Parameter display device, parameter display method, and parameter display program

Abstract

To provide a parameter display device, a parameter display method, and a parameter display program that make it easier to confirm whether the parameters used to determine sewing defects are set appropriately compared to conventional methods. [Solution] The parameter display device comprises a display unit and a control unit. The control unit performs a data acquisition process to acquire sewing operation data representing the detection result of each stitch during the sewing process in which the sewing machine forms stitches on the workpiece (S24). The control unit performs a parameter acquisition process to acquire parameters (S25). The control unit performs a display control process to display a graph on the display unit for selected sewing defects, including the detection result for each stitch, parameters, and defect determination timing. The defect determination timing is the timing at which it is determined that a selected sewing defect has occurred based on the comparison result between the sewing operation data and the parameters.

Description

Technical Field

[0001] The present invention relates to a parameter display device, a parameter display method, and a parameter display program.

Background Art

[0002] Conventional electronic devices for production management attach one sensor to at least a part of components such as a needle bar and a balance that perform repetitive operations during sewing work on a sewing machine. The electronic device for production management performs production management through analysis of sensing data acquired by the sensor. Specifically, the electronic device for production management acquires sensing data and generates work information based on the sensing data. When a production information request signal related to the sewing work is received, the electronic device for production management displays the production information confirmed based on the work information. When a quality information request signal for the sewing work is received, the electronic device for production management displays the quality information confirmed based on the work information.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a conventional sewing machine, during the execution of a sewing process in which the sewing machine forms a seam on a sewn product, the presence or absence of a sewing defect is detected based on sewing operation data representing the detection result of the sewing operation. There are various types of sewing defects, and there are different judgment criteria for each sewing defect. Depending on the sewing defect, since a plurality of parameters contribute to the judgment criteria, it is difficult for the operator of the sewing machine to grasp whether the parameters used for judging the sewing defect are appropriately set.

[0005] The object of the present invention is to provide a parameter display device, a parameter display method, and a parameter display program that contribute to making it easier to confirm whether the parameters used to determine sewing defects are set appropriately compared to conventional methods. [Means for solving the problem]

[0006] The parameter display device according to claim 1 of the present invention comprises a display unit and a control unit, wherein the control unit is configured to perform data acquisition processing to acquire sewing operation data representing the detection result of each stitch during the sewing process in which a sewing machine forms stitches on a sewn workpiece; parameter acquisition processing to acquire parameters; and display control processing to display a graph on the display unit that includes the detection result for each stitch, the parameters, the sewing operation data, and the defect determination timing at which it is determined that a selected sewing defect has occurred based on a comparison result between the parameters, for a first sewing defect and a second sewing defect different from the first sewing defect. The display control processing performed by the control unit of the parameter display device according to claim 1 contributes to making it easier than before to confirm whether the parameters used for determining sewing defects are set appropriately.

[0007] In the parameter display device according to claim 2 of the present invention, the control unit is configured to further perform a transmission process that transmits the sewing operation data and the parameters to a server, and a reception process that receives the defect determination timing determined by the server based on the comparison result between the sewing operation data and the parameters, and the graph includes the defect determination timing received from the server. The transmission process and reception process performed by the control unit of the parameter display device according to claim 2 contribute to simplifying the processing performed by the parameter display device.

[0008] In the parameter display device according to claim 3 of the present invention, the sewing operation data is thread tension data that includes the thread tension of the upper thread detected by the thread tension sensor of the sewing machine as the detection result, and the graph includes the thread tension of the upper thread for each stitch. The display control processing of the parameter display device according to claim 3 contributes to making it easier than before to confirm whether the parameters for selected sewing defects detected based on the thread tension of the upper thread are set appropriately.

[0009] In the parameter display device according to claim 4 of the present invention, the thread tension data includes multiple thread tensions within a sewing cycle in which one stitch constitutes one cycle, and the thread tension of the upper thread for each stitch is the thread tension of the upper thread for a predetermined period within the sewing cycle. The display control processing of the parameter display device according to claim 4 contributes to making it easier than before to confirm whether the parameters for selected sewing defects detected based on the thread tension of the upper thread for a predetermined period are set appropriately.

[0010] In the parameter display device according to claim 5 of the present invention, the control unit is configured to further perform a parameter change process to accept changes to the parameters, and the graph includes the defect determination timing at which it is determined that a selected sewing defect has occurred based on the comparison result between the sewing operation data and the changed parameters. The parameter change process of the parameter display device according to claim 5 contributes to making it easier than before to confirm whether the parameters for selected sewing defects after change are set appropriately.

[0011] In the parameter display device according to claim 6 of the present invention, the control unit acquires a first parameter associated with the first sewing defect and a second parameter associated with the second sewing defect as parameters in the parameter acquisition process, and in the parameter change process, displays the selected parameter from the first parameter and the second parameter that corresponds to the selected sewing defect on the display unit and accepts a change to the selected parameter. The parameter change process of the parameter display device according to claim 6 contributes to improving the convenience of the operator when changing the selected parameter compared to the case in which the first parameter and the second parameter are displayed in the parameter change process.

[0012] In the parameter display device according to claim 7 of the present invention, the control unit is configured to further perform a parameter output process that enables the modified parameters to be output to an external device. The parameter output process of the parameter display device according to claim 7 contributes to improving the convenience of the operator when setