Sewing management system and sewing management method

Abstract

To provide a management system of power consumption of a sewing machine.SOLUTION: A sewing management system includes a data acquisition part that acquires utilization data of a sewing machine, a processing part that calculates power consumption of the sewing machine based on the utilization data, and an output part that allows an output device to output the power consumption.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The technology disclosed in this specification relates to a sewing management system and a sewing management method.

Background Art

[0002] In the technical field related to sewing management systems, a sewing management system as disclosed in Patent Document 1 is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A sewing machine operates based on electricity. When managing the power consumption of a sewing machine, it is conceivable to install a power sensor on the sewing machine. However, when managing the power consumption of industrial sewing machines that are numerous in a sewing factory, installing power sensors on all industrial sewing machines incurs the cost of installing the power sensors.

[0005] The technology disclosed in this specification aims to manage the power consumption of a sewing machine.

Means for Solving the Problems

[0006] This specification discloses a sewing management system. The sewing management system includes a data acquisition unit that acquires operation data of a sewing machine, a processing unit that calculates the power consumption of the sewing machine based on the operation data, and an output unit that outputs the power consumption to an output device.

Effects of the Invention

[0007] According to the technology disclosed in this specification, the power consumption of a sewing machine can be managed.

Brief Description of the Drawings

[0008]

Figure 1

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Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present technology will be described with reference to the drawings, but the present technology is not limited to the embodiments. The components of the embodiments described below can be combined as appropriate. Also, some components may not be used.

[0010] [Sewing Management System] FIG. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages the production process of sewn products. The production process includes a sewing process of sewing a sewing target using a sewing machine 2. The sewing machine 2 is an industrial sewing machine. The sewn product is produced on a production line including the sewing machine 2. A plurality of sewing machines 2 are installed on the production line. The production line is installed in a sewing factory. The sewing machine 2 operates in the sewing factory. When the sewing target is sewn by the sewing machine 2, a sewn product is produced. In the embodiment, the management device 3 is installed in the sewing factory. Note that the management device 3 may be installed outside the sewing factory.

[0011] In the sewing process, when the sewing target is sewn by the sewing machine 2, a sewn product is produced. As the sewing target, fabric is exemplified. As the sewn product, clothing is exemplified.

[0012] A plurality of types of sewing machines 2 according to the application are installed in the sewing factory. In the sewing factory, a plurality of types of sewing machines 2 are installed so as to correspond to each of a plurality of sewing processes for producing sewn products. Examples of the types of the sewing machine 2 include a straight stitch sewing machine for sewing the body, a button sewing machine for attaching buttons to the body, and a pocket sewing machine for attaching pockets to the body. A large number of various types of sewing machines 2 are installed in one sewing factory. For simplicity of explanation, three sewing machines 2 are shown in FIG. 1. The first sewing machine 2A is used in the first process for producing a sewn product. The second sewing machine 2B is used in the second process for producing a sewn product. The third sewing machine 2C is used in the third process for producing a sewn product. Note that a plurality of sewing machines 2 of one type may be installed in the sewing factory.

[0013] In a sewing factory, a manager and workers are employed. The manager manages the workers and the sewing machines 2. The workers sew the items to be sewn using the sewing machines 2 in the sewing process. Each of the manager and the workers may be regarded as a user of the sewing machines 2. The manager may be one person or a plurality of persons. The workers may be a plurality of persons or one person. For example, one worker may operate a plurality of sewing machines 2.

[0014] The management device 3 includes a display device 4, an input device 5, and a management controller 6. The display device 4 displays display data. The display device 4 includes a flat panel display such as a liquid crystal display or an organic EL display. The input device 5 generates input data when operated by the manager. Note that the input device 5 may be operated by the worker. The input device 5 includes a touch panel (touch sensor) arranged on the display screen of the display device 4. Note that the input device 5 may be a computer keyboard, a mouse, or a voice input device. The management controller 6 includes a computer system. The management controller 6 has at least one processor and a main memory that stores a computer program executable by the processor.

[0015] The sewing machine 2 has a sewing machine controller 8. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 has at least one processor and a main memory that stores a computer program executable by the processor.

[0016] The management device 3 is shared by a plurality of sewing machines 2 in a sewing factory. The number of management devices 3 is less than the number of sewing machines 2. The management device 3 can communicate with the sewing machines. The management controller 6 of the management device 3 communicates with the sewing controller 8 of the sewing machine 2. The management controller 6 and the sewing controller 8 perform wireless communication. The management controller 6 and the sewing controller 8 perform wireless communication via a local area network (LAN). As the wireless LAN, Wifi (registered trademark) is exemplified. Note that the management controller 6 and the sewing controller 8 may perform wireless communication via a personal area network (PAN). As the wireless PAN, Bluetooth (registered trademark) is exemplified.

