Sewing system and sewing method

Abstract

A sewing system (100) includes a plurality of imaging devices (37) that acquire images of an object to be sewn (S), one or a plurality of sewing machines (1) that perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn (S), and a data processing unit (50) that acquires template data (70) of the object to be sewn (S) created based on an image captured by a first imaging device (37) among the plurality of imaging devices (37) and transmits the template data to another second imaging device (37). The sewing machine (1) includes inherent data (60B) including imaging conditions of the imaging devices (37). The sewing machine (1) including the second imaging device (37) executes image recognition processing by using template data (72) corrected based on the inherent data (60B) of the second imaging device (37), or corrects a recognition result obtained using the template data (70), based on the inherent data (60B) of the second imaging device (37).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a sewing system and a sewing method.BACKGROUND ART

[0002] In order to enhance the design property of an object to be sewn, stitches may be formed on the object to be sewn. Patent Literature 1 discloses a technique for forming stitches on a skin material used for a vehicle seat.CITATION LISTPATENT LITERATURE

[0003] Patent Literature 1: JP2013-162957ASUMMARY OF INVENTIONTECHNICAL PROBLEM

[0004] A skin material used for a vehicle seat has thickness and elasticity. When a stitch is formed on an object to be sewn having thickness and elasticity, the object to be sewn may be contracted, thereby causing the surface of the object to be sewn to be displaced. For example, when forming a second stitch after a first stitch is formed, it is preferable to form the second stitch at a target position on the object to be sewn according to the displacement of the surface of the object to be sewn caused by the formation of the first stitch. As a measure for forming a stitch at a target position of an object to be sewn, the surface of the object to be sewn may be photographed before sewing processing to detect displacement of the surface of the object to be sewn. For displacement detection, image recognition processing such as template matching is used.

[0005] When manufacturing the same product by using a plurality of sewing machines in a sewing factory or the like, the plurality of sewing machines form stitches of the same shape on the objects to be sewn of the same shape, and therefore the template data used for image recognition processing is also common. However, in practice, since imaging conditions of imaging devices provided in the respective sewing machines differ due to individual variations, assembly errors, or the like of the imaging devices, template data is prepared separately for each sewing machine. Consequently, the total work man-hours and data management man-hours across all sewing machines increase.

[0006] An aspect of the present disclosure is to reduce the work man-hours and data management man-hours related to image recognition in a sewing system including a plurality of sewing machines.SOLUTION TO PROBLEM

[0007] According to a first aspect of the present disclosure, a sewing system is provided, including: a plurality of imaging devices configured to acquire images of an object to be sewn; one or a plurality of sewing machines configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn; and a data processing unit configured to acquire template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of imaging devices and to transmit the template data to another second imaging device, in which the sewing machine includes inherent data including imaging conditions of the imaging devices, and the sewing machine including the second imaging device performs image recognition processing by using the template data corrected based on the inherent data of the second imaging device, or corrects a recognition result obtained using the template data, based on the inherent data of the second imaging device.

[0008] According to a second aspect of the present disclosure, there is provided a sewing method using a plurality of sewing machines, each of which includes an imaging device configured to acquire an image of an object to be sewn and is configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn, or using a sewing machine including a plurality of the imaging devices, the sewing method including: acquiring template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of sewing machines or the plurality of imaging devices, and transmitting the template data to another second imaging device; and, in the sewing machine including the second imaging device, executing image recognition processing by using the template data corrected based on inherent data including an imaging condition of the second imaging device, or correcting a recognition result obtained using the template data, based on the inherent data.ADVANTAGEOUS EFFECTS OF INVENTION

[0009] According to the aspect of the present disclosure, it is possible to reduce the work man-hours and data management man-hours related to image recognition in a sewing system including a plurality of sewing machines.BRIEF DESCRIPTION OF DRAWINGS

[0010] Fig. 1 is a diagram schematically illustrating a sewing system according to the present embodiment. Fig. 2 is a functional block diagram illustrating a sewing machine and a data processing unit according to the present embodiment. Fig. 3 is an illustrative diagram of inherent data provided in a plurality of sewing machines. Fig. 4 is a cross-sectional view illustrating a part of an object to be sewn. Fig. 5 is a plan view illustrating the object to be sewn. Fig. 6 is a cross-sectional view illustrating an example of the object to be sewn. Fig. 7 is an illustrative diagram of template data of a recognition object. Fig. 8 is an illustrative diagram of correction of template data by the sewing system according to the present embodiment. Fig. 9 is a schematic diagram illustrating transmission of inherent template data. Fig. 10 is an illustrative diagram of a sewing method according to the present embodiment. Fig. 11 is a perspective view illustrating a sewing machine according to the present embodiment. Fig. 12 is a perspective view illustrating a part of the sewing machine according to the present embodiment. Fig. 13 is a plan view illustrating an arrangement example of imaging devices according to the present embodiment. Fig. 14 is a flow chart showing a sewing operation of the sewing machine according to the present embodiment. Fig. 15 is a schematic diagram illustrating an image stitching process. Fig. 16 is a schematic diagram illustrating a recognition object detection process. DESCRIPTION OF EMBODIMENTS

[0011] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings, but the present disclosure is not limited thereto. Components of the embodiments described below can be combined appropriately. In addition, some components may not be used.

[0012] In the present embodiment, a local coordinate system is defined for a sewing machine 1. In the following description, the local coordinate system defined for the sewing machine 1 is appropriately referred to as a sewing machine coordinate system. The sewing machine coordinate system is defined by the XYZ orthogonal coordinate system. In the present embodiment, the positional relationship of each part will be described based on the sewing machine coordinate system. A direction parallel to an X-axis in a predetermined plane is defined as an X-axis direction. A direction parallel to a Y-axis in the predetermined plane orthogonal to the X-axis is defined as a Y-axis direction. A direction parallel to a Z-axis orthogonal to the predetermined plane is defined as a Z-axis direction. In addition, a rotational direction or an inclination direction about the X-axis is defined as a θX direction. A rotational direction or an inclination direction about the Y-axis is defined as a θY direction. A rotational direction or an inclination direction about the Z-axis is defined as a θZ direction. In addition, in the present embodiment, a plane including the X-axis and the Y-axis is appropriately referred to as an XY plane. A plane including the X-axis and the Z-axis is appropriately referred to as an XZ-plane. A plane including the Y-axis and the Z-axis is appropriately referred to as a YZ-plane. The XY plane is parallel to the predetermined plane. The XY plane, the XZ plane, and the YZ plane are orthogonal to one another. Additionally, in the present embodiment, the XY plane is parallel to a horizontal plane. The Z-axis direction is an up-down direction in the predetermined plane. The +Z direction is an upward direction. The -Z direction is a downward direction. Note that the XY plane may be inclined with respect to the horizontal plane.[Overview of Sewing System]

[0013] Fig. 1 is a diagram schematically illustrating a sewing system 100 according to the present embodiment. As illustrated in Fig. 1, the sewing system 100 includes a plurality of sewing machines 1, a plurality of gateways 101 corresponding to the respective sewing machines 1, a communication network 102, and a data processing unit 50. The sewing system 100 is arranged in, for example, a sewing factory, which is an operational facility in which the plurality of sewing machines 1 are in operation. In the sewing factory, a sewing product is manufactured by sewing an object to be sewn S with sewing thread using the sewing machine 1. Note that, in Fig. 1, three sewing machines 1 are illustrated, but the number of sewing machines 1 provided in the sewing system 100 is not particularly limited. The number of sewing machines 1 provided in the sewing system 100 may be 1, 2, or 4 or more.

[0014] In addition, data may be exchanged between the sewing machine 1 and the data processing unit 50 without passing through the communication network 102. Data may also be exchanged between the sewing machine 1 and the data processing unit 50 via an external memory medium such as a USB memory.

[0015] In addition, even when the number of the sewing machines is one, or even when imaging conditions have changed due to replacement caused by a failure of a camera or the like, template data can be corrected according to the same principle as described below. The correction of the template data makes it possible to reduce the work man-hours of the sewing system 100.

[0016] The sewing machine 1 is an industrial sewing machine that is operated by an operator Ma. The sewing machine 1 of the present embodiment is a cycle sewing machine that automatically executes pattern sewing on the basis of a set predetermined sewing pattern. The sewing machine 1 starts processing for sewing a set predetermined sewing pattern when the operator Ma performs a predetermined operation in a state in which the object to be sewn S and sewing thread are set at predetermined positions.

[0017] In the present embodiment, the plurality of sewing machines 1 are used to manufacture the same products. That is, the plurality of sewing machines 1 perform sewing of the same pattern on the objects to be sewn S of the same shape. For example, a plurality of manufacturing lines for manufacturing the same products are provided in the sewing factory. The respective sewing machines 1 are installed on the plurality of manufacturing lines for manufacturing the same products, respectively.

[0018] The sewing machine 1 connects to the communication network 102 via a corresponding gateway 101. The gateway 101 is arranged on a communication line connecting the sewing machine 1 and the communication network 102. The gateway 101 is a device that relays transmission and reception of various data in communication between the sewing machine 1 and the communication network 102, and transfers received data after converting its protocol.

[0019] The data processing unit 50 is an information terminal that is operated by a manager Mb in order to manage data of the plurality of sewing machines 1 of the sewing system 100. A typical example of the data processing unit 50 is assumed to be a file server or a NAS (Network Attached Storage) that performs file management. The data processing unit 50 may also be implemented by utilizing file management and sharing functions of a desktop PC (personal computer), a laptop PC, a smartphone, a tablet terminal, and the like. One of the plurality of sewing machines 1 may be used as a master machine and also serve as the data processing unit 50.

[0020] The data processing unit 50 may connect to the communication network 102 and communicate with the plurality of sewing machines 1 via the respective gateways 101. The data processing unit 50 transmits and receives data necessary for sewing to and from each sewing machine 1 via the communication network 102.[Sewing Machine and Management Device]

[0021] Fig. 2 is a functional block diagram illustrating the sewing machine 1 and the data processing unit 50 according to the present embodiment. In Fig. 2, only the schematic configuration of the sewing machine 1 is illustrated.

[0022] As illustrated in Fig. 2, the sewing machine 1 includes a sewing machine body 10, a control device 30, a storage device 35, an image processing unit 36, an imaging device 37, an illumination device 38, and a communication device 39.

[0023] The sewing machine body 10 is a mechanism part that performs sewing on the object to be sewn S. The sewing machine body 10 includes an actuator 10A and a drive amount sensor 10B.

[0024] The actuator 10A includes various drive mechanisms and drive sources that operate each unit of the sewing machine body 10. The actuator 10A executes various operations for the sewing machine 1 to sew a set predetermined sewing pattern.

[0025] The drive amount sensor 10B detects a drive amount of the actuator 10A. The drive amount sensor 10B includes, for example, an encoder that detects a rotation amount of a motor, a position sensor that detects a position of a holding member for a sewing needle, and the like. Based on a detection result of the drive amount sensor 10B, the actuator 10A of the sewing machine body 10 is controlled by the control device 30.

[0026] The control device 30 includes a computer system. The control device 30 executes various controls in each unit of the sewing machine 1. The control unit 30 includes a processor such as a central processing unit (CPU) or a micro processing unit (MPU). The processor executes various computation processes to realize functions as the control device 30, based on a program stored in the storage device 35. The control device 30 controls the actuator 10A of the sewing machine body 10 in accordance with sewing data set in the storage device 35.

[0027] The storage device 35 includes a primary storage device, which is a volatile memory that temporarily stores data, and a secondary storage device, which is a non-volatile memory that stores various programs and data used by the processor for computation. The primary storage device is, for example, a random access memory (RAM) or the like. The secondary storage device is, for example, a read only memory (ROM), a hard disk drive (HDD), a solid state drive (SSD), a storage, or the like. As described below, inherent data 60 related to the imaging device 37 and the sewing machine body 10 of the sewing machine 1 is stored in the storage device 35, in addition to the program of the control device 30. In the storage device 35, sewing data for executing sewing processing is stored.

[0028] The sewing data is known data that can be derived from design data of the object to be sewn S, such as CAD (Computer Aided Design) data. The sewing data is referenced by the control device 30 in the sewing processing. The sewing processing refers to processing for forming a stitch CH (see Fig. 6) on the object to be sewn S. In addition, template data that is used for image recognition processing of an image of the object to be sewn S captured by the imaging device 37 is stored in the storage device 35.

[0029] The image processing unit 36 includes a computer system. The image processing unit 36 includes a processor, a storage device including a non-volatile memory and a volatile memory, and an input / output unit including an input / output interface. The processor is, for example, a central processing unit (CPU). The non-volatile memory is, for example, a read only memory (ROM) or a storage. The volatile memory is, for example, a random access memory (RAM) or the like. The image processing unit 36 performs image recognition processing for capturing an image of the object to be sewn S by the imaging device 37 and detecting a recognition object UP (see Fig. 5) from the image, in accordance with a computer program stored in the storage device.

[0030] The imaging device 37 captures an image of the object to be sewn S. The imaging device 37 includes an optical system and an image sensor that receives light incident through the optical system. The image sensor includes a charge coupled device (CCD) image sensor or a complementary metal oxide semiconductor (CMOS) image sensor.

[0031] The illumination device 38 irradiates light toward an imaging field of view of the imaging device 37. The illumination device 38 includes a light source such as an LED light emitting element.

[0032] The communication device 39 communicates with the data processing unit 50 via the gateway 101 and the communication network 102. The communication device 39 includes a communication interface compliant with a wired or wireless communication standard.

[0033] The data processing unit 50 includes a computer system. The data processing unit 50 includes a processor 51, a storage device 52, and an input / output unit 53.

[0034] The data processing unit 50 may be connected to an input device or a display device (not illustrated). The input device is implemented by, for example, a keyboard, a mouse, operation keys, a microphone that receives voice input, or the like. The display device displays various information. The display device includes, for example, a flat panel display. The flat panel display is, for example, a liquid crystal monitor or an organic EL display.

[0035] In addition, the data processing unit 50 may also be a simple shared storage. When the data processing unit 50 is a simple shared storage, the input device or the display device becomes unnecessary. When the data processing unit 50 is a simple shared storage, the operation information to the input / output unit 53 is performed through communication.

[0036] The processor 51 is composed of a CPU, an MPU, and the like. The processor 51 operates based on a program stored in the storage device 52 and executes various processes. The processor 51 includes a master data management unit 51A and a data adjustment unit 51B. The master data management unit 51A and the data adjustment unit 51B implement various functions as the processor 51 execute a program. The master data management unit 51A and the data adjustment unit 51B may be configured separately with dedicated processors.

[0037] The master data management unit 51A creates, for example, generalized template data 71 illustrated in Fig. 8. The generalized template data 71 of Fig. 8 is generalized template data created by generalizing the template data 70 of a first sewing machine SM1. The generalized template data 71 is template data that is used for image recognition processing on an image of the object to be sewn S, and is data excluding individual differences among the sewing machines 1 and imaging conditions of images for each machine. Excluding the imaging conditions of images means generalizing and correcting into an ideal form using design values. Although data conversion processing may be performed in a centralized manner as in the configuration illustrated in Fig. 2, the system may alternatively be constructed in a distributed manner by providing this function on the sewing machine side. In general, the distributed configuration is more efficient and simpler, and is therefore easier to implement.

[0038] The data adjustment unit 51B acquires inherent data 60 of the plurality of imaging devices 37, and creates inherent template data 72 (see a second sewing machine SM2 in Fig. 8) for each imaging device based on the generalized template data 71 and the inherent data 60. The inherent template data 72 is template data in which an individual difference and an imaging condition of each imaging device 37 are reflected with respect to the generalized template data 71. This function is implemented by a computation equivalent to the generalization of the template data, and therefore can also be provided on the sewing machine side. When the system is of a distributed type in which the data conversion processing is implemented on the sewing machine side, the data processing unit 50 only needs to manage the generalized template data. As a result, there is no need to centrally manage data of all the plurality of sewing machines, and a simpler configuration can also be achieved.

[0039] The storage device 52 includes a primary storage device, which is a volatile memory that temporarily stores data, and a secondary storage device, which is a non-volatile memory that stores various programs and data used by the processor 51 for computation. The volatile memory is, for example, a RAM or the like. The non-volatile memory is, for example, a ROM, an HDD, an SSD, a storage, or the like. In the storage device 52, a program for implementing functions of the data processing unit 50 is stored. In the storage device 52, the inherent data 60 of each imaging device 37 is stored. In the storage device 52, the generalized template data 71 is stored as master data. By centrally managing the inherent data 60 of each imaging device 37, the safety of the data is ensured. However, since the data is also managed on each sewing machine 1, this function can be reduced in the data processing unit 50, thereby reducing the load.

[0040] The input / output unit 53 communicates with each of the sewing machines 1 via the communication network 102. The input / output unit 53 includes a communication interface compliant with a wired or wireless communication standard. The input / output unit 53 receives, for example, inherent data 60A or the template data 70 transmitted from the first sewing machine SM1 in Fig. 8. The input / output unit 53 transmits, to a second sewing machine SM2, inherent template data 72 in which inherent data 60B of (the imaging device 37 included in) the second sewing machine SM2 is reflected with respect to the generalized template data 71. When each sewing machine 1 is provided with a data conversion processing function as the master data management unit 51A and the data adjustment unit 51B, the input / output unit 53 transmits and receives the generalized template data 71 to and from each sewing machine 1.[Inherent Data]

[0041] Fig. 3 is an illustrative diagram of the inherent data 60 provided in the plurality of sewing machines 1. The inherent data 60 is data that is inherent to each imaging device 37 of the plurality of sewing machines 1. A difference between the inherent data 60 represents an individual difference of the imaging device 37 of each sewing machine 1. In the present embodiment, the inherent data 60 includes information related to imaging of the object to be sewn S. The information related to the imaging of the object to be sewn S corresponds to imaging conditions of the imaging device 37. Specifically, the inherent data 60 includes information on the imaging conditions inherent to each sewing machine 1. The information on the imaging conditions inherent to each sewing machine 1 is information resulting from variation factors such as individual differences and assembly errors of the imaging device 37 and the illumination device 38 of each sewing machine 1. Note that the inherent data 60 may include data other than those illustrated in Fig. 3.

[0042] The inherent data 60 is managed for each imaging device 37 of each sewing machine 1. Additionally, each time a template is captured, the inherent data 60 is embedded in a template data file. By embedding the inherent data 60 in the template data file each time imaging is performed, the corresponding data is always managed as a pair without being separated even after being output from the sewing machine to a communication line, thereby allowing reliable management. This is useful for sharing data not only between different sewing machines 1 but also between different imaging devices 37 of the same sewing machine 1.

[0043] The inherent data 60 includes, as imaging conditions, a pixel rate 61, an imaging offset 62, and illumination information 63 of the imaging device 37.

[0044] The pixel rate 61 of the imaging device 37 is information representing an actual distance per pixel of a captured image. The pixel rate 61 varies according to a distance between the imaging device 37 and a subject (object to be sewn S). The pixel rate 61 may be acquired through calibration in which an image of a measurement jig having a known distance between two points is captured and the number of pixels between the two points in the image is measured. By performing calibration at a plurality of distances and determining a regression line from each pixel rate at the plurality of distances, the pixel rate 61 for an arbitrary distance can be obtained.

[0045] The imaging offset 62 is information representing a deviation of a camera coordinate system of the imaging device 37 from a design value in the sewing machine coordinate system. The imaging offset 62 is information for correcting deviations caused by assembly errors of the imaging device 37, individual differences of the optical system of the imaging device 37, or the like. The individual differences of the optical system of the imaging device 37 include, for example, an optical axis deviation and a lens aberration. The imaging offset 62 includes information such as XYZ position coordinates of the imaging device 37, inclinations of a camera optical axis (in the θX direction and the θY direction), a rotation angle around the camera optical axis (in the θZ direction), and a lens distortion coefficient. The imaging offset 62 may be acquired through calibration in which a measurement jig of a known shape is positioned at a predetermined position and an image thereof is captured, and XY positional deviation, image distortion, and angular deviation are calculated from a position and a shape of the measurement jig appearing in the image.

[0046] The illumination information 63 is information representing an amount of illumination light emitted from the illumination device 38. The illumination information may be acquired through calibration in which an image of a predetermined subject is captured while changing a light quantity setting value of the illumination device 38, and a light quantity setting value that causes an image contrast to fall within a desired range is determined. The predetermined subject is, for example, the object to be sewn S. The illumination information 63 may further include information such as a luminance adjustment parameter or a look-up table when luminance adjustment is performed on a captured image by image processing.

[0047] In the sewing system 100 according to the present embodiment, a calibration operation is performed in advance for each of the imaging devices 37 of the plurality of sewing machines 1, so that the inherent data 60 including the pixel rate 61, the imaging offset 62, and the illumination information 63 is acquired for each sewing machine 1. Each of the plurality of sewing machines 1 stores, in the storage device 35, the inherent data 60 including the imaging conditions of the imaging device 37.[Object To Be Sewn]

[0048] Fig. 4 is a cross-sectional view illustrating a part of the object to be sewn S according to the present embodiment. Fig. 5 is a plan view illustrating a part of the object to be sewn S according to the present embodiment. Figs. 4 and 5 illustrate the object to be sewn S before a sewing process. In the present embodiment, the object to be sewn S is a skin material used for a vehicle seat.

[0049] As illustrated in Fig. 4, the object to be sewn S includes a surface material 4, a padding material 5, and a back material 6. A hole 7 is provided in the surface material 4.

[0050] A surface of the surface material 4 is a seating surface that comes into contact with a passenger when the passenger sits on a vehicle seat. The surface material 4 includes at least one of woven fabric, nonwoven fabric, and leather. The padding material 5 has elasticity. The padding material 5 includes, for example, a urethane resin. The back material 6 includes at least one of woven fabric, nonwoven fabric, and leather.

[0051] As illustrated in Fig. 5, the hole 7 is provided in plurality in the surface material 4. The holes 7 are formed to be distributed over the object to be sewn S. The holes 7 are arranged in a regular pattern. That is, the object to be sewn S includes a plurality of reference patterns DPh. Each reference pattern DPh is formed by a regular array of a plurality of holes 7. In the example of Fig. 5, the reference pattern DPh is composed of 17 holes 7.

[0052] As illustrated in Fig. 5, the reference patterns DPh are arranged on the surface material 4 at intervals. The reference patterns DPh are arranged at equal intervals in each of the X-axis direction and the Y-axis direction. The reference patterns DPh located at different positions in the Y-axis direction are arranged between the reference patterns DPh adjacent in the X-axis direction. No hole 7 is formed between adjacent reference patterns DPh.

[0053] In areas between the reference patterns DPh, target patterns RP (RP1, RP2, RP3, RP4, RP5, RP6, RP7, RP8, RP9, RP10) of stitches CH to be formed on the object to be sewn S are defined. Fig. 5 virtually illustrates the target pattern RP of the stitch CH on the object to be sewn S before sewing. The sewing machine 1 forms a stitch CH so as to follow each target pattern RP in accordance with a preset sewing pattern.

[0054] When performing a plurality of sewing processes to form a plurality of stitches CH, a first sewing process is performed to form a first stitch CH on the object to be sewn S on the basis of a first target pattern RP1, and following the first sewing process, a second sewing process is performed to form a second stitch CH on the object to be sewn S on the basis of a second target pattern RP2. Thereafter, the sewing processes from a third sewing process to an Nth sewing process are sequentially performed according to the number N of stitches CH that are to be formed. Fig. 5 illustrates an example in which N is 10, and the target patterns from the first target pattern RP1 to the tenth target pattern RP10 are defined.

[0055] In addition, a plurality of recognition objects UP (UP1, UP2, UP3, UP4, UP5, UP6, UP7) are arranged on the object to be sewn S. In the present embodiment, the recognition object UP is an array of the plurality of holes 7 existing in a predetermined pattern on the object to be sewn S. Specifically, the recognition object UP is a part of the reference pattern DPh. In the example of Fig. 5, the recognition object UP (UP1, UP2, UP3, UP4, UP5, UP6, UP7) is a pattern (an array of the holes 7) including one acute-angled corner portion of the reference pattern DPh having a rhombic outer shape. The recognition object UP is a pattern that can be specified by a template matching method, which is a type of image processing method.

[0056] Referring to Fig. 6, displacement that occurs on the surface of the object to be sewn S when a stitch CH is formed on the object to be sewn S having thickness and elasticity will be described. Fig. 6 is a cross-sectional view illustrating an example of the object to be sewn S according to the present embodiment. Fig. 6 illustrates the object to be sewn S after the sewing processing has been performed. The object to be sewn S has thickness and elasticity. When a stitch CH is formed on the object to be sewn S having thickness and elasticity, the object to be sewn S is highly likely to be contracted, as illustrated in Fig. 6. When the object to be sewn S is contracted, the surface of the object to be sewn S may be displaced. When the surface of the object to be sewn S is displaced, a target position of the stitch CH defined on the surface of the object to be sewn S is highly likely to be displaced in the XY plane. If the target position of the stitch CH is displaced in the XY plane, it becomes difficult to form the stitch CH at the target position when the object to be sewn S is moved to the position coordinates of the target pattern RP defined in design.

[0057] Therefore, in the present embodiment, a displacement amount (a correction amount for correcting the displacement amount) of the surface of the object to be sewn S is acquired by the image processing unit 36 (see Fig. 2). Even if the surface of the object to be sewn S is displaced due to the contraction of the object to be sewn S caused by the formation of the stitch CH, the object to be sewn S is moved according to the displacement amount by using the acquired displacement amount of the surface of the object to be sewn S such that a next stitch CH is to be formed at the target position. The image processing unit 36 detects the recognition object UP from the image of the object to be sewn S captured by the imaging device 37, and acquires the displacement amount on the basis of displacement of the recognition object UP.[Template Data]

[0058] Fig. 7 is an illustrative diagram of the template data 70 of the recognition object UP. The template data 70 is created using a first imaging device 37, which is any one of the plurality of imaging devices 37. Hereinafter, the sewing machine 1 including the first imaging device 37 used for creation of the template data 70 is referred to as a "first sewing machine SM1." In addition, among the plurality of sewing machines 1, sewing machines 1 other than the first sewing machine SM1 are referred to as "second sewing machines SM2." The second sewing machine SM2 is a sewing machine 1 including a second imaging device 37 other than the first imaging device 37.

[0059] The template data 70 is data used for image recognition processing of the recognition object UP. Specifically, the template data 70 is a captured image of the recognition object UP and is a reference image that is referenced in template matching. The template data 70 is acquired by capturing an image of the recognition object UP formed on the object to be sewn S by the first imaging device 37 of the first sewing machine SM1.

[0060] Accordingly, the template data 70 becomes an image that depends on the inherent data 60 of the first imaging device 37. That is, parameters such as a size, a distortion, an inclination, an average luminance, and a contrast of the recognition object UP included in the image of the template data 70 reflect the imaging conditions (the pixel rate 61, the imaging offset 62, the illumination information 63) of the first imaging device 37 of the first sewing machine SM1.

[0061] In an actual sewing operation, an image that is captured by the first sewing machine SM1 (the first imaging device 37) is captured under the same imaging conditions as those of the template data 70. Accordingly, in the first sewing machine SM1, the image of the object to be sewn S and the template data 70 related to the sewing operation have matching image parameters, and can be detected with high accuracy.

[0062] On the other hand, the image captured by the second imaging device 37 of the second sewing machine SM2 reflects the imaging conditions of the second imaging device 37 and has different image parameters from those of the image captured by the first imaging device 37. Accordingly, in the sewing operation, if the template data 70 created by the first sewing machine SM1 (the first imaging device 37) is used as it is by the second sewing machine SM2 (the second imaging device 37), the image parameters of the template data 70 and the image parameters of the image of the object to be sewn S captured by the second imaging device 37 may not match, thereby leading to a deterioration in detection accuracy of the recognition object UP.

[0063] Therefore, in the sewing system 100 according to the present embodiment, the inherent data 60 of the imaging device 37 of each sewing machine 1 is used to correct the mismatch between the imaging conditions of the template data 70 and the imaging conditions of the object to be sewn S by each imaging device 37.[Correction of Template Data]

[0064] Fig. 8 is an illustrative diagram of correction of the template data 70 by the sewing system 100 according to the present embodiment.

[0065] Fig. 8 illustrates processing of applying the template data 70 created by one first sewing machine SM1 (the first imaging device 37) to another second sewing machine SM2 (the second imaging device 37). Here, the inherent data 60 of the first sewing machine SM1 is referred to as inherent data 60A, and the inherent data 60 of the second sewing machine SM2 is referred to as inherent data 60B. In the present embodiment, the data processing unit 50 creates template data (inherent template data 72), in which the inherent data 60B of the second sewing machine SM2 is reflected, from the template data 70 created by the first sewing machine SM1. The template data 70 created by the first sewing machine SM1 reflects the inherent data 60A of the first sewing machine SM1, and therefore is also the inherent template data 72 of the first sewing machine SM1.

[0066] The data processing unit 50 acquires, from the first sewing machine SM1, the template data 70 created by the first sewing machine SM1 and the inherent data 60A of the first sewing machine SM1.

[0067] The data processing unit 50 creates generalized template data 71 obtained by generalizing (normalizing) the template data 70, based on the template data 70 and inherent data 60A of the first sewing machine SM1, by the master data management unit 51A.

[0068] That is, the template data 70 is inherent template data in which the inherent data 60A of the first sewing machine SM1 is reflected, and the inherent data 60A is known through calibration. To briefly explain the concept of normalization, each parameter is examined individually. The master data management unit 51A normalizes an image scale on the basis of the pixel rate 61 of the inherent data 60A. The generalized template data 71 is provided with information on the pixel rate 61, and therefore becomes normalized data that can be converted to a scale of a captured image under desired imaging conditions. Accordingly, the generalized template data 71 can be made to match the pixel rate 61 of an image captured by the second sewing machine SM2 by applying the pixel rate 61 of the inherent data 60B of the second sewing machine SM2 that uses the data.

[0069] The master data management unit 51A normalizes luminance information of the image on the basis of the illumination information 63 of the inherent data 60A. The generalized template data 71 is provided with the illumination information 63, and therefore becomes normalized data that can reproduce a luminance distribution of a captured image under desired capturing conditions. Accordingly, the generalized template data 71 can be made to match a luminance distribution (average luminance and contrast) of an image captured by the second sewing machine SM2 by applying the illumination information 63 of the inherent data 60B of the second sewing machine SM2 that uses the data.

[0070] The master data management unit 51A normalizes geometric information of an image on the basis of the imaging offset 62 of the inherent data 60A. That is, from the information on the imaging offset 62, an image position deviation, a distortion, and a deviation in rotation angle of the template data 70 are removed. In other words, the template data is converted into data obtained when the imaging device 37 is accurately attached at a designed position. The generalized template data 71 is converted into a certain reference position (here, a design value) on the basis of the information on the imaging offset 62a, and therefore becomes normalized data that can be converted into geometric conditions of a captured image under desired imaging conditions having a known relative positional relationship. Accordingly, the generalized template data 71 can be made to match geometric information of an image captured by the second sewing machine SM2 by applying the capturing offset 62 of the inherent data 60B of the second sewing machine SM2 that uses the data. In addition, when both the imaging offset of the inherent data 60A and the imaging offset of the inherent data 60B are available, it is also possible to directly calculate the conversion from the geometric information of the first sewing machine SM1 to the geometric information of the second sewing machine SM2 without using a generalization template.

[0071] The master data management unit 51A records the created generalized template data 71 as master data common to each sewing machine 1 in the storage device 52 (see Fig. 2).

[0072] The data processing unit 50 acquires the inherent data 60B of the second sewing machine SM2. The data processing unit 50 creates the inherent template data 72 for each sewing machine on the basis of the generalized template data 71 and the inherent data 60B by the data adjustment unit 51B.

[0073] That is, the data adjustment unit 51B acquires the inherent data 60B of the second sewing machine SM2, which is an application destination of the generalized template data 71, and creates template data (the inherent template data 72) in which the inherent data 60B of the second sewing machine SM2, which is an application destination, is reflected by applying the inherent data 60B to the generalized template data 71. The generalized template data 71 is created as one for all the sewing machines 1 (the sewing system 100). The inherent template data 72 is created separately for each sewing machine 1 (the imaging device 37).

[0074] Fig. 9 is a schematic diagram illustrating transmission of the inherent template data 72. In Fig. 9, the three second sewing machines SM2P, SM2Q, and SM2R are exemplified. The second sewing machines SM2P, SM2Q, and SM2R each transmit the inherent data 60B to the data processing unit 50. Here, the inherent data 60B of the second sewing machines SM2P, SM2Q, and SM2R is respectively referred to as inherent data 60P, 60Q, and 60R.

[0075] The data adjustment unit 51B creates inherent template data 72P of the second sewing machine SM2P by applying the inherent data 60P to the generalized template data 71, and transmits it to the second sewing machine SM2P. The data adjustment unit 51B creates inherent template data 72Q of the second sewing machine SM2Q by applying the inherent data 60Q to the generalized template data 71, and transmits it to the second sewing machine SM2Q. The data adjustment unit 51B creates inherent template data 72R of the second sewing machine SM2R by applying the inherent data 60R to the generalized template data 71, and transmits it to the second sewing machine SM2R.

[0076] The second sewing machines SM2P, SM2Q, and SM2R each execute image recognition processing by using their own inherent template data 72P, 72Q, and 72R acquired from the data processing unit 50. Note that the first sewing machine SM1 executes image recognition processing by using the template data 70 as it is, because the template data 70 created by the machine is the inherent template data 72 of the first sewing machine SM1.

[0077] In this way, in the present embodiment, the data processing unit 50 acquires the template data of the object to be sewn S created based on an image captured by the first sewing machine SM1 (the first imaging device 37) among the plurality of sewing machines 1 (the imaging devices 37), and transmits the data to another second sewing machine SM2 (second imaging device 37). Then, the second sewing machine SM2 executes image recognition processing by using the inherent template data 72 obtained by correcting the generalized template data 71 on the basis of its own inherent data 60.

[0078] Note that, here, an example is illustrated in which the data processing unit 50 creates the inherent template data 72 of each second sewing machine SM2 from the generalized template data 71. However, the creation of the inherent template data 72 is not limited to the above-described example. The generalized template data 71 may be distributed from the data processing unit 50 to the second sewing machines SM2, and each of the second sewing machines SM2 (the image processing units 36) may create the inherent template data 72 by using its own inherent data 60.

[0079] In addition, the second sewing machine SM2 may execute image recognition processing by using the generalized template data 71 instead of using the inherent template data 72, and may correct a recognition result obtained using the generalized template data 71, based on its own inherent data 60. For example, when an error from the design value of the imaging conditions of the sewing machine becomes sufficiently small as a result of calibration, the recognition object UP may be appropriately detected using the generalized template data 71 (or the template data 70 of the first sewing machine SM1). Therefore, after the image recognition processing during the sewing operation, appropriate image recognition of the object to be sewn S can be performed simply by correcting the XY position coordinates, rotation angle, and the like of the detected recognition object UP using the inherent data 60 of the sewing machine.[Sewing Method]

[0080] Fig. 10 is an illustrative diagram of a sewing method according to the present embodiment. Referring to Fig. 10, a transmission flow of the template data 70 in the sewing system 100 will be described.

[0081] First, in each of the plurality of sewing machines 1 (the plurality of imaging devices 37), an operation of acquiring the inherent data 60 is performed (S (step) 1). That is, the inherent data 60 including the pixel rate 61, the imaging offset 62, and the illumination information 63 of the imaging device 37 is acquired for each imaging device 37 through a calibration operation. The acquisition of the inherent data 60 is performed in any of the first sewing machine SM1 and the second sewing machine SM2 described above.

[0082] Next, the first sewing machine SM1 including the first imaging device 37, which is any one of the plurality of imaging devices 37, creates the template data 70 (S2). The control device 30 of the first sewing machine SM1 actually captures an image of the object to be sewn S by the first imaging device 37 of the first sewing machine SM1, and acquires an image of the recognition object UP. The image processing unit 36 of the first sewing machine SM1 creates the template data 70 (see Fig. 7), based on the acquired image of the recognition object UP.

[0083] Next, the data processing unit 50 creates the generalized template data 71 (S3). The data processing unit 50 acquires the template data 70 created in S2 and the inherent data 60A of the first imaging device 37 from the first sewing machine SM1 by the input / output unit 53. The master data management unit 51A creates the generalized template data 71 by normalizing the template data 70 using the inherent data 60A, and records it in the storage device 52.

[0084] Next, the data processing unit 50 creates the inherent template data 72 (S4). The data processing unit 50 acquires the inherent data 60B of the second imaging device 37 from another second sewing machine SM2, other than the first sewing machine SM1, by the input / output unit 53. The data adjustment unit 51B creates the inherent template data 72 of the second imaging device 37 of the second sewing machine SM2 by applying the inherent data 60B to the generalized template data 71 recorded in the storage device 52. The data adjustment unit 51B, when there are a plurality of second sewing machines SM2, creates the inherent template data 72 for each machine by using the inherent data 60B acquired from each second sewing machine SM2.

[0085] Next, the data processing unit 50 transmits the inherent template data 72 to the second sewing machine SM2 (S5). The data processing unit 50 transmits the corresponding inherent template data 72 to each second sewing machine SM2 by the input / output unit 53.

[0086] Thereafter, the plurality of sewing machines 1 each perform sewing processing. That is, the plurality of sewing machines 1 each acquire an image of the object to be sewn S by the imaging device 37, execute image recognition processing of the object to be sewn S by the image processing unit 36, and perform sewing based on a recognition result obtained by the image recognition processing. At this time, each second sewing machine SM2 executes image recognition processing by using the inherent template data 72 corrected by its own inherent data 60B. In addition, the first sewing machine SM1 executes image recognition processing by using the template data 70 created in S2 as its own inherent template data.

[0087] Note that, as described above, in the sewing method according to the present embodiment, the second sewing machine SM2 may correct the recognition result obtained using template data (the generalized template data 71) on the basis of the inherent data 60, instead of using the corrected template data (the inherent template data 72).[Sewing Machine]

[0088] Next, a specific example of the sewing machine 1 of the sewing system 100 will be described below. Fig. 11 is a perspective view illustrating the sewing machine 1 according to the present embodiment. Fig. 12 is a perspective view illustrating a part of the sewing machine 1 according to the present embodiment. The sewing machine 1 illustrated in Fig. 11 includes the sewing machine body 10, an operation device 20 that is operated by the operator Ma, the control device 30 that controls the sewing machine body 10, the image processing unit 36, and the plurality of imaging devices 37.

