Sewing system

Abstract

To reduce power consumption of a sewing machine.SOLUTION: A sewing system comprises: a plurality of sewing machines that operate in a normal mode and a low power waiting mode to wait with a lower power consumption than the normal mode; and a control part connected to the plurality of sewing machines through network. The control part acquires information relating to operating state from the plurality of sewing machines and transmits instruction to shift to the low power waiting mode to the sewing machine with the operating state satisfying a mode switching condition among the plurality of sewing machines.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a sewing system. [Background technology]

[0002] There is known an electric sewing machine that uses an electric motor as a power source. Patent Document 1 describes a driving device for a stepping motor of a sewing machine that controls ON / OFF of a switching element so that when the stepping motor is stopped, the current flowing from the coil due to self-induction of the coil flows back to the coil itself. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2009-095148 A Summary of the Invention [Problem to be solved by the invention]

[0004] As the activities for the Sustainable Development Goals (SDGs) become more active, there is room for improvement in reducing the power consumption of conventional sewing machines. In particular, there is a demand for reducing the power consumption of sewing machines in sewing factories that have multiple sewing machines.

[0005] An aspect of the present invention aims to reduce the power consumption of a sewing machine. [Means for solving the problem]

[0006] According to one aspect of the present invention, a sewing system includes a plurality of sewing machines that operate in a normal mode and a low-power standby mode in which the sewing machines are in standby mode with lower power consumption than the normal mode, and a control unit that controls the mode switching of the plurality of sewing machines, and the control unit acquires information regarding the operating status of the plurality of sewing machines and sends an instruction to transition to the low-power standby mode to a sewing machine among the plurality of sewing machines whose operating status satisfies a mode switching condition. Effect of the Invention

[0007] According to an aspect of the present invention, the power consumption of a sewing machine can be reduced. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a configuration diagram of a sewing system. [Diagram 2] FIG. 2 is a perspective view showing the sewing machine according to the embodiment. [Diagram 3] FIG. 3 is a perspective view showing a part of the sewing machine according to the embodiment. [Figure 4] FIG. 4 is a perspective view showing a part of the sewing machine according to the embodiment. [Diagram 5] FIG. 5 is a block diagram illustrating an example of a functional configuration of the sewing machine according to the embodiment. [Figure 6] FIG. 6 is a block diagram illustrating an example of the configuration of a management device. [Figure 7] FIG. 7 is an explanatory diagram showing an example of switching from the normal mode to the low power standby mode. [Figure 8] FIG. 8 is an explanatory diagram illustrating an example of the operation result information. [Figure 9] FIG. 9 is a flowchart showing an example of a process of switching to the low power standby mode by the sewing system. [Figure 10] FIG. 10 is a flowchart showing an example of a process for stopping the power supply to the sewing machine by the sewing system. [Figure 11] FIG. 11 is a configuration diagram of a sewing system according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment according to the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiment. The components of the embodiments described below can be appropriately combined. In addition, some components may not be used.

[0010] [Sewing system] FIG. 1 is a configuration diagram of a sewing system 500. As shown in FIG. 1, the sewing system 500 includes a plurality of sewing machines 1 and a management device 400 that manages the plurality of sewing machines 1. The plurality of sewing machines 1 and the management device 400 are configured to be able to communicate with each other via a network NW. In the example shown in FIG. 1, the sewing machines 1 are illustrated as five machines, namely, sewing machine 1A, sewing machine 1B, sewing machine 1C, sewing machine 1D, and sewing machine 1E, but when describing contents common to these sewing machines, they are referred to as "sewing machine 1" and overlapping descriptions are omitted.

[0011] The sewing system 500 is configured as a production facility for sewn products in a sewing factory or the like. Each of the multiple sewing machines 1 performs sewing to manufacture the same or different types of sewn products. The management device 400 communicates with the multiple sewing machines 1 via a network NW and manages each of the sewing machines 1.

[0012] In the example of FIG. 1, the sewing system 500 has a power supply unit 300 that supplies power to a plurality of sewing machines 1. The power supply unit 300 constitutes part of a power supply facility (such as a distribution board) in a facility such as a sewing factory. The power supply unit 300 supplies power, for example, from a commercial power source to each sewing machine 1. The power supply unit 300 is also communicably connected to a management device 400 via a network NW. Note that the solid lines connecting the various parts in FIG. 1 indicate communication paths (wired or wireless) through the network NW, and the dashed lines indicate power supply paths from the power supply unit 300. The management device 400 may receive power from the power supply unit 300 or from another power source.

[0013] [sewing machine] Next, an example of the configuration of the sewing machine 1 will be described. A local coordinate system is defined in the sewing machine 1. In the embodiment, the local coordinate system defined in the sewing machine 1 is appropriately referred to as the sewing machine coordinate system. The sewing machine coordinate system is defined by an XYZ orthogonal coordinate system. In the embodiment, the positional relationship of each part will be described based on the sewing machine coordinate system. The direction parallel to the X axis in a predetermined plane is defined as the X axis direction. The direction parallel to the Y axis in a predetermined plane perpendicular to the X axis is defined as the Y axis direction. The direction parallel to the Z axis perpendicular to the predetermined plane is defined as the Z axis direction. The rotation direction or tilt direction around the X axis is defined as the θX direction. The rotation direction or tilt direction around the Y axis is defined as the θY direction. The rotation direction or tilt direction around the Z axis is defined as the θZ direction. In the embodiment, the plane including the X axis and the Y axis is appropriately referred to as the XY plane. The XY plane is parallel to the predetermined plane. In the embodiment, the XY plane and the horizontal plane are parallel to each other. The Z axis direction is the up-down direction. The +Z direction is the upward direction and the -Z direction is the downward direction. Note that the XY plane may be inclined with respect to the horizontal plane.

[0014] FIG. 2 is a perspective view showing an example of the configuration of the sewing machine 1. FIGS. 3 and 4 are each a perspective view showing a part of the sewing machine 1. In the embodiment, the sewing machine 1 is an electronic cycle sewing machine, but the sewing machine 1 is not limited to this. The type of the sewing machine 1 is not limited to the examples shown in FIGS. 2 to 4, and any type of sewing machine 1 may be used. The sewing machine 1 includes a table 2, a frame 3, a head 4, a head rotation device 5, a holding member 6, a holding member moving device 7, a shuttle 8 (see FIG. 4), a shuttle rotation device 9 (see FIG. 4), a power switch 10, a start switch 11, a pause switch 12, an emergency stop switch 13, and an operation panel 14.

[0015] The table 2 is a base on which each part of the sewing machine 1 is assembled. The upper surface of the table 2 is a working surface for sewing work.

[0016] The frame 3 is supported on the upper surface of the table 2. The frame 3 has a first pillar portion 31 installed at a corner on the +X side and +Y side of the table 2, a second pillar portion 32 installed at a corner on the -X side and +Y side of the table 2, and a beam portion 30 connecting an upper end portion of the first pillar portion 31 and an upper end portion of the second pillar portion 32. The frame 3 is a so-called gate-shaped frame.

[0017] The head 4 is supported by the beam 30 of the frame 3. The head 4 is disposed above the holding member 6. The head 4 supports a needle bar 40 (see FIG. 3). With the head 4 supporting the needle bar 40, the head 4 is rotatable about a rotation axis AX that is perpendicular to the upper surface of the table 2. In the embodiment, the rotation axis AX is substantially parallel to the Z axis. A cover member 33 is disposed around the head 4.

[0018] As shown in Fig. 3, needle bar 40 is supported by head 4 so as to be movable back and forth in the Z-axis direction. Needle bar 40 holds sewing needle 41. Needle bar 40 holds sewing needle 41 so that sewing needle 41 is parallel to the Z-axis. In this embodiment, rotation axis AX (see Fig. 2) and sewing needle 41 coincide with each other.

[0019] As shown in Fig. 2, a thread winding device 16 is provided on the table 2. As shown in Fig. 3, a thread stand 17 is provided on the head 4. The upper thread is supplied from the thread winding device 16 through the thread stand 17 to a sewing needle 41. The upper thread is passed through a needle eye 42 of the sewing needle 41.

[0020] 2, the head rotating device 5 generates power to rotate the head 4 about a rotation axis AX. The head rotating device 5 includes an electric actuator such as a stepping motor.

[0021] The holding member 6 holds the sewing object 50. The holding member 6 is a frame-shaped member. The holding member 6 holds the sewing object 50 by clamping the periphery of the sewing object 50 from above and below. The holding member 6 is supported on the upper surface of the table 2 so as to be movable. The holding member 6 is movable while holding the sewing object 50 on the upper surface of the table 2 including the sewing position directly below the sewing needle 41. The holding member 6 is movable within an XY plane parallel to the upper surface of the table 2.

[0022] The holding member moving device 7 generates power to move the holding member 6 in the XY plane. The holding member moving device 7 is disposed on the upper surface of the table 2. The holding member moving device 7 has an X-axis moving device 7X that moves the holding member 6 in the X-axis direction, and a Y-axis moving device 7Y that moves the holding member 6 in the Y-axis direction. The X-axis moving device 7X has an X-axis guide member extending in the X-axis direction at the edge of the +Y side of the table 2, and an X-axis driving section including an electric motor and a ball screw mechanism. The Y-axis moving device 7Y has a Y-axis guide member extending in the Y-axis direction, and a Y-axis driving section including an electric motor and a ball screw mechanism.

[0023] The head 4 has a presser foot 43 (see FIG. 3) that presses down the sewing object 50 from above. The presser foot 43 has an opening through which the sewing needle 41 passes. The presser foot 43 presses down the sewing object 50 around the sewing needle 41. The sewing needle 41 moves back and forth in the Z-axis direction. The presser foot 43 prevents the sewing object 50 from lifting up due to the movement of the sewing needle 41. The sewing needle 41 penetrates the sewing object 50 held down by the presser foot 43.

[0024] 3, needle plate 20 is disposed below needle bar 40. Needle plate 20 is fixed to table 2. Needle plate 20 is disposed directly below needle bar 40. Needle plate 20 has an opening 26 through which sewing machine needle 41 can pass.

[0025] As shown in FIG. 4, the shuttle 8 is disposed directly below the needle plate 20. A bobbin case is housed in the shuttle 8. The bobbin case holds a bobbin wound with a lower thread. The shuttle 8 supplies the lower thread to cooperate with the sewing needle 41 to form a stitch on the sewing object 50. The shuttle 8 is supported by a support member 80. The support member 80 is disposed so as to surround the shuttle 8.

[0026] The shuttle 8 rotates about the rotation axis CX as the sewing needle 41 moves back and forth. The rotation axis CX is substantially parallel to the XY plane. When the sewing needle 41, which has penetrated the sewing object 50, rises, a loop of the upper thread is formed. The loop of the upper thread is hooked on the tip of the rotating shuttle 8. The loop of the upper thread hooked on the tip spreads with the rotation of the shuttle 8 and passes through the surface of the bobbin case. When the loop of the upper thread is released from the tip, the upper thread is attracted to the sewing object 50 and entangles with the lower thread. The upper thread and the lower thread are entangled to form a stitch on the sewing object 50.

[0027] The shuttle 8 rotates about the rotation axis AX in synchronization with the head 4. That is, the head 4 and the shuttle 8 rotate together about the rotation axis AX. The shuttle 8 and the support member 80 rotate together about the rotation axis AX. The relative positions of the shuttle 8 and the support member 80 are constant.