[0017] Based on the input data generated by operating the input device 5, the management controller 6 sends a control command to the sewing controller 8 of the sewing machine 2.

[0018] The sewing controller 8 sends the operation data of the sewing machine 2 to the management controller 6. The operation data of the sewing machine 2 includes the operating conditions of the sewing machine 2. The operating conditions of the sewing machine 2 include the number of stitches, stitch length, stitch pitch, stitch pattern, feeding speed of the sewing object, thread tension, and pressing pressure of the sewing object. The sewing controller 8 monitors the operating conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor 7 (see FIG. 3) for detecting the operating conditions of the sewing machine 2. As the sensor 7, a stitch number sensor for detecting the number of stitches, a tension sensor for detecting the thread tension, and a pressing pressure sensor for detecting the pressing pressure of the sewing object are exemplified. The sewing controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring the detection data of the sensor 7.

[0019] Further, the sewing machine 2 has a sewing machine motor for operating the needle bar and the balance. The operating data of the sewing machine 2 includes the operating conditions of the sewing machine motor. The sewing machine controller 8 inputs a control command to the sewing machine drive circuit that drives the sewing machine motor. The sewing machine drive circuit includes a switching element such as a field effect transistor (FET). The operating data of the sewing machine 2 includes the control command input from the sewing machine controller 8 to the sewing machine drive circuit. The control command includes at least one of a rotational speed command value for commanding the rotational speed of the sewing machine motor and a current command value for commanding the current value input to the sewing machine motor. The sewing machine motor rotates at a rotational speed determined based on the rotational speed command value. The rotational speed command value may be an average rotational speed command value during operation of the sewing machine motor or a maximum rotational speed command value. The rotational speed of the sewing machine motor may be an average rotational speed during operation of the sewing machine motor or a maximum rotational speed. A current value determined based on the current command value is input to the sewing machine motor.

[0020] The management controller 6 collects the operating data of each of the plurality of sewing machines 2. The management controller 6 causes the display device 4 to display the operating data of each of the plurality of sewing machines 2.

[0021] [Computer System] FIG. 2 is a hardware configuration diagram showing the management controller 6 according to the embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a CPU (Central Processing Unit), a main memory 1002 including a non-volatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 1003, and an interface 1004 including an input / output circuit. The functions of the management controller 6 are stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, expands it in the main memory 1002, and executes processing according to the computer program. Note that the computer program may be distributed to the computer system 1000 via a network.

[0022] Similarly, the sewing machine controller 8 includes a computer system having a processor, a main memory, a storage, and an interface.

[0023] [Management Device and Sewing Machine] FIG. 3 is a functional block diagram showing the management device 3 and the sewing machine 2 according to the embodiment. As shown in FIG. 3, each of the plurality of sewing machines 2 has a sewing machine controller 8 and a sensor 7. As described above, the sensor 7 detects the operating conditions of the sewing machine 2.

[0024] The management controller 6 has a data acquisition unit 61, a processing unit 62, and an output unit 63.

[0025] The data acquisition unit 61 acquires the operation data of the sewing machine 2. The data acquisition unit 61 acquires operation data from each of the plurality of sewing machines 2 (2A, 2B, 2C).

[0026] The processing unit 62 calculates the power consumption of the sewing machine 2 based on the operation data of the sewing machine 2 acquired by the data acquisition unit 61. The processing unit 62 calculates the power consumption of each of the plurality of sewing machines 2 (2A, 2B, 2C).

[0027] Correlation data indicating the relationship between the operation data and the power consumption is stored in the processing unit 62. The correlation data is obtained in advance by a preliminary experiment or a simulation. The processing unit 62 can calculate the power consumption of the sewing machine 2 based on the operation data of the sewing machine 2 acquired by the data acquisition unit 61 and the correlation data.

[0028] As described above, the operation data of the sewing machine 2 includes a control command input from the sewing machine controller 8 to the sewing machine drive circuit. The control command includes at least one of a rotation speed command value for commanding the rotation speed of the sewing machine motor and a current command value for commanding the current value input to the sewing machine motor.

[0029] When the operation data is the rotation speed command value of the sewing machine motor, the correlation data indicates the relationship between the rotation speed command value of the sewing machine motor and the power consumption. The higher the rotation speed command value, the greater the power consumption. The lower the rotation speed command value, the smaller the power consumption. The processing unit 62 can calculate the power consumption of the sewing machine 2 based on the rotation speed command value of the sewing machine motor acquired by the data acquisition unit 61 and the correlation data.

[0030] When the operation data is the current command value of the sewing machine motor, the correlation data indicates the relationship between the current command value of the sewing machine motor and the power consumption. The higher the current command value, the greater the power consumption. The lower the current command value, the smaller the power consumption. The processing unit 62 can calculate the power consumption of the sewing machine 2 based on the current command value of the sewing machine motor acquired by the data acquisition unit 61 and the correlation data.

[0031] Note that the operation data may be the number of stitches of the sewing machine 2. The number of stitches refers to the number of reciprocations of the sewing needle (needle bar) that reciprocates in the vertical direction by the sewing machine motor. The above-described sensor 7 includes a stitch number sensor that detects the number of stitches. The correlation data indicates the relationship between the number of stitches and the power consumption. The higher the number of stitches, the greater the power consumption. The lower the number of stitches, the smaller the power consumption. The processing unit 62 can calculate the power consumption of the sewing machine 2 based on the number of stitches and the correlation data acquired by the data acquisition unit 61.

[0032] Note that the operation data may include the operation time of the sewing machine motor. The processing unit 62 can calculate the power consumption amount of the sewing machine 2 based on the power consumption calculated according to the above example and the operation time of the sewing machine motor.

[0033] The output unit 63 causes the display device 4 to display the power consumption calculated by the processing unit 62. The display device 4 is an example of an output device that outputs the power consumption calculated by the processing unit 62.

[0034] [Sewing management method] FIG. 4 is a flowchart showing a sewing management method according to the embodiment. The data acquisition unit 61 acquires the operation data of the sewing machine 2 from the sewing machine controller 8 (step S1).

[0035] The processing unit 62 calculates the power consumption of the sewing machine 2 based on the operation data of the sewing machine 2 acquired in step S1 and the correlation data obtained in advance (step S2).

[0036] The output unit 63 causes the display device 4 to display the power consumption of the sewing machine 2 calculated in step S2 (step S3).

[0037] FIG. 5 is a diagram showing an example of display data displayed on the display device 4 according to the embodiment. As shown in FIG. 5, the output unit 63 can cause the display device 4 to display the power consumption of one sewing machine 2. In the example shown in FIG. 5, the power consumption of the first sewing machine 2A is displayed on the display device 4. As shown in FIG. 5, the output unit 63 may cause the display device 4 to display a graph showing the relationship between the elapsed time since the operation of the sewing machine 2 started and the power consumption.

[0038] FIG. 6 is a diagram showing an example of display data displayed on the display device 4 according to the embodiment. As shown in FIG. 6, the output unit 63 can cause the display device 4 to simultaneously display the power consumption of a plurality of sewing machines 2. In the example shown in FIG. 6, the daily power consumption (power consumption amount) of each of the first sewing machine 2A, the second sewing machine 2B, and the third sewing machine 2C is displayed on the display device 4. As shown in FIG. 6, the output unit 63 may cause the display device 4 to display a graph showing the daily power consumption (power consumption amount) of each of the first sewing machine 2A, the second sewing machine 2B, and the third sewing machine 2C.

[0039] [Abnormality Detection] The processing unit 62 can determine whether the sewing machine 2 is abnormal based on the calculated power consumption of the sewing machine 2. When the calculated power consumption changes suddenly, the processing unit 62 can determine that an abnormality has occurred in the sewing machine motor or the motor drive circuit. When the calculated power consumption increases or decreases suddenly, the processing unit 62 can determine that an abnormality has occurred in the sewing machine motor or the motor drive circuit. The fact that the power consumption changes suddenly means that the amount of change (change rate) in the power consumption per unit time is equal to or greater than a predetermined threshold. The processing unit 62 determines that an abnormality has occurred in the sewing machine motor or the motor drive circuit when the change rate of the calculated power consumption is equal to or greater than a predetermined threshold.

[0040] When the processing unit 62 determines that the sewing machine 2 is abnormal, the output unit 63 causes the display device 4 to display that the sewing machine 2 is abnormal. Thereby, the administrator can recognize the abnormality of the sewing machine 2 at an early stage. Note that the output unit 63 may cause the display device 4 to display that there is a sign of abnormality in the sewing machine 2.

[0041] When the processing unit 62 determines that the sewing machine 2 is abnormal, the output unit 63 may cause an information terminal to output that the sewing machine 2 is abnormal.

[0042] FIG. 7 is a diagram for explaining the processing of the output unit 63 according to the embodiment. As shown in FIG. 7, when the processing unit 62 determines that the sewing machine 2 is abnormal, the output unit 63 may cause an information terminal 11 held by a maintenance person of the sewing machine 2 to output that the sewing machine 2 is abnormal. Thereby, the maintenance person can recognize the abnormality of the sewing machine 2 at an early stage and can perform maintenance on the sewing machine 2 at an early stage. Note that the output unit 63 may cause the information terminal 11 to output that there is a sign of abnormality in the sewing machine 2.