[0089] The sewing machine body 10 is mounted on an upper surface of a table 2. As illustrated in Fig. 12, the sewing machine body 10 includes a sewing machine frame 11, a needle bar 12, a throat plate 13, a holding member 15, an actuator 16, an actuator 17, and an actuator 18. The needle bar 12 and the throat plate 13 are each supported by the sewing machine frame 11. The holding member 15 is supported by the sewing machine frame 11 via a support member 14. The actuator 16 (see Fig. 11) generates power to move the needle bar 12. The actuator 17 (see Fig. 11) generates power to move the holding member 15. The actuator 18 (see Fig. 11) generates power to move at least a portion of the holding member 15. The actuator 16, the actuator 17, and the actuator 18 are examples of the actuator 10A illustrated in Fig. 2.

[0090] The sewing machine frame 11 includes a horizontal arm 11A, a bed 11B, a vertical arm 11C, and a head 11D. The horizontal arm 11A extends in the Y-axis direction. The bed 11B (see Fig. 11) is arranged lower than the horizontal arm 11A. The vertical arm 11C (see Fig. 11) is arranged to connect an end portion on the +Y side of the horizontal arm 11A and the bed 11B. The head 11D is arranged on the -Y side of the horizontal arm 11A.

[0091] The needle bar 12 holds a sewing needle 3. The needle bar 12 holds the sewing needle 3 such that the sewing needle 3 is parallel to the Z-axis. The needle bar 12 is supported by the head 11D so as to be movable in the Z-axis direction.

[0092] The throat plate 13 supports the object to be sewn S. The throat plate 13 supports the holding member 15. The throat plate 13 is supported by the bed 11B (see Fig. 11). The throat plate 13 is arranged lower than the holding member 15.

[0093] The holding member 15 holds the object to be sewn S. The holding member 15 is capable of moving while holding the object to be sewn S, in the XY plane including a sewing position Ps directly below the sewing needle 3. The holding member 15 is capable of holding the object to be sewn S in the XY plane including a position directly below the imaging device 37. The holding member 15 moves in the XY plane based on sewing data while holding the object to be sewn S. As a result, a stitch CH (see Fig. 6) is formed on the object to be sewn S having passed through the sewing position Ps. The holding member 15 is supported by the horizontal arm 11A via the support member 14.

[0094] The holding member 15 includes a pressing member 15A and a lower plate 15B facing the pressing member 15A. The pressing member 15A is a frame-shaped member. The pressing member 15A is movable in the Z-axis direction. The lower plate 15B is arranged below the pressing member 15A. The holding member 15 holds the object to be sewn S by sandwiching the object to be sewn S with the pressing member 15A and the lower plate 15B.

[0095] When the pressing member 15A moves in the +Z direction, the pressing member 15A and the lower plate 15B are separated from each other. As a result, the operator Ma can arrange the object to be sewn S between the pressing member 15A and the lower plate 15B. When the pressing member 15A moves in the -Z direction while the object to be sewn S is arranged between the pressing member 15A and the lower plate 15B, the object to be sewn S is sandwiched between the pressing member 15A and the lower plate 15B. As a result, the object to be sewn S is held by the holding member 15. In addition, when the pressing member 15A moves in the +Z direction, the object to be sewn S is released from being held by the holding member 15. As a result, the operator Ma can take out the object to be sewn S from between the pressing member 15A and the lower plate 15B.

[0096] As illustrated in Fig. 11, the actuator 16 generates power to move the needle bar 12 in the Z-axis direction. The actuator 16 includes a pulse motor. The actuator 16 is arranged on the horizontal arm 11A.

[0097] Inside the horizontal arm 11A, a horizontal arm shaft extending in the Y-axis direction is arranged. The actuator 16 is connected to an end portion on the +Y side of the horizontal arm shaft. An end portion on the -Y side of the horizontal arm shaft is connected to the needle bar 12 via a power transmission mechanism arranged inside the head 11D. By an operation of the actuator 16, the horizontal arm shaft rotates. The power generated by the actuator 16 is transmitted to the needle bar 12 via the horizontal arm shaft and the power transmission mechanism. As a result, the sewing needle 3 held by the needle bar 12 reciprocates in the Z-axis direction.

[0098] Inside the vertical arm 11C, a timing belt extending in the Z-axis direction is arranged. In addition, inside the bed 11B, a bed shaft extending in the Y-axis direction is arranged. A pulley is arranged on each of the horizontal arm shaft and the bed shaft. The timing belt is looped around each of the pulley arranged on the horizontal arm shaft and the pulley arranged on the bed shaft. The horizontal arm shaft and the bed shaft are connected to each other via the power transmission mechanism including the timing belt.

[0099] Inside the bed 11B, a shuttle is arranged. In the shuttle, a bobbin contained in a bobbin case is accommodated. By an operation of the actuator 16, each of the horizontal arm shaft and the bed shaft rotates. The power generated by the actuator 16 is transmitted to the shuttle via the horizontal arm shaft, the timing belt, and the bed shaft. As a result, the shuttle rotates in synchronization with reciprocation of the needle bar 12 in the Z-axis direction.

[0100] The actuator 17 generates power to move the holding member 15 in the XY plane. The actuator 17 includes a pulse motor. The actuator 17 includes an X-axis motor 17X that generates power to move the holding member 15 in the X-axis direction, and a Y-axis motor 17Y that generates power to move the holding member 15 in the Y-axis direction. The actuator 17 is arranged inside the bed 11B.

[0101] The power generated by the actuator 17 is transmitted to the holding member 15 via the support member 14. As a result, the holding member 15 can move in the X-axis direction and the Y-axis direction, respectively, between the sewing needle 3 and the throat plate 13. By an operation of the actuator 17, the holding member 15 can move while holding the object to be sewn S, in the XY plane including the sewing position Ps directly below the sewing needle 3.

[0102] The actuator 18 generates power to move the pressing member 15A of the holding member 15 in the Z-axis direction. The actuator 18 includes a pulse motor. When the pressing member 15A moves in the +Z direction, the pressing member 15A and the lower plate 15B are separated from each other. When the pressing member 15A moves in the -Z direction, the object to be sewn S is sandwiched between the pressing member 15A and the lower plate 15B.

[0103] As illustrated in Fig. 12, the sewing machine body 10 includes an intermediate pressing member 19 arranged around the sewing needle 3. The intermediate pressing member 19 presses the object to be sewn S around the sewing needle 3. The intermediate pressing member 19 is supported by the head 11D so as to be movable in the Z-axis direction. Inside the head 11D, an intermediate pressing motor is arranged that generates power to move the intermediate pressing member 19 in the Z-axis direction. By an operation of the intermediate pressing motor, the intermediate pressing member 19 moves in the Z-axis direction in synchronization with the needle bar 12. The intermediate pressing member 19 suppresses lifting of the object to be sewn S caused by movement of the sewing needle 3.

[0104] As illustrated in Fig. 11, the sewing machine 1 includes a drive amount sensor 31 that detects a drive amount of the actuator 16, and a drive amount sensor 32 that detects a drive amount of the actuator 17. The drive amount sensor 31 and the drive amount sensor 32 are examples of the drive amount sensor 10B of Fig. 2.

[0105] The control device 30 controls the actuator 16 on the basis of the detection data from the drive amount sensor 31. The control device 30 determines, for example, an operation timing of the actuator 16 on the basis of the detection data from the drive amount sensor 31.

[0106] The drive amount sensor 32 includes an X-axis sensor 32X that detects a drive amount of the X-axis motor 17X of the actuator 17, and a Y-axis sensor 32Y that detects a drive amount of the Y-axis motor 17Y of the actuator 17. The X-axis sensor 32X includes an encoder that detects a rotation amount of the X-axis motor 17X. The Y-axis sensor 32Y includes an encoder that detects a rotation amount of the Y-axis motor 17Y. Detection data of the drive amount sensor 32 is output to the control device 30. The control device 30 controls the actuator 17 on the basis of the detection data from the drive amount sensor 32. The control device 30 feedback-controls the actuator 17 so that the holding member 15 moves to a target position, based on the detection data from the drive amount sensor 32.

[0107] The drive amount sensor 32 serves as a position sensor that detects a position of the holding member 15 in the XY plane. The drive amount of the actuator 17 and a movement amount of holding member 15 correspond to each other on a one-to-one basis.

[0108] The X-axis sensor 32X can detect a movement amount of the holding member 15 in the X-axis direction from the origin in the sewing machine coordinate system by detecting a rotation amount of the X-axis motor 17X. The Y-axis sensor 32Y can detect a movement amount of the holding member 15 in the Y-axis direction from the origin in the sewing machine coordinate system by detecting a rotation amount of the Y-axis motor 17Y.

[0109] The operation device 20 receives an operation input from the operator Ma. When the operation device 20 is operated, the sewing machine 1 is operated. The operation device 20 includes an operation panel 21 and an operation pedal 22. The operation panel 21 is mounted on the upper surface of the table 2. The operation pedal 22 is arranged below the table 2. The operator Ma operates the operation pedal 22 with a foot. The sewing machine 1 operates when at least one of the operation panel 21 and the operation pedal 22 is operated by the operator Ma.

[0110] The plurality of imaging devices 37 capture images of the object to be sewn S held by the holding member 15. The plurality of imaging devices 37 are arranged higher than the throat plate 13 and the holding member 15. The plurality of imaging devices 37 each capture, from above, an image of at least a portion of the object to be sewn S held by the holding member 15. The number of imaging devices 37 is not particularly limited. Fig. 11 illustrates an example in which four imaging devices 37 are provided.[Imaging Device]

[0111] Fig. 13 is a plan view illustrating an arrangement example of the imaging devices 37 according to the present embodiment. The plurality of imaging devices 37 are arranged, for example, as illustrated in Fig. 13.

