematic diagram of the assembly structure of the embroidery thread pressing component of the embroidery thread tension control system of an embroidery machine according to an embodiment of the present invention. Detailed Implementation

[0035] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0036] It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be an intermediary component present. Conversely, when a component is said to be "directly" connected to another component, there is no intermediary component.

[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0038] like Figure 1 As shown, an embroidery thread tension control system for an embroidery machine includes a fixed plate 1, a support base 2, a fixed wheel assembly 3, several movable wheel assemblies 4, a thread length measuring assembly 5, and an embroidery thread pressing assembly 6.

[0039] The support base 2 is mounted on the fixed plate 1, the fixed wheel assembly 3 is disposed on the top surface of the fixed plate 1, the plurality of movable wheel assemblies 4 are movably disposed on the support base 2 in the vertical direction and correspond to the fixed wheel assembly 3, and the embroidery thread pressing assembly 6 is mounted on the fixed plate 1 and abuts against the bottom of at least one movable wheel assembly 4, for controlling the movable wheel assembly 4 to move closer to or away from the fixed wheel assembly 3;

[0040] like Figure 2 As shown, the line length measuring component 5 includes at least one photoelectric turntable 51 and at least one photoelectric sensor 52. The photoelectric turntable 51 is mounted on the wheel 7 and rotates synchronously with the rotation of the wheel 7. The photoelectric sensor 52 is mounted on the fixed plate 1 and is adapted to the position of the photoelectric turntable 51.

[0041] like Figure 3 As shown, the fixed wheel assembly 3 includes a mounting base 31 and a plurality of fixed wheels 32. The mounting base 31 is fixedly mounted on the fixed plate 1, and the plurality of fixed wheels 32 are rotatably mounted on the mounting base 31.

[0042] The movable wheel assembly 4 includes a base 41 and a movable wheel 42. The base 41 is movably mounted on the support 2 in a vertical direction, and the movable wheel 42 is rotatably mounted on the base 41.

[0043] Embroidery patterns are typically created using different colored threads. During embroidery, different colored threads pass between multiple fixed wheels 32 and movable wheels 42, arranged vertically in a one-to-one correspondence. The tension of the thread passing between the fixed wheels 32 and movable wheels 42 is controlled by both. The closer the fixed wheels 32 and movable wheels 42 are, the smaller the gap, resulting in greater thread tension; conversely, the farther apart they are, the larger the gap, the smaller the thread tension. In actual embroidery, the different thread tensions lead to different thread consumption. Higher thread tension results in a taut, wrinkled embroidery, with less thread consumption than the preset value; lower thread tension results in looser, floating threads, with more thread consumption than the preset value. Different colored embroidery threads are wound around different discs 7 after passing between fixed wheel 32 and movable wheel 42. During embroidery, these discs 7 rotate. Each disc 7 is wound with a different colored embroidery thread, and each disc 7 corresponds to a thread length measuring component 5. The thread length measuring component 5 measures the current consumption of the different colored embroidery thread wound on the corresponding disc 7 and sends this data to the control module. The control module compares the current consumption with a preset consumption. If the current consumption is less than the preset consumption, the tension is too high. The control module then sends a control signal to the thread tightening component 6, which controls the movable wheel component 4 to move away from the corresponding fixed wheel component 3, thus reducing the tension of the red embroidery thread. Conversely, if the current consumption of red embroidery thread is less than the preset consumption, the control module sends a control signal to the thread tightening component 6, which controls the movable wheel component 4 corresponding to the red embroidery thread to move away from the corresponding fixed wheel component 3, reducing the tension of the red embroidery thread.

[0044] In this way, the embroidery thread tension control system of the embroidery machine is set up in cooperation with the fixed wheel assembly 3, several movable wheel assemblies 4, thread length measuring assembly 5, and embroidery thread pressing assembly 6. The thread length measuring assembly 5 detects the current consumption of different colors of embroidery thread in a pattern in real time and sends it to the control module. The control module judges the difference between the current consumption of different colors of embroidery thread in the same pattern and the preset consumption. The control module sends a control signal to the embroidery thread pressing assembly 6 based on the difference. The embroidery thread pressing assembly 6 drives the movable wheel assembly 4 corresponding to different colors of embroidery thread to move closer to or away from the fixed wheel assembly 3 at the corresponding position. It can judge whether the tension of the embroidery thread is appropriate based on the difference between the current consumption of different colors of embroidery thread and the preset consumption, so as to dynamically adjust the tension of the embroidery thread to ensure the quality of the embroidery.

[0045] In one embodiment, a plurality of guide posts 21 are symmetrically arranged on both sides of the support base 2, and a plurality of guide members 411 are symmetrically arranged on the base 41. The guide members 411 are provided with guide holes 4111, and the guide posts 21 pass through the guide holes 4111. When the base 41 moves in the vertical direction, the guide members 411 slide along the guide posts 21. A spring is sleeved on the guide posts 21, and the two ends of the spring abut against the support base 2 and the guide members 411 respectively.