[0028] The hook rotation device 9 generates power to rotate the hook 8 about the rotation axis AX. The hook rotation device 9 includes an electric actuator such as a stepping motor. The hook rotation device 9 drives the head 4 and the hook 8 to rotate together about the rotation axis AX.

[0029] As shown in FIG. 2, the power switch 10, the start switch 11, the pause switch 12, the emergency stop switch 13, and the operation panel 14 are arranged on the edge of the table 2 and are operated by an operator. The power switch 10 is operated to turn on the power supply of the sewing machine 1. The start switch 11 is operated to start the operation of the sewing machine 1, and the sewing process by the sewing machine 1 is started. The sewing process refers to a process of forming a stitch on the sewing object 50. In the embodiment, the sewing machine 1 forms a stitch on the sewing object 50 based on sewing data created in advance. With the holding member 6 holding the sewing object 50, the holding member 6 moves in an XY plane including a sewing position based on the sewing data, thereby forming a stitch on the sewing object 50. The pause switch 12 is operated to stop the operation of the sewing machine 1. The emergency stop switch 13 is operated to forcibly stop the operation of the sewing machine 1.

[0030] Operation panel 14 is mounted on the upper surface of table 2. Operation panel 14 displays various information related to sewing machine 1 and receives various information related to the operation of sewing machine 1. Operation panel 14 has an input device 18 and a display device 19. Input device 18 is realized by a touch screen that specifies an input position or coordinates on the display surface of display device 19. Display device 19 is realized by a display device such as a liquid crystal display or an organic EL display.

[0031] [Sewing machine function configuration] FIG. 5 is a block diagram showing an example of a functional configuration of the sewing machine 1 according to the embodiment. As shown in FIG. 5, the sewing machine 1 has a control unit 110, a storage unit 120 connected to the control unit 110, a communication unit 130, the above-mentioned operation panel 14, a power supply circuit 150, and a sewing machine motor 160. The control unit 110 is composed of a central processing unit such as a CPU (Central Processing Unit). The storage unit 120 stores a program executed by the control unit 110 and functions as a work area for the control unit 110. The control unit 110 controls the functional units of the sewing machine 1 according to data and commands, thereby realizing various functions. The functional units include, but are not limited to, the operation panel 14, the communication unit 130, and the sewing machine motor 160, for example.

[0032] The storage unit 120 can store various information such as a program 121, sewing machine information 122, and sewn product information 123. The program 121 is a program that causes the control unit 110 to execute functions for implementing processes related to various operations of the sewing machine 1. The sewing machine information 122 has information such as a sewing machine ID assigned to the sewing machine 1. The sewn product information 123 is information on the sewn product that the sewing machine 1 sews (manufactures), and is acquired from the management device 400. The sewn product information 123 includes ID information (product number) of the sewn product. The sewn product information 123 may include design data of the sewing portion of the sewing object 50, and the like. The sewn product is manufactured by sewing according to the design data.

[0033] The communication unit 130 communicates with, for example, other communication devices. The communication unit 130 can support various communication standards. The communication unit 130 transmits and receives various information via, for example, a wired or wireless network. The communication unit 130 supplies the received information to the control unit 110. The communication unit 130 transmits the information to a destination instructed by the control unit 110.

[0034] The operation panel 14 has an input device 18 and a display device 19. The input device 18 accepts input from an operator or the like, and supplies the input information to a control unit 110. The display device 19 displays various information under the control of the control unit 110.

[0035] The power supply circuit 150 supplies power obtained from the power supply unit 300 to each functional unit of the sewing machine 1, including the control unit 110 and the memory unit 120. When the power switch 10 is turned on, power is supplied to the power supply circuit 150 from the power supply unit 300. When the power switch 10 is turned off, the power supply circuit 150 cuts off the power supply from the power supply unit 300. The power supply circuit 150 may include a power converter that converts the power supplied from the power supply unit 300 into a predetermined voltage and current to be supplied to the functional units. The power supply circuit 150 may include a circuit that measures the voltage and current of each functional unit.

[0036] The sewing machine motor 160 is a drive source for various mechanisms of the sewing machine 1. The sewing machine motor 160 includes, for example, a stepping motor, a servo motor, etc. The sewing machine motor 160 generates power for the reciprocating mechanism of the sewing needle 41 using power from the power supply circuit 150. The operation of the sewing machine motor 160 is controlled by the control unit 110. The sewing machine motor 160 includes motors for the head rotation device 5, the holding member moving device 7, the hook rotation device 9, etc. described above.

[0037] The control unit 110 is a computer that controls the functional units that operate using the power supplied by the power supply circuit 150. The control unit 110 transmits information about the operating state of the sewing machine 1 to the management device 400 via the communication unit 130. The information about the operating state is not particularly limited as long as it is information that can identify whether the sewing machine 1 is in an operating state or a non-operating state. In this embodiment, the control unit 110 transmits the operating state itself of the sewing machine 1 (i.e., whether it is in an operating state or a non-operating state). In this specification, the operating state is a state in which the sewing machine motor 160 reciprocates the needle bar 40 (sewing needle 41), and the non-operating state is a state in which the needle bar 40 (sewing needle 41) is stopped. The control unit 110 acquires the operating state based on the operation of the sewing machine motor 160.

[0038] The sewing machine 1 according to this embodiment operates in a normal mode and a low-power standby mode in which the sewing machine 1 is on standby with lower power consumption than in the normal mode. The control unit 110 controls switching between the normal mode and the low-power standby mode. The control unit 110 switches from the normal mode to the low-power standby mode in response to an instruction received from the management device 400. The control unit 110 switches from the low-power standby mode to the normal mode in response to a return instruction from the management device 400 or an input operation on the operation panel 14 or the start switch 11.