[0112] The plurality of imaging devices 37 are arranged at intervals in the horizontal plane so as to be aligned with the sewing machine body 10. The plurality of imaging devices 37 are arranged in a sewing area SA. The sewing area SA is a range in the XY plane in which the object to be sewn S can be moved by the holding member 15 and sewn by the head 11D. At a center of the sewing area SA, the head 11D (i.e., the sewing position Ps) is arranged. The plurality of imaging devices 37 are aligned to follow the head 11D of the sewing machine body 10.

[0113] In the example of Fig. 13, the sewing machine 1 includes imaging units 40A and 40B that are arranged one on each of both sides (+X side and -X side) so as to be adjacent to the head 11D in the X-axis direction. The plurality of imaging devices 37 can be attached to the imaging units 40A and 40B. The imaging units 40A and 40B are arranged above the sewing area SA. The imaging units 40A and 40B are fixed to the sewing machine 1.

[0114] In the example of Fig. 13, two imaging devices 37 are attached to an attachment portion 41A of the imaging unit 40A, and two imaging devices 37 are also attached to an attachment portion 41B. The two imaging devices 37 of the imaging unit 40A are arranged along a longitudinal direction (X-axis direction) of the sewing area SA. Two imaging devices 37 are attached to an attachment portion 41C of the imaging unit 40B, and two imaging devices 37 are also attached to an attachment portion 41D. The two imaging devices 37 of the imaging unit 40B are arranged along a width direction (Y-axis direction) of the sewing area SA.

[0115] The imaging device 37 acquires an image of at least a portion of the object to be sewn S arranged in the imaging field of view. Each of the plurality of imaging devices 37 is arranged to have an overlapping region JA in which its imaging field of view partially overlaps with that of another adjacent imaging device 37. Specifically, the imaging device 37 of the attachment portion 41A has an imaging field of view 42A. The imaging device 37 of the attachment 41B has an imaging field of view 42B. The imaging field of view 42A and the imaging field of view 42B have an overlapping region JA having a rectangular shape and extending in the Y-axis direction. By the imaging field of view 42A and the imaging field of view 42B, an enlarged imaging region 43A is formed. The enlarged imaging region 43A is a region formed by combining the imaging fields of view of the plurality of imaging devices 37 that share the overlapping region JA. The imaging field of view 42A and the imaging field of view 42B aligned in the X-axis direction form the wide enlarged imaging region 43A extending in the X-axis direction.

[0116] The imaging device 37 of the attachment portion 41C has an imaging field of view 42C. The imaging device 37 of the attachment portion 41D has an imaging field of view 42D. The imaging field of view 42C and the imaging field of view 42D have an overlapping region JA having a rectangular shape and extending in the X-axis direction. By the imaging field of view 42C and the imaging field of view 42D, an enlarged imaging region 43B is formed. The imaging field of view 42C and the imaging field of view 42D aligned in the Y-axis direction form the wide enlarged imaging region 43B extending in the Y-axis direction.

[0117] In the configuration of Fig. 13, a size of the imaging field of view of the imaging device 37, a size of the overlapping region JA (an interval between the attachment portions), and the number of imaging devices 37 are set according to a dimension of the target pattern RP of the object to be sewn S (see Fig. 5). That is, the enlarged imaging regions 43A and 43B formed by the plurality of imaging devices 37 are designed to have a shape that encompasses the entirety of one target pattern RP of the object to be sewn S. The object to be sewn S on which a stitch CH extending in the X-axis direction is formed can be arranged and imaged in the enlarged imaging region 43A of the imaging unit 40A, and the object to be sewn S on which a stitch CH extending in the Y-axis direction is formed can be arranged and imaged in the enlarged imaging region 43B of the imaging unit 40B. Accordingly, even when forming a stitch CH extending in either direction, an image of the entire target pattern RP can be captured without changing attachment positions of the imaging devices 37.

[0118] Note that the position of each imaging device 37 is fixed at one of the six attachment positions. A relative position between the imaging device 37 and the sewing machine frame 11 is fixed. A relative position between an optical axis of the imaging device 37 and the sewing needle 3 (the sewing position Ps) in the XY plane is fixed. Relative position data representing the relative position between a center of each of the enlarged imaging regions 43A and 43B and the sewing needle 3 in the XY plane is known data that can be derived from design data of the sewing machine 1.

[0119] A position of an image acquired by the imaging device 37 is defined in the camera coordinate system. The position of the image defined in the camera coordinate system is converted into a position of the image defined in the sewing machine coordinate system by a predetermined transformation formula or transformation matrix.

[0120] In addition, the imaging units 40A and 40B hold a plurality of illumination devices 38A and 38B. The imaging units 40A and 40B hold the illumination devices 38A and 38B fixed above the sewing area SA. The illumination devices 38A and 38B are examples of the illumination device 38 of Fig. 2.

[0121] In the imaging unit 40A, the illumination devices 38A (three in total) are arranged one on each of both outer sides of the array of the attachment portion 41A and the attachment portion 41B aligned along the X-axis direction, and one between the attachment portion 41A and the attachment portion 41B. Each illumination device 38A extends linearly along the Y-axis. Each illumination device 38A irradiates light in the form of epi-illumination toward the imaging fields of view set below the attachment portions 41A and 41B. In the imaging unit 40B, the illumination devices 38B (three in total) are arranged one each on both outer sides of the array of the attachment portion 41C and the attachment portion 41D aligned along the Y-axis direction, and one between the attachment portion 41C and the attachment portion 41D. Each illumination device 38B extends linearly along the X-axis. Each illumination device 38B irradiates light in the form of epi-illumination toward the imaging fields of view set below the attachment portions 41C and 41D.[Image Processing]

[0122] Next, image processing using the plurality of imaging devices 37 will be described. The image processing unit 36 (see Fig. 11) acquires images relating to the object to be sewn S from the plurality of imaging devices 37. When the object to be sewn S is positioned at a predetermined imaging position by the control device 30, the image processing unit 36 controls operations of the imaging device 37 and the illumination device 38 corresponding to the imaging position, and acquires an image relating to the object to be sewn S.

[0123] In Fig. 13, the imaging position Pf is set at the center of each of the enlarged imaging regions 43A and 43B. Imaging is performed with the central portion of the holding member 15 (the object to be sewn S) arranged at one of the imaging positions Pf of the enlarged imaging regions 43A and 43B. For example, in the imaging unit 40A, when the object to be sewn S is arranged at the imaging position Pf of the enlarged imaging region 43A, the image processing unit 36 turns on the illumination device 38A and causes the imaging device 37 of the attachment portion 41A and the imaging device 37 of the attachment portion 41B to perform imaging substantially simultaneously. As a result, an image corresponding to the imaging field of view 42A and an image corresponding to the imaging field of view 42B are acquired. In the imaging unit 40B, when the object to be sewn S is arranged at the imaging position Pf of the enlarged imaging region 43B, the image processing unit 36 turns on the illumination device 38B and causes the imaging device 37 of the attachment portion 41C and the imaging device 37 of the attachment portion 41D to perform imaging substantially simultaneously. The imaging may be performed in sequence.

[0124] The image processing unit 36 performs image stitching processing for stitching together the images captured by the plurality of imaging devices 37 when the recognition object UP is positioned at a boundary between the images captured by the plurality of imaging devices 37. In this case, it is necessary to align the coordinate systems of the two imaging devices 37. The imaging conditions of one imaging device 37 are matched to those of the other imaging device 37. That is, the data conversion processing using the inherent data 60 of Fig. 3 is performed not between the sewing machines 1, but between the imaging devices 37 of the same sewing machine 1. The image processing unit 36 stitches together a plurality of images constituting the enlarged imaging region (43A or 43B) on the basis of image portions of the overlapping regions JA with each other, thereby generating one composite image 46 (see Fig. 15). Accordingly, the composite image 46 is an image that captures a range corresponding to the enlarged imaging region 43A or 43B. The enlarged imaging regions 43A and 43B have a size that encompasses a plurality of recognition objects UP of the object to be sewn S (see Fig. 5). Therefore, the composite image 46 is an image that captures the plurality of recognition objects UP. Preferably, the composite image 46 includes all of the recognition objects UP (UP1 to UP7) detected when forming one stitch CH.

[0125] The image processing unit 36 executes image recognition processing for detecting the plurality of recognition objects UP from the composite image 46. The image processing unit 36 acquires the position coordinates of the recognition object UP in the composite image 46 through matching with the inherent template data 72. The image processing unit 36 sequentially detects the plurality of recognition objects UP included in the composite image 46, and acquires the position coordinates of each of the plurality of recognition objects UP.

[0126] The image processing unit 36 generates correction data for correcting displacement of the surface of the object to be sewn S, based on the detection result obtained by the image processing unit 36.

[0127] Here, the sewing data stored in the storage device 35 (see Fig. 2) includes the target pattern RP of the stitch CH that is formed on the object to be sewn S, the position coordinates of the recognition object UP, and movement conditions of the holding member 15.

[0128] The target pattern RP defines a target shape of the stitch CH that is formed on the object to be sewn S and a target position of the stitch CH in the sewing machine coordinate system.

[0129] The movement conditions of the holding member 15 include a movement trajectory of the holding member 15 defined in the sewing machine coordinate system. The movement trajectory of the holding member 15 includes a movement trajectory of the holding member 15 in the XY plane. The movement conditions of the holding member 15 are determined based on the target pattern RP.

[0130] The target pattern RP of the sewing data is generated on the assumption that the object to be sewn S is not contracted, and is stored in the control device 30. When displacement occurs on the surface of the sewing target S, the image processing unit 36 obtains a displacement amount of the detected recognition object UP, and generates correction data for correcting sewing data.