[0043] Note that when a vibration sensor for detecting the vibration of the sewing machine 2 is provided in the sewing machine 2 as the sensor 7, the processing unit 62 may determine whether the sewing machine 2 is abnormal based on the detection value of the vibration sensor. When the detection value of the vibration sensor increases rapidly, the processing unit 62 can determine that an abnormality has occurred in at least a part of the sewing machine 2. The output unit 63 may cause the display device 4 or the information terminal 11 to output that the sewing machine 2 is abnormal or that there is a sign of abnormality in the sewing machine 2.

[0044] Note that when a temperature sensor for detecting the temperature of the sewing machine 2 is provided in the sewing machine 2 as the sensor 7, the processing unit 62 may determine whether the sewing machine 2 is abnormal based on the detection value of the temperature sensor. When the detection value of the temperature sensor increases rapidly, the processing unit 62 can determine that an abnormality has occurred in at least a part of the sewing machine 2. The output unit 63 may cause the display device 4 or the information terminal 11 to output that the sewing machine 2 is abnormal or that there is a sign of abnormality in the sewing machine 2.

[0045] [Effect] As described above, in the embodiment, the sewing management system 1 includes a data acquisition unit 61 that acquires operation data of the sewing machine 2, a processing unit 62 that calculates the power consumption of the sewing machine 2 based on the operation data, and an output unit 63 that outputs the power consumption to a display device 4 which is an output device.

[0046] According to the embodiment, the power consumption of the sewing machine 2 is calculated based on the operation data of the sewing machine 2. Thereby, the power consumption of the sewing machine 2 is managed. Even if a power sensor is not installed in the sewing machine 2, the power consumption of the sewing machine 2 can be managed.

[0047] Correlation data indicating the relationship between the operation data of the sewing machine 2 and the power consumption is obtained in advance. Thereby, the processing unit 62 can calculate the power consumption of the sewing machine 2 based on the operation data acquired by the data acquisition unit 61 and the correlation data.

[0048] The operation data of the sewing machine 2 includes at least one of a rotation speed command value of the sewing machine motor and a current command value of the sewing machine motor. Even if a power sensor is not installed in the sewing machine, the power consumption of the sewing machine 2 is calculated based on a control command output from the sewing machine controller 8 to the sewing machine drive circuit.

[0049] The processing unit 62 can determine whether the sewing machine 2 is abnormal based on the power consumption of the sewing machine 2. The output unit 63 outputs to the display device 4 or the information terminal 11 that the sewing machine is abnormal. Thereby, the administrator or the maintenance person can recognize the abnormality of the sewing machine 2 at an early stage.

Explanation of Reference Numerals

[0050] 1…Sewing management system, 2…Sewing machine, 2A…First sewing machine, 2B…Second sewing machine, 2C…Third sewing machine, 3…Management device, 4…Display device, 5…Input device, 6…Management controller, 7…Sensor, 8…Sewing machine controller, 11…Information terminal, 61…Data acquisition unit, 62…Processing unit, 63…Output unit, 1000…Computer system, 1001…Processor, 1002…Main memory, 1003…Storage, 1004…Interface.

Claims

1. A data acquisition unit that acquires the operating data of a sewing machine, A processing unit that calculates the power consumption of the sewing machine based on the operating data, An output unit that causes the output device to output the power consumption, and A sewing management system.

2. Correlation data indicating the relationship between the operating data and the power consumption is obtained in advance, The processing unit calculates the power consumption based on the operating data acquired by the data acquisition unit and the correlation data. The sewing management system according to Claim 1.

3. The operating data includes at least one of a rotation speed command value of a sewing machine motor and a current command value of the sewing machine motor. The sewing management system according to Claim 1.

4. The processing unit determines whether the sewing machine is abnormal based on the power consumption, The output unit causes the output device to output that the sewing machine is abnormal. The sewing management system according to Claim 1.

5. When the power consumption changes rapidly, the processing unit determines that an abnormality has occurred in the sewing machine motor or the motor drive circuit. The sewing management system according to Claim 4.

6. When the processing unit determines that the sewing machine is abnormal, the output unit causes the display device to display that the sewing machine is abnormal. The sewing management system according to Claim 4.

7. When the processing unit determines that the sewing machine is abnormal, the output unit causes the information terminal of the maintenance staff to output that the sewing machine is abnormal. The sewing management system according to Claim 4.

8. Obtaining the operating data of a sewing machine, Calculating the power consumption of the sewing machine based on the operating data, and Causing the output device to output the power consumption, including A sewing management method.

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