[0039] The normal mode is a mode in which the sewing machine 1 operates by power supply from the power supply unit 300, and is a mode in which the power consumption reduction control in the low power standby mode is not performed. In the normal mode, the sewing machine motor 160 operates, the power supply circuit 150 controls the voltage and current to the sewing machine motor 160, and the control unit 110 controls each functional unit. In the normal mode, the sewing machine 1 can perform sewing operations (can be in an operating state). In the normal mode, the control unit 110 performs holding control of the sewing machine motor 160, control of the power supply circuit 150, and operation control of each functional unit by the control unit 110 even when the sewing machine 1 is in a non-operating state. Holding control is control that holds the control positions of each motor and actuator of the sewing machine 1, such as the position of the needle bar 40, the position of the head rotation device 5, the position of the holding member moving device 7, and the position of the shuttle rotation device 9, so that they do not change. As a result, in the normal mode, the sewing work that has been temporarily stopped can be resumed as is.

[0040] The low power standby mode is a mode in which the device operates by power supply from the power supply unit 300, and is a mode in which each functional unit is turned off or in a standby state to reduce power consumption. The low power standby mode is a mode in which sewing operation is on standby, and is therefore executed only in a non-operating state. In the low power standby mode, the control unit 110 turns off the power supply to the sewing machine motor 160 and does not perform holding control. Therefore, the power consumption required for holding control is reduced compared to the normal mode. In the low power standby mode, the control unit 110 does not perform current and voltage control for the sewing machine motor 160 by the power supply circuit 150. Therefore, the power consumption in the power supply circuit 150 is reduced compared to the normal mode. In the low power standby mode, the control unit 110 may stop a part of the power generation operation of the power supply circuit 150. Specifically, the control unit 110 may stop the operation of the power generation circuit for driving the sewing machine motor 160 of the power supply circuit 150. In the low power standby mode, the control unit 110 transitions to a standby state or turns off the power supply to maintain only the minimum functions. Therefore, the power consumption of the control unit 110 is reduced compared to the normal mode. On the other hand, even in the low power standby mode, the power supply to functions used for preparing for the next sewing operation (such as the holding member moving device 7 related to setting the sewing object 50 and lighting (not shown)) may be maintained.

[0041] [Management device] The management device 400 is, for example, a computer, a server device, etc. Fig. 6 is a block diagram showing an example of the configuration of the management device 400. As shown in Fig. 6, the management device 400 includes a display unit 410, an operation unit 420, a communication unit 430, a storage unit 440, and a control unit 450. The control unit 450 is electrically connected to the display unit 410, the operation unit 420, the communication unit 430, the storage unit 440, etc.

[0042] The display unit 410 can display various information under the control of the control unit 450. The display unit 410 has a display panel such as a liquid crystal display, an organic EL display, etc. The display unit 410 displays various information in response to a signal input from the control unit 450.

[0043] The operation unit 420 has one or more devices for accepting user operations. The devices for accepting user operations include, for example, keys, buttons, a touch screen, a mouse, etc. The operation unit 420 can supply a signal corresponding to the accepted operation to the control unit 450.

[0044] The communication unit 430 can communicate with, for example, the sewing machine 1, the power supply unit 300, and other communication devices. The communication unit 430 can support various communication standards. The communication unit 430 transmits and receives various information via, for example, a wired or wireless network NW. The communication unit 430 can supply the received information to the control unit 450. The communication unit 430 transmits the information to a destination instructed by the control unit 450.

[0045] The storage unit 440 can store programs and data. The storage unit 440 is also used as a work area for temporarily storing processing results of the control unit 450. The storage unit 440 can store various information, such as a program 441, management information 442, and operation record information 443. The program 441 causes the control unit 450 to execute functions such as managing multiple sewing machines 1. The management information 442 has information such as the operation status of each sewing machine 1, the current mode (whether normal mode or low power standby mode), and sewn product information 123 currently being sewn. The operation record information 443 will be described later.

[0046] The control unit 450 is an arithmetic processing device. The control unit 450 can execute commands included in the program 441 stored in the storage unit 440 while referring to the information stored in the storage unit 440 as necessary. The control unit 450 controls the configuration of the sewing machine 1 in accordance with the data and commands, thereby achieving various functions.

[0047] By executing the program 441, the control unit 450 can provide a function for managing the operating state of each of the multiple sewing machines 1, in particular a function for controlling switching between a normal mode and a low-power standby mode. That is, the control unit 450 performs control for switching between modes of the multiple sewing machines 1.

[0048] Specifically, the control unit 450 acquires information about the operating state from the sewing machine 1, and transmits an instruction to switch to the low power standby mode to the sewing machine 1 whose operating state satisfies the mode switching condition. In response to this, the control unit 450 performs control to switch the sewing machine 1 from the normal mode to the low power standby mode according to the operating state of the sewing machine 1.

[0049] In this embodiment, the mode switching condition includes that the continuous non-operating time of the sewing machine 1 exceeds a set value V. The control unit 450 acquires the continuous non-operating time based on information on the operating state periodically acquired from the sewing machine 1. The continuous non-operating time is the length of time that the sewing machine 1 remains in the non-operating state after transitioning from the operating state to the non-operating state. In other words, the continuous non-operating time is the length of time that the needle bar 40 of the sewing machine 1 is continuously stopped. When the sewing machine 1 enters the non-operating state, the control unit 450 counts the continuous non-operating time of the sewing machine 1. When the count value of the continuous non-operating time reaches the set value V (threshold value), the control unit 450 determines that the sewing machine 1 satisfies the mode switching condition and transitions the sewing machine 1 to the low-power standby mode.