[0046] In this way, the base 41 can move vertically, thereby causing the movable wheel 42 to move closer to or further away from the fixed wheel 32, thus adjusting the tension of the embroidery thread between the fixed wheel 32 and the movable wheel 42. A spring is fitted on the guide post 21. When the embroidery thread pressing assembly 6 pushes the base 41 and the movable wheel 42 towards the fixed wheel 32, the spring provides a certain buffering effect, allowing for fine adjustment of the gap between the fixed wheel 32 and the movable wheel 42.

[0047] like Figure 4 As shown, in one embodiment, the embroidery thread pressing assembly 6 includes a motor mounting base 61, a motor 62, a drive wheel 63, a driven wheel 64, a lead screw 65, a lead screw nut 66, and a pressure block 67. The motor mounting base 61 is mounted on the fixed plate 1, the motor 62 is fixedly mounted on the motor mounting base 61, the drive wheel 63 is rotatably mounted on the motor 62, the driven wheel 64 is rotatably mounted on the motor mounting base 61 and meshes with the drive wheel 63, one end of the lead screw 65 is mounted on the driven wheel 64, and the other end is rotatably mounted on the motor mounting base 61, the lead screw nut 66 is mounted on the lead screw 65, and the pressure block 67 is fixedly mounted on the lead screw nut 66 and abuts against the bottom of the base 41. The top surface of the pressure block 67 has a symmetrically arranged inclined surface structure 671.

[0048] Thus, when it is necessary to adjust the gap between the fixed wheel 32 and the movable wheel 42, the motor 62 is started. The motor 62 drives the driving wheel 63 to rotate, the driving wheel 63 drives the driven wheel 64 to rotate, and the driven wheel 64 drives the lead screw 65 to rotate. This causes the lead screw nut 66 to move the pressure block 67 to the bottom of the movable wheel 42 that needs to be adjusted, so that the inclined structure 671 of the pressure block 67 abuts against the bottom of the base 41. As the base 41 moves on the inclined structure 671, the movable wheel 42 on the base 41 moves closer to or further away from the fixed wheel 32, thereby adjusting the gap between the fixed wheel 32 and the movable wheel 42.

[0049] A method for controlling the tension of embroidery thread in an embroidery machine, applied to the control method of the embroidery thread tension control system of the embroidery machine, the method comprising:

[0050] S1. The thread length measuring component 5 detects the current consumption of different colored embroidery threads in a pattern in real time and sends it to the control module.

[0051] S11. The embroidery thread drives the photoelectric turntable 51 to rotate via the wheel 7.

[0052] S12. The marks on the photoelectric turntable 51 pass through the photoelectric sensor 52 in sequence; the photoelectric turntable 51 usually has evenly distributed marks (such as holes or reflective strips) for the photoelectric sensor 52 to detect.

[0053] S13. For each marker detected, photoelectric sensor 52 outputs a pulse signal. Photoelectric sensor 52 typically includes a transmitter and a receiver, and outputs a pulse signal by detecting changes in the marker.

[0054] S14, photoelectric sensor 52 records the number and direction of pulse signals and calculates the rotation angle or number of revolutions of wheel 7;

[0055] S15. Obtain the current consumption of different colored embroidery threads in a pattern by rotating the roulette wheel 7 by its rotation angle and number of rotations.

[0056] The current consumption of one pattern and one color of embroidery thread is: L=N×C+θ / 360×C, where L is the current consumption of one pattern and one color of embroidery thread, N is the number of rotations of the wheel 7, C is the circumference of the wheel 7, and θ is the angle of rotation of the wheel 7.

[0057] S2. The control module determines the difference between the current consumption of different colored embroidery threads and the preset consumption in the same pattern.

[0058] S21. Calculate in advance the basic consumption of embroidery thread for each embroidery step of the same pattern but different colors;

[0059] For example, if a pattern includes three different colors of embroidery thread—red, yellow, and blue—then the basic thread consumption for each embroidery step for red, yellow, and blue thread must be calculated. Besides this basic consumption, thread consumption is also affected by the embroidery machine speed and the thread material. The faster the machine, the more thread is consumed due to inertia and friction. Different thread materials (cotton, silk, polyester, etc.) have different elasticities and coefficients of friction, which also affect thread consumption. Therefore, in addition to considering the basic thread consumption, the thread material and speed must also be taken into account to adjust the preset thread consumption.