[0131] The image processing unit 36 transmits the correction data calculated by the image processing unit 36 to the control device 30. The control device 30 executes sewing processing on the basis of the correction data.[Sewing Operation]

[0132] Fig. 14 is a flow chart showing a sewing operation of the sewing machine 1 according to the present embodiment. The sewing operation of the sewing machine 1 includes an imaging process S11, an image stitching process S12, a recognition object detection process S13, a correction data calculation process S14, a sewing process S15, and an end determination process S16.(Imaging Process)

[0133] The imaging process S11 is a process for capturing images of the object to be sewn S by the plurality of imaging devices 37. Whether to acquire an image of the enlarged imaging region 43A extending in the X-axis direction by the imaging unit 40A or to acquire an image of the enlarged imaging region 43B extending in the Y-axis direction by the imaging unit 40B is set in advance by the operator Ma, or by the control device 30 based on sewing data. The control device 30 moves the holding member 15 holding the object to be sewn S and arranges the holding member 15 at a preset imaging position. The image processing unit 36 performs imaging by the plurality of set imaging devices 37 when the holding member 15 is arranged at the corresponding imaging position Pf.

[0134] Hereinafter, as an example, a case in which an image of the enlarged imaging region 43A is acquired by each imaging device 37 of the imaging unit 40A of Fig. 13 will be described. In this case, the image processing unit 36 acquires an image corresponding to the imaging field of view 42A and an image corresponding to the imaging field of view 42B by the imaging device 37 of the attachment portion 41A and the imaging device 37 of the attachment portion 41B.(Image Stitching Process)

[0135] The image stitching process S12 is a process for stitching together the images of the object to be sewn S captured by the plurality of imaging devices 37. Fig. 15 is a schematic diagram illustrating the image stitching process S12.

[0136] As illustrated in Fig. 15, the image obtained by the imaging device 37 of the attachment portion 41A is defined as a first image 44. The image obtained by the imaging device 37 of the attachment portion 41B is defined as a second image 45. In this case, the second image 45 includes a region on the +X direction side with respect to the first image 44. The first image 44 corresponds to the imaging field of view 42A, and the second image 45 corresponds to the imaging field of view 42B. The first image 44 and the second image 45 share the overlapping region JA.

[0137] The overlapping region JA of the first image 44 and the second image 45 includes image elements GE that are common to at least a portion of the recognition object UP. That is, as illustrated in Fig. 5, when the recognition object UP is an array of the plurality of holes 7 existing in a predetermined pattern in the object to be sewn S, the image element GE is an image of each hole 7. The hole 7 is a component that constitutes the recognition object UP or the reference pattern DPh. In Fig. 15, for convenience of description, an example is illustrated in which the array of the holes 7 is simplified such that the holes 7 are arranged in an array pattern vertically and horizontally. The image processing unit 36 may, prior to the image stitching process S12, binarize each image obtained in the imaging process S11. In this case, the template data 70 (the generalized template data 71, the inherent template data 72) also becomes a binarized image.

[0138] As illustrated in Fig. 15, the image processing unit 36 detects the image elements GE included in the overlapping region JA of the first image 44 and the image elements GE included in the overlapping region JA of the second image 45, respectively. Since the position coordinates of the imaging centers of the imaging devices 37 attached to the attachment portions 41A and 41B and the sizes of the imaging fields of view 42A and 42B are known, the range of the overlapping region JA in each image is known. The image processing unit 36 selects three or more image elements GE included in the overlapping regions JA, and transforms the second image 45 such that the selected image elements GE match those in the first image 44. The transformation of the second image 45 is, for example, performed by affine transformation. As a result of the transformation, the first image 44 and the second image 45 after the transformation (hereinafter referred to as second image 45A) substantially match each other in the images of the overlapping regions JA.

[0139] The image processing unit 36 generates a composite image 46 by stitching together the first image 44 and the second image 45A. For the pixels constituting the overlapping region JA, the pixels from one of the first image 44 and the second image 45A may be used, or the pixel information of both may be averaged. In this way, in the image stitching process S12, the composite image 46 having a size corresponding to the enlarged imaging region 43A is generated.(Recognition Object Detection process)

[0140] Next, the recognition object detection process S13 of Fig. 14 is a process for detecting the recognition object UP from the composite image 46 generated by the image stitching process S12 and acquiring the position coordinates of the detected recognition object UP. Fig. 16 is a schematic diagram illustrating the recognition object detection process S13.

[0141] As illustrated in Fig. 16, the image processing unit 36 extracts, from within the composite image 46, images of recognition regions AR in which detection processing for the recognition objects UP is performed. The recognition region AR is set to a range that takes into account an assumed positional deviation amount of the recognition object UP associated with stitch formation, with respect to the design position coordinates of the recognition object UP set in the sewing data. Fig. 16 schematically illustrates the setting of the recognition regions AR for the target pattern RP having an arbitrary shape. The image processing unit 36 sets the recognition region AR for each of the plurality of recognition objects UP to be detected in one stitch formation, and acquires extracted images obtained by cutting out images of the set recognition regions AR. For example, in the example of Fig. 5, the recognition region AR is set for each of the seven recognition objects UP from the recognition object UP1 to the recognition object UP7.

[0142] The image processing unit 36 sequentially performs image recognition processing using a template matching method on each extracted image acquired. The image processing unit 36 reads out the inherent template data 72 from the storage device 35, and acquires the position coordinates of the recognition object UP in the extracted image (recognition region AR) through matching with the inherent template data 72.

[0143] Through the recognition object detection process S13, the image processing unit 36 acquires the position coordinates in the sewing machine coordinate system of each of the recognition objects UP (UP1 to UP7) to be detected in one stitch formation.(Correction Data Calculation Process)

[0144] The correction data calculation process S14 is a process for calculating correction data for correcting displacement of the surface of the object to be sewn S, based on the detection result obtained by the recognition object detection process S13. The image processing unit 36 calculates a displacement amount of the recognition object UP from an initial position to a current position, based on the initial position and the current position of the recognition object UP related to the current sewing process. The initial position of the recognition object UP is design position coordinates of the recognition object UP set in the sewing data. The current position of the recognition object UP is position coordinates of the recognition object UP detected by the recognition object detection process S13. The image processing unit 36 calculates, based on the calculated displacement amount, correction position coordinates of each correction point CP (see Fig. 14) on the target pattern RP such that the stitch CH is formed at a target position in the sewing machine coordinate system, and calculates correction data for the target pattern RP passing through the correction point CP. Note that, in a first sewing process, the displacement of the surface of the object to be sewn S caused by stitch formation has not occurred, and therefore displacement of the recognition object UP also does not occur. Therefore, in the first sewing process, the target pattern RP in an initial state defined by the sewing data is used as it is, so no correction data is calculated.(Sewing Process)

[0145] The sewing process S15 is a process for forming a stitch CH on the basis of the target pattern RP. The sewing process S15 is performed as each unit of the sewing machine 1 is controlled by the control device 30. The sewing process includes sewing processes from a first sewing process to an Nth sewing process. The first sewing process is performed based on the target pattern RP in the initial state defined by the sewing data. In the first sewing process, the control device 30 outputs a control command to the actuator 17 so that a stitch CH is formed in accordance with the target pattern RP in the initial state defined by the sewing data. The sewing processes from the second sewing process to the Nth sewing process are performed based on the correction data (the target pattern RP after correction) calculated by the correction data calculation process S14. From the second sewing process onward, the control device 30 acquires the correction data from the image processing unit 36, and outputs a control command to the actuator 17 so that a stitch CH is formed in accordance with the target pattern RP of the acquired correction data.

[0146] The end determination process S16 is a process for determining whether the sewing process for the object to be sewn S has been completed. The control device 30 determines whether the sewing process for the object to be sewn S has been completed on the basis of the sewing data. In a state in which the sewing processes from the first sewing process to the (N-1) sewing process have been completed, the control device 30 determines in the end determination process S16 that the sewing process has not been completed. In a state in which the Nth sewing process has been completed, the control device 30 determines in the end determination process S16 that the sewing process has been completed.

[0147] Accordingly, during the sewing processes from the first sewing process to the Nth sewing process, each time one sewing process is completed, the imaging process S11, the image stitching process S12, the recognition object detection process S13, and the correction data calculation process S14 are performed, whereby the correction data for the next sewing process is calculated, and the next sewing process is performed based on the calculated correction data. Such a series of processes is repeated.

[0148] As described above, in the example illustrated in Figs. 11 to 16, the plurality of sewing machines 1 of the sewing system 100 each include the plurality of imaging devices 37 having the overlapping region JA in which the imaging fields of view (42A and 42B, 42C and 42D) partially overlap with each other. Then, the image recognition processing based on the template data (the inherent template data 72) is performed on the composite image 46 obtained by stitching together the plurality of images acquired from the plurality of imaging devices 37.

[0149] Accordingly, the plurality of recognition objects UP detected in one sewing process for the stitch CH can be detected from the composite image 46 obtained by a single imaging operation performed by the plurality of imaging devices 37. As a result, compared with a case where each recognition object UP is individually captured and detected by one imaging device 37, the processing time required for the imaging process S11, the recognition object detection process S13, and the correction data calculation process S14, which are performed for each sewing process, is reduced.