[0050] Fig. 7 is an explanatory diagram showing an example of switching from the normal mode to the low power standby mode. Fig. 7 shows a graph of the change in the operating state of the sewing machine 1, with the vertical axis of the graph representing the operating state and the horizontal axis representing the elapsed time. The operating state is represented by two values, "operating" and "not operating."

[0051] In FIG. 7, the periods from time t0 to time t1, from time t2 to time t3, from time t4 to time t5, and from time t6 onwards correspond to the continuous non-operating time. In the example of FIG. 7, the control unit 450 determines that the mode switching condition is satisfied at the timing (time tc) when the continuous non-operating time reaches the set value V after time t4. The control unit 450 transmits an instruction to the sewing machine 1 to transition to the low-power standby mode at time tc. As a result, the sewing machine 1 operates in the low-power standby mode from time tc. In FIG. 7, at time t5, for example, the operator turns on the start switch 11 to start sewing work, and the sewing machine 1 returns from the low-power standby mode to the normal mode. The control unit 450 can also transmit an instruction to return to the normal mode to the sewing machine 1 in the low-power standby mode in response to an operation input to the operation unit 420, for example.

[0052] The length of the non-operating time from time t0 to time t1 and the length of the non-operating time from time t2 to time t3 are shorter than the set value V. Therefore, the control unit 450 does not switch to the low power standby mode during these continuous non-operating times. In the example of Fig. 7, the sewing machine 1 operates in the normal mode from time t0 to time tc and from time t5 onwards.

[0053] The set value V (threshold value) of the continuous non-operation time can be set by a user, such as an administrator of the sewing system 500, through manual input using the operation unit 420. Alternatively, the control unit 450 may set the set value V of the continuous non-operation time by itself. For example, the control unit 450 can calculate the set value V of the continuous non-operation time based on the operation record information 443 (see FIG. 6).

[0054] Specifically, the control unit 450 acquires operation record information 443 (see FIG. 6) of the sewing machine 1 and records it in the storage unit 440. The operation record information 443 is information indicating changes in the operation state of the sewing machine 1 over time, and is log data in which the operation state is associated with time information and accumulated and recorded. The control unit 450 obtains a representative value representing multiple continuous non-operational times in past results from the operation record information 443, and calculates a setting value V for the continuous non-operational time (i.e., a mode switching condition) according to the representative value.

[0055] Fig. 8 is an explanatory diagram showing an example of the operation result information 443. Fig. 8 shows the operation result information 443 in a graph format, in which the vertical axis of the graph represents the operation state and the horizontal axis represents the elapsed time.

[0056] In this embodiment, the operation performance information 443 is acquired by a teaching operation for measuring the operation performance. When manufacturing sewn products in a sewing factory, the operation time and non-operation time vary due to various external factors. The teaching operation here means that irregular external factors are eliminated as much as possible, sewing work is actually performed with the sewing machine 1 according to standard sewing content and work flow, and the change in the operation state at that time is measured.

[0057] In the example shown in Figure 8, it can be seen that sewing work on a first sewn product was carried out during the operating time from time t11 to time t12, sewing work on a second sewn product was carried out during the operating time from time t13 to time t14, sewing work on a third sewn product was carried out during the operating time from time t15 to time t16, and sewing work on a fourth sewn product was carried out during the operating time from time t17 to time t18.

[0058] The control unit 450 obtains the maximum (longest) continuous non-operating time from the operation result information 443 covering a certain period as shown in Fig. 8. In the example of Fig. 8, the continuous non-operating time from time t14 to time t15 is the maximum. The control unit 450 calculates, for example, a time length obtained by adding a certain margin (allowance time) to the maximum continuous non-operating time as the setting value V of the mode switching condition.

[0059] The non-operating time of the sewing machine 1 may include the time required to move the sewn product, the time required for the worker to rest and deal with problems, the time required for preparation work before and after sewing, etc. Among these, the length of non-operating time required for preparation work before and after sewing varies depending on the type of sewn product. In other words, depending on the type of sewn product, some preparation work before sewing takes a long time, while others can be completed in a short time. Therefore, the length of operation time and the maximum length of non-operating time in the operation record information 443 shown in FIG. 8 may vary depending on the type of sewn product.

[0060] Therefore, the control unit 450 can record the operation record information 443 of the sewing machine 1 for each sewn product. For example, the product number of the sewn product included in the management information 442 and the operation record information 443 for manufacturing the sewn product with that product number are recorded in association with each other. Then, the control unit 450 calculates a set value V of the continuous non-operation time corresponding to the sewn product based on the operation record information 443. In this case, the set value V(A) corresponding to the product number (A) is applied when sewing the product number (A), and the set value V(B) corresponding to the product number (B) is applied when sewing the product number (B), and so on, so that the set value V is changed for each sewn product. This makes it possible to optimize the switching to the power-saving standby mode for each sewn product.

[0061] The mode switching condition may be other than the continuous non-operating time of the sewing machine 1.

[0062] For example, the mode switching condition includes at least one of the arrival of a predetermined time and the occurrence of a predetermined event. For example, a total break time set in a sewing factory in which the sewing system 500 is installed is set in the control unit 450. When the start time of the break time arrives, the control unit 450 determines that the mode switching condition is satisfied, and when the end time of the break time arrives, the control unit 450 determines that the mode switching condition is no longer satisfied. Instead of setting the break time by time, the break time or the like may be registered in the control unit 450 as an event. When a break event occurs, the control unit 450 determines that the mode switching condition is satisfied, and when the break event ends, the control unit 450 determines that the mode switching condition is no longer satisfied.

[0063] [Coordination with the power supply unit] In addition to switching to the power-saving standby mode described above, power consumption can be further reduced by turning on and off the power supply itself to each sewing machine 1. As shown in Fig. 1, the power supply unit 300 is connected to a control unit 450 (see Fig. 6) of the management device 400 via a network NW. This allows the control unit 450 to control the power supply to the multiple sewing machines 1 via the power supply unit 300.