[0060] S22. Obtain the embroidery speed coefficient for different colors of embroidery thread with the same pattern; embroidery speed coefficient K V =1+C1*V+C2*V 2 , K VHere, V is the embroidery speed coefficient, C1 and C2 are constants. C1 = μ*d / E*A;

[0061] μ: coefficient of friction between embroidery thread and conductor, d: length of embroidery thread path, E: elastic modulus of embroidery thread, A: cross-sectional area of ​​embroidery thread;

[0062] C2=ρ* L0 / 2* T 设计 ρ: Thread density (kg / m), L0: Length of free section of thread, T 设计 Design tension;

[0063] S23. Obtain the material coefficient of different colors of embroidery thread for the same pattern; K M =1+α*(T 实际 -T 设计 ), K M Here, α is the material coefficient for the embroidery thread, and α is a material-related correction factor. The value of α can be obtained using the formula α=1 / E*A*L. 设计 / △T, E: Elastic modulus of embroidery thread, A: Cross-sectional area of ​​embroidery thread, L 设计 : Design length of embroidery thread; △T: Thread tension;

[0064] △T=E*A*△L / L0, where △L is the elongation of the embroidery thread and L0 is the initial length of the embroidery thread.

[0065] S24. Using the embroidery thread preset consumption model, predict the consumption of different colors of embroidery thread in each embroidery step based on the basic consumption of different colors of embroidery thread in each embroidery step, the embroidery speed coefficient, and the embroidery thread material coefficient.

[0066] L 总 =L*K V *K M L 总 This is the preset thread consumption for each embroidery step using a single color of thread. To obtain the preset thread consumption for multiple embroidery steps, simply add up the preset thread consumption for each step.

[0067] When comparing thread consumption, it actually involves comparing the preset thread consumption of a particular color with the current thread consumption for the same number of steps. For example, if the preset thread consumption is 20cm and the current thread consumption is 30cm for the same 10 steps, then the preset thread consumption is less than the current thread consumption, indicating that the tension is too low and needs to be increased.

[0068] S3. The control module sends a control signal to the embroidery thread pressing component 6 according to the difference;

[0069] S4, the embroidery thread pressing component 6 drives the movable wheel component 4 corresponding to different colored embroidery threads to move closer to or away from the fixed wheel component 3 at the corresponding position.

[0070] If the current thread consumption is less than the preset consumption, the tension is high. The control module sends a control signal to the thread tightening component 6, which controls the movable wheel component 4 to move away from the corresponding fixed wheel component 3. If the current thread consumption is greater than the preset consumption, the tension is low. The control module sends a control signal to the thread tightening component 6, which controls the movable wheel component 4 to move closer to the corresponding fixed wheel component 3. The thread tension is dynamically adjusted based on the current thread consumption.

[0071] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A tension control system for embroidery thread in an embroidery machine, characterized in that: Includes a fixed plate, support base, fixed wheel assembly, several movable wheel assemblies, thread length measuring assembly, and embroidery thread clamping assembly; The support base is mounted on the fixed plate, the fixed wheel assembly is disposed on the top surface of the fixed plate, the plurality of movable wheel assemblies are movably disposed on the support base in the vertical direction and correspond to the fixed wheel assembly, and the embroidery thread pressing assembly is mounted on the fixed plate and abuts against the bottom of at least one movable wheel assembly, for controlling the movable wheel assembly to move closer to or away from the fixed wheel assembly; The line length measuring component includes at least one photoelectric turntable and at least one photoelectric sensor. The photoelectric turntable is mounted on a wheel and rotates synchronously with the rotation of the wheel. The photoelectric sensor is mounted on the fixed plate and is adapted to the position of the photoelectric turntable.

2. The embroidery thread tension control system for an embroidery machine according to claim 1, characterized in that: The fixed wheel assembly includes a mounting base and a plurality of fixed wheels. The mounting base is fixedly mounted on the fixed plate, and the plurality of fixed wheels are rotatably mounted on the mounting base.

3. The embroidery thread tension control system for an embroidery machine according to claim 1, characterized in that: The movable wheel assembly includes a base and movable wheels. The base is movably mounted on the support in a vertical direction, and the movable wheels are rotatably mounted on the base.

4. The embroidery thread tension control system for an embroidery machine according to claim 3, characterized in that: Several guide posts are symmetrically arranged on both sides of the support base, and several guide members are symmetrically arranged on the base. Each guide member has a guide hole, and the guide posts pass through the guide holes. When the base moves vertically, the guide members slide along the guide posts. A spring is sleeved on each guide post, and the two ends of the spring abut against the support base and the guide members, respectively.

5. The embroidery thread tension control system for an embroidery machine according to claim 4, characterized in that: The embroidery thread clamping assembly includes a motor mounting base, a motor, a drive wheel, a driven wheel, a lead screw, a lead screw nut, and a pressure block. The motor mounting base is mounted on the fixed plate, and the motor is fixedly mounted on the motor mounting base. The drive wheel is rotatably mounted on the motor, and the driven wheel is rotatably mounted on the motor mounting base and meshes with the drive wheel. One end of the lead screw is mounted on the driven wheel, and the other end is rotatably mounted on the motor mounting base. The lead screw nut is mounted on the lead screw, and the pressure block is fixedly mounted on the lead screw nut and abuts against the bottom of the base.

6. The embroidery thread tension control system for an embroidery machine according to claim 5, characterized in that: The top surface of the pressure block has a symmetrically arranged inclined surface structure.

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