[0150] On the other hand, when creating a wide-range composite image 46 by stitching together images obtained from the plurality of imaging devices 37, the imaging field of view of each imaging device 37 also becomes larger, and the influence of variations in imaging conditions of each imaging device 37 also increases. Therefore, compared with a case where each recognition object UP is individually captured and detected simply by one imaging device 37, the difference between the imaging conditions at the time of creating the template data 70 in the first sewing machine SM1 and the imaging conditions in the second sewing machine SM2 has a greater effect on the image recognition processing. Therefore, the configuration of the present embodiment, in which the difference between the imaging conditions of the template data 70 and those of the second sewing machine SM2 can be corrected by the inherent data 60, is effective in achieving recognition accuracy in image recognition processing using the composite image 46.[Effects]

[0151] As described above, according to the present embodiment, the second sewing machine SM2 (the sewing machine 1 including the second imaging device 37) executes image recognition processing by using the template data (the inherent template data 72) corrected based on the inherent data 60B of the second imaging device 37. Accordingly, in the second sewing machine SM2, the template data 70 created by the first sewing machine SM1 (the sewing machine 1 including the first imaging device 37) and reflecting the imaging conditions inherent to the first sewing machine SM1 is corrected so as to match the imaging conditions inherent to the second sewing machine SM2, and image recognition processing is performed. As a result, it is not necessary to separately create the template data 70 for each of the plurality of sewing machines 1 of the sewing system 100. In addition, the manager Mb only needs to manage one template data 70 (the generalized template data 71) created in the data processing unit 50 by the first sewing machine SM1, and does not need to manage separate template data (the inherent template data 72) for each sewing machine 1. As a result, the work man-hours and data management man-hours affecting image recognition in the sewing system 100 including the plurality of sewing machines 1 can be reduced. Note that the second sewing machine SM2 may perform image recognition processing by using the template data 70 created by the first sewing machine SM1, and correct the recognition result on the basis of the inherent data 60B of the second sewing machine SM2. Also in this case, the work man-hours and data management man-hours affecting image recognition can be reduced.

[0152] In addition, as illustrated in Figs. 12 and 13, also in the configuration in which one sewing machine 1 includes the plurality of imaging devices 37 (i.e., the first imaging device 37 and the second imaging device 37), the similar effect is achieved by correcting the template data 70 created by the first imaging device 37 on the basis of the inherent data 60 of the second imaging device 37, or by correcting the image recognition result using the template data 70 on the basis of the inherent data 60 of the second imaging device 37.

[0153] In addition, according to the present embodiment, since the data processing unit 50 includes the master data management unit 51A that creates the generalized template data 71, elements attributable to the inherent data 60A of the first sewing machine SM1 can be excluded from the template data 70 created by the first sewing machine SM1 (the sewing machine 1 including the first imaging device 37). As a result, when creating the inherent template data 72 of the second sewing machine SM2 (the sewing machine 1 including the second imaging device 37), there is no need to use the inherent data 60A of the first sewing machine SM1, which serves as a source for creating the template data 70, each time, so the data management man-hours can be reduced. In addition, since the data processing unit 50 includes the data adjustment unit 51B that creates the inherent template data 72 for each imaging device on the basis of the generalized template data 71 and the inherent data 60, it is possible to acquire the inherent template data 72 suitable for the second sewing machine SM2 without needing to correct the image recognition result of the second sewing machine SM2 each time.[Other Embodiments]

[0154] In the above-described embodiment, the example has been illustrated in which the inherent template data 72 for the second sewing machine SM2 is created from the template data 70 of the first sewing machine SM1 and transmitted to the second sewing machine SM2. However, in the present disclosure, the correction of template data is not limited to the above-described example. The data processing unit 50 may transmit the template data 70 and inherent data 60A of the first sewing machine SM1 as they are to the second sewing machine SM2, and the second sewing machine SM2 may correct the template data 70 (create the inherent template data 72) on the basis of a difference between the inherent data 60A of the first sewing machine SM1 and the inherent data 60B of the second sewing machine SM2. In addition, when the difference in the imaging conditions is small, the second sewing machine SM2 may execute image recognition processing by using the template data 70 of the first sewing machine SM1 as it is, and correct the recognition result obtained using the template data 70 on the basis of the difference between the inherent data 60A of the first sewing machine SM1 and the inherent data 60B of the second sewing machine SM2.

[0155] In the above embodiment, the master data management unit 5 1A that creates the generalized template data 71 is provided in the data processing unit 50. However, the generalized template data 71 does not need to be created. As described above, the inherent template data 72 of the second sewing machine SM2 may be created using the template data 70 and inherent data 60A of the first sewing machine SM1 and the inherent data 60B of the second sewing machine SM2. In this case, the template data 70 and inherent data 60A of the first sewing machine SM1 may be managed as master data, rather than the generalized template data 71.

[0156] In the above embodiment, the data processing unit 50 is provided with the data adjustment unit 51B that creates the inherent template data 72 for each sewing machine. However, the data processing unit 50 may not be provided with the data adjustment unit 51B. The generalized template data 71 may be transmitted from the data processing unit 50 to each of the second sewing machines SM2, and each of the second sewing machines SM2 may create its own inherent template data 72 by using its own inherent data 60.

[0157] In the above embodiment, the example has been illustrated in which the sewing machine 1 is provided with the plurality of imaging devices 37 and the image recognition processing is executed using the composite image 46 obtained by stitching together a plurality of images. However, the number of imaging devices 37 provided in the sewing machine 1 may be one. The sewing machine 1 may capture an image of the object to be sewn S a plurality of times and execute image recognition processing on each image.

[0158] The present disclosure includes the following aspects. (1) A sewing system including: a plurality of imaging devices configured to acquire images of an object to be sewn; one or a plurality of sewing machines configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn; and a data processing unit configured to acquire template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of imaging devices and to transmit the template data to another second imaging device, wherein the sewing machine includes inherent data including imaging conditions of the imaging devices, and the sewing machine including the second imaging device executes image recognition processing by using the template data corrected based on the inherent data of the second imaging device, or corrects a recognition result obtained using the template data, based on the inherent data of the second imaging device. (2) The sewing system according to the above (1), wherein the inherent data includes a pixel rate, an imaging offset, and illumination information of the imaging device. (3) The sewing system according to the above (1) or (2), wherein the data processing unit includes a master data management unit configured to create generalized template data by generalizing template data, based on the template data and inherent data of the first imaging device, and the sewing machine including the second imaging device executes image recognition processing by using inherent template data obtained by correcting the generalized template data on the basis of its own inherent data, or corrects a recognition result obtained using the generalized template data, based on its own inherent data. (4) The sewing system according to the above (3), wherein the data processing unit includes a data adjustment unit configured to acquire the inherent data of the plurality of imaging devices, and to create the inherent template data for each imaging device on the basis of the inherent data and the inherent template data including the inherent data of the imaging device used in creating the generalized template data or a template, and the sewing machine including the second imaging device performs image recognition processing by using its own inherent template data acquired from the data processing unit. (5) The sewing system according to any one of the above (1) to (4), wherein the sewing machine includes a plurality of the imaging devices having overlapping regions in which their imaging fields of view partially overlap with each other, and performs image recognition processing based on the template data on a composite image obtained by stitching together a plurality of images obtained from the plurality of imaging devices. (6) A sewing method using a plurality of sewing machines, each of which includes an imaging device configured to acquire an image of an object to be sewn and is configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn, or a sewing method using a sewing machine including a plurality of the imaging devices, the sewing method including: acquiring template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of sewing machines or the plurality of imaging devices, and transmitting the template data to another second imaging device; and in the sewing machine including the second imaging device, executing image recognition processing by using the template data corrected based on inherent data including an imaging condition of the second imaging device, or correcting a recognition result obtained using the template data, based on the inherent data.

[0159] The present application is based on Japanese Patent Application No. 2023-108670 filed on June 30, 2023, the contents of which are incorporated herein by reference.

Claims

1. A sewing system comprising: a plurality of imaging devices configured to acquire images of an object to be sewn; one or a plurality of sewing machines configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn; and a data processing unit configured to acquire template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of imaging devices and to transmit the template data to another second imaging device, wherein the sewing machine comprises inherent data comprising imaging conditions of the imaging devices, and the sewing machine comprising the second imaging device performs image recognition processing by using the template data corrected based on the inherent data of the second imaging device, or corrects a recognition result obtained using the template data, based on the inherent data of the second imaging device.

2. The sewing system according to claim 1, wherein the inherent data comprises a pixel rate, an imaging offset, and illumination information of the imaging device.

3. The sewing system according to claim 1 or 2, wherein the data processing unit comprises a master data management unit configured to create generalized template data by generalizing template data, based on the template data and inherent data of the first imaging device, and the sewing machine comprising the second imaging device executes image recognition processing by using inherent template data obtained by correcting the generalized template data on the basis of its own inherent data, or corrects a recognition result obtained using the generalized template data, based on its own inherent data.

4. The sewing system according to claim 3, wherein the data processing unit comprises a data adjustment unit configured to acquire the inherent data of the plurality of imaging devices, and to create the inherent template data for each imaging device on the basis of the inherent data and the inherent template data including the inherent data of the imaging device used in creating the generalized template data or a template, and the sewing machine comprising the second imaging device performs image recognition processing by using its own inherent template data acquired from the data processing unit.

5. The sewing system according to any one of claims 1 to 4, wherein the sewing machine comprises a plurality of the imaging devices having overlapping regions in which their imaging fields of view partially overlap with each other, and performs image recognition processing based on the template data on a composite image obtained by stitching together a plurality of images obtained from the plurality of imaging devices.

6. A sewing method using a plurality of sewing machines, each of which comprises an imaging device configured to acquire an image of an object to be sewn and is configured to perform sewing based on a recognition result obtained through image recognition processing of the object to be sewn, or a sewing method using a sewing machine comprising a plurality of the imaging devices, the sewing method comprising: acquiring template data of the object to be sewn created based on an image captured by a first imaging device among the plurality of sewing machines or the plurality of imaging devices, and transmitting the template data to another second imaging device; and in the sewing machine including the second imaging device, executing image recognition processing by using the template data corrected based on inherent data including an imaging condition of the second imaging device, or correcting a recognition result obtained using the template data, based on the inherent data.

Images