[0064] When the sewing machine 1 that has transitioned to the low power standby mode satisfies the power stopping condition, the control unit 450 transmits to the power supply unit 300 an instruction to stop the supply of power to the sewing machine 1 that satisfies the power stopping condition.

[0065] 1, the power supply unit 300 that has received the instruction stops the power supply to the corresponding sewing machine 1. This stops the power supply itself to the sewing machine 1. This also makes it possible to reduce the power consumption (so-called standby power) that occurs in the low power standby mode.

[0066] The power stopping condition includes, for example, all sewing machines 1 belonging to a predetermined group transitioning to a low power standby mode. The predetermined group is composed of two or more sewing machines 1 that are preset among the multiple sewing machines 1 included in the sewing system 500. For example, among the five sewing machines 1 shown in FIG. 1, sewing machines 1A, 1B, and 1C may be grouped in the same group, and sewing machines 1D and 1E may be grouped in another group. The predetermined group may include all sewing machines 1 included in the sewing system 500. That is, in the example of FIG. 1, all of the sewing machines 1A to 1E may be grouped in one group.

[0067] The number of sewing machines 1 belonging to a given group can be set appropriately according to the scale (total number of sewing machines 1) of the sewing system 500. When there are multiple production lines that manufacture sewn products, the sewing machines 1 belonging to one production line may be considered as one group. The power supply unit 300 can switch the power supply to each sewing machine 1 on and off for each group or for each sewing machine 1 individually.

[0068] The control unit 450 transmits an instruction to the power supply unit 300 to stop the power supply to all sewing machines 1 belonging to the group that satisfies the power stopping condition. Upon receiving the instruction, the power supply unit 300 collectively stops the power supply to all sewing machines 1 belonging to the corresponding group on a group basis.

[0069] Stopping the power supply by the power supply unit 300 is particularly suitable for switching to a low-power standby mode at a predetermined time or when an event occurs. This is because all of the sewing machines 1 belonging to a group are in a non-operating state at the same time during a predetermined time period, such as a lunch break in a sewing factory. This allows the management device 400 (control unit 450) to collectively power off the sewing machines 1 belonging to the group by simply setting the time period in advance, without the worker having to operate the power switch 10 of each of the sewing machines 1 individually.

[0070] Note that the control unit 450 transmits an instruction to the power supply unit 300 to resume power supply when the group to which power supply has been stopped no longer satisfies the power stopping condition or in response to an input operation by the operation unit 420. Upon receiving the instruction, the power supply unit 300 resumes power supply to all sewing machines 1 belonging to the corresponding group collectively on a group basis.

[0071] [Sewing system operation] Next, an example of the operation of the sewing system 500 will be described. Fig. 9 is a flowchart showing an example of a switching process to the low power standby mode by the sewing system 500. The process procedure shown in Fig. 9 is realized by cooperation between the control unit 450 of the management device 400 and the control unit 110 of each sewing machine 1. The process procedure shown in Fig. 9 is repeatedly executed.

[0072] 9, immediately after startup, control unit 110 of each sewing machine 1 starts operating in normal mode (step S1). Control unit 450 of management device 400 starts acquiring information related to the operating status of each sewing machine 1 (step S2A). That is, control unit 110 of each sewing machine 1 starts transmitting information related to the operating status to management device 400 via communication unit 130 (step S2B). Control unit 450 of management device 400 receives the operating status transmitted from each sewing machine 1 via network NW via communication unit 430.

[0073] The control unit 450 of the management device 400 determines whether or not the mode switching condition is met for each sewing machine 1 based on the information on the operating state acquired from each sewing machine 1 (step S3). Specifically, the control unit 450 determines whether or not the continuous non-operating time of the sewing machine 1 has exceeded a set value. If a switching time or event is set as the mode switching condition, the control unit 450 determines whether or not the time has arrived or the event has occurred. If the control unit 450 determines that the mode switching condition is not met, it repeats the determination of step S3 to monitor changes in the operating state acquired over time from each sewing machine 1, the arrival of a scheduled time, and the occurrence of an event.

[0074] When the control unit 450 of the management device 400 determines that the mode switching condition is satisfied, it transmits an instruction to switch to the low power standby mode to the sewing machines 1 that satisfy the mode switching condition via the communication unit 430 (step S4A). When there are multiple sewing machines 1 that satisfy the mode switching condition, the control unit 450 transmits an instruction to switch to the low power standby mode to those multiple sewing machines 1. Then, when the control unit 110 of each sewing machine 1 receives the instruction to switch to the low power standby mode via the communication unit 130, it switches the operating mode from the normal mode to the low power consumption mode (step S4B).

[0075] Fig. 10 is a flowchart showing an example of processing for controlling the stop of power supply to the sewing machine 1 by the sewing system 500. The processing procedure shown in Fig. 10 is realized by the control unit 450 of the management device 400. The processing procedure shown in Fig. 10 is repeatedly executed.

[0076] The power supply unit 300 starts supplying power to each sewing machine 1 (step S11). The control unit 450 of the management device 400 determines whether or not there is a group that satisfies the power stopping condition (step S12). That is, the control unit 450 determines whether or not all sewing machines 1 belonging to the same group have transitioned to the low-power standby mode. If there are multiple groups in the sewing system 500, the control unit 450 determines whether or not the power stopping condition is satisfied for each group. If the control unit 450 determines that the power stopping condition is not satisfied, it repeats the determination of step S12 to monitor the operating mode (whether normal mode or low-power standby mode) of each sewing machine 1 belonging to the group over time.

[0077] When the control unit 450 of the management device 400 determines that the power stopping condition is satisfied, the control unit 450 transmits an instruction to the power supply unit 300 via the communication unit 430 to stop the power supply to the group that satisfied the power stopping condition (step S13A). When the power supply unit 300 receives the instruction to stop the power supply to the group that satisfied the power stopping condition, the power supply unit 300 stops the power supply to all sewing machines 1 that belong to the group (step S13B).

[0078] If there is a group to which power supply has been stopped, the control unit 450 of the management device 400 determines whether or not to release the power supply stop to that group. When the time period (e.g., the time period of a break) set in the mode switching conditions has passed, when a preset event has ended, or when an instruction to resume the power supply has been received via the operation unit 420, the control unit 450 transmits an instruction to the power supply unit 300 to release the power supply stop to that group. When the power supply unit 300 receives the instruction to release the power supply stop, it resumes the power supply to all sewing machines 1 belonging to that group.

[0079] An example of the functional configuration of the sewing system 500 according to the present embodiment has been described above. Note that the above configuration is merely an example, and the functional configuration of the sewing system 500 according to the present embodiment is not limited to the above example. The functional configuration of the sewing system 500 according to the present embodiment can be flexibly modified according to the specifications and operation.

[0080] [effect] As described above, according to this embodiment, the control unit 450 acquires information on the operating states of the multiple sewing machines 1, and transmits an instruction to switch to the low power standby mode to the sewing machine 1 whose operating state satisfies the mode switching condition among the multiple sewing machines 1. As a result, the sewing machine 1 that receives the instruction to switch to the low power standby mode switches from the normal mode to the low power standby mode and enters a state in which power consumption is reduced. As a result, the power consumption of the sewing machine 1 can be reduced. In addition, in this embodiment, the control unit 450 transmits an instruction to switch to the low power standby mode to each sewing machine 1 via the network NW, so that it is not necessary to set the mode switching condition individually for each control unit 110 of the multiple sewing machines 1. Therefore, a further effect of reducing the workload of the administrator is achieved. The number of sewing machines 1 in the sewing system 500 of this embodiment is not particularly limited, but it is effective because the greater the number of sewing machines 1, the greater the effect of reducing power consumption and the effect of reducing the workload.

[0081] The mode switching condition also includes the continuous non-operating time of the sewing machine 1 exceeding a set value V. This makes it possible to appropriately reduce power consumption even in cases where the operator who operates the sewing machine 1 is engaged in changing setup, troubleshooting, or leaving his / her desk and the power is left on for a long period of non-operating time, without the operator having to manually switch the mode. The mode switching condition also includes at least one of the arrival of a predetermined time and the occurrence of a predetermined event. This makes it possible to perform processes such as switching multiple sewing machines 1 collectively to a low-power standby mode according to the sewing factory schedule.

[0082] The control unit 450 also acquires operation record information 443 indicating changes in the operating state of the sewing machine 1 over time, and calculates a set value for the continuous non-operation time based on the operation record information 443. This makes it possible to set an appropriate mode switching condition (set value for the continuous non-operation time) according to the operation record. Furthermore, the control unit 450 acquires operation record information 443 of the sewing machine 1 for each sewn product, and calculates a set value V for the continuous non-operation time according to the sewn product. This makes it possible to optimize the mode switching condition (set value for the continuous non-operation time) for each sewn product according to differences in preparation time depending on the type of sewn product, etc. As a result, it is possible to improve the effect of reducing power consumption.

[0083] Furthermore, when the sewing machine 1 that has transitioned to the low power standby mode satisfies the power stopping condition, the control unit 450 transmits an instruction to the power supply unit 300 to stop the power supply to the sewing machine 1 that satisfies the power stopping condition. This makes it possible to further reduce power consumption by stopping the power supply to the sewing machine 1 itself when the power stopping condition is satisfied. Even in this case, the control unit 450 controls the power supply unit 300 of the installation facility such as a sewing factory, so there is no workload imposed on the manager to operate the power supply unit 300.

[0084] The power stopping condition includes that all of the sewing machines 1 belonging to a predetermined group among the multiple sewing machines 1 have transitioned to a low-power standby mode. This allows the control unit 450 to collectively stop the power supply to the multiple sewing machines 1 in a case where the multiple sewing machines 1 are collectively inactive due to a break, a temporary suspension of the production line, or the like. This contributes to both an effective reduction in power consumption and suppression of an increase in the workload of the manager.

[0085] [Other embodiments] In the above embodiment, the mode switching conditions for transitioning to the low power standby mode are, for example, that the continuous non-operating time exceeds a set value, that a predetermined time has arrived, and that a predetermined event has occurred, but conditions other than the above-mentioned conditions may be set as the mode switching conditions. Similarly, the power stopping condition is, for example, that all sewing machines 1 belonging to a group have transitioned to the low power standby mode, but conditions other than the above-mentioned conditions may be set as the power stopping condition.

[0086] 2 to 5 are merely examples. The sewing machine 1 may be of any structure and type. The sewing machine 1 is not limited to a machine that uses a sewing needle 41 and a thread, and may be an ultrasonic sewing machine that welds fabric by applying ultrasonic vibrations.

[0087] In the above embodiment, the control unit 450 of the management device 400 determines the mode switching conditions and controls the transmission of an instruction to transition to a low-power standby mode, but this is not limited to the above. For example, any one of the multiple sewing machines 1 may perform the same management function as the management device 400. In this case, the control unit 110 of the sewing machine 1 that performs the management function may determine the mode switching conditions and control the transmission of an instruction to transition to a low-power standby mode for the other sewing machines 1 connected via the network NW.

[0088] In the above embodiment, the control unit 450 of the management device 400 acquires information about the operating state of each sewing machine 1 (control unit 110) from each sewing machine 1 (control unit 110), but the present invention is not limited to this. For example, in the example shown in Fig. 11, the management device 400 (control unit 450) acquires information about the operating state of the sewing machine 1 from an operation information acquisition device 90 that detects information about the operating state of the sewing machine 1. Fig. 11 is a configuration diagram of a sewing system according to another embodiment.

[0089] Some types of sewing machines 1 do not have a function for outputting information about the operating state. The operating information acquisition device 90 is provided in addition to a sewing machine 1 that does not have a function for outputting information about the operating state, and acquires information about the operating state from outside the sewing machine 1. The operating information acquisition device 90 includes a detection device having sensors that detect detection information for acquiring information about the operating state of the sewing machine 1, a control device that processes the detection information to acquire information about the operating state, and a communication device that transmits information about the operating state to the management device 400. The operation information acquisition device 90 can communicate with the management device 400 via the network NW by the communication device. The sensors of the detection device include, for example, a sensor that detects a change in state of an operating member that performs a periodic operation in the same cycle as the up-and-down movement of the needle bar 40. Such a sensor is, for example, a photoelectric sensor that detects the rotation of a pulley connected to a main shaft that transmits a driving force to the needle bar 40. The pulley is used when the needle bar 40 is manually rotated, and rotates together with the main shaft even when driven by the sewing machine motor 160. The control device determines whether the pulley is rotating or stopped based on the detection information from the photoelectric sensor, and generates information about the operating state of the sewing machine 1, which indicates whether the sewing machine 1 is in an operating state or a non-operating state.

[0090] Control unit 450 of management device 400 acquires information related to the operating state of sewing machine 1 from operation information acquisition device 90. Therefore, in the embodiment shown in Fig. 11, acquisition of information related to the operating state of sewing machine 1 in steps S2A and S2B of Fig. 9 is performed by communication between management device 400 and operation information acquisition device 90. In step S4A of Fig. 9, control unit 450 of management device 400 may directly transmit an instruction to sewing machine 1 that satisfies the mode switching condition to transition to the low power standby mode, or, if operation information acquisition device 90 is capable of communicating with control unit 110 of sewing machine 1, control unit 450 may transmit an instruction to sewing machine 1 to transition to the low power standby mode via operation information acquisition device 90.

[0091] Similarly, the determination as to whether or not there is a group that satisfies the power stopping condition in step S12 of FIG.

[0092] There may be a mixture of sewing machines 1 having a function for outputting information relating to their operating states and sewing machines 1 not having this function. In the example of Fig. 11, sewing machines 1F, 1G, and 1H do not have a function for outputting information relating to their operating states. Sewing machines 1D and 1E have a function for outputting information relating to their operating states. The control unit 450 of the management device 400 can acquire information relating to the operating states of sewing machines 1F, 1G, and 1H from the operation information acquisition devices 90 provided therewith, respectively, and can acquire information relating to the operating states of sewing machines 1D and 1E directly from the respective sewing machines 1D and 1E. [Explanation of symbols]

[0093] 1, 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H... sewing machine, 2... table, 3... frame, 4... head, 5... head rotation device, 6... holding member, 7... holding member moving device, 7X... X-axis moving device, 7Y... Y-axis moving device, 8... hook, 9... hook rotation device, 10... power switch, 11... start switch, 12... pause switch, 13... emergency stop switch, 14... operation panel, 16... thread winding device, 17... thread stand device, 18... input device, 19... display device, 20... needle plate, 26... opening, 30... beam portion, 31... first pillar portion, 32... second pillar portion, 33... cover member, 40... needle bar, 41...sewing machine needle, 42...pinhole, 43...middle presser foot, 50...sewing object, 80...support member, 90...operation information acquisition device, 110...control unit, 120...memory unit, 121...program, 122...sewing machine information, 123...sewn product information, 130...communication unit, 150...power supply circuit, 160...sewing machine motor, 300...power supply unit, 400...management device, 410...display unit, 420...operation unit, 430...communication unit, 440...memory unit, 441...program, 442...management information, 443...operation history information, 450...control unit, 500...sewing system, NW...network, V...set value of continuous non-operation time.

Claims

1. a plurality of sewing machines each of which operates in a normal mode and a low-power standby mode in which the sewing machines are in standby mode with lower power consumption than the normal mode; a control unit that controls mode switching of the plurality of sewing machines, The control unit is Obtaining information regarding the operating status of the plurality of sewing machines; transmitting an instruction to switch to the low power standby mode to a sewing machine whose operating state satisfies a mode switching condition among the plurality of sewing machines; Sewing system.

2. the mode switching condition includes a continuous non-operating time of the sewing machine exceeding a set value; The sewing system of claim 1 .

3. The control unit is acquiring operational performance information indicating a change in an operational state of the sewing machine over time; calculating a set value of the continuous non-operation time based on the operation result information; The sewing system of claim 2 .

4. The control unit is Acquire operation record information of the sewing machine for each sewn product; calculating a set value of the continuous non-operation time corresponding to the sewn product based on the operation result information; The sewing system of claim 3 .

5. the mode switching condition includes at least one of the following: arrival of a predetermined time; and occurrence of a predetermined event; The sewing system of claim 1 .

6. a power supply unit connected to the control unit via a network and supplying power to the plurality of sewing machines; When the sewing machine that has transitioned to the low power standby mode satisfies a power stopping condition, the control unit transmits, to the power supply unit, an instruction to stop power supply to the sewing machine that has satisfied the power stopping condition. The sewing system according to any one of claims 1 to 5.

7. the power stopping condition includes that all of the sewing machines belonging to a predetermined group among the plurality of sewing machines have entered the low power standby mode, The control unit transmits, to the power supply unit, an instruction to stop power supply to all of the sewing machines belonging to the group that satisfies the power stopping condition. The sewing system of claim 6.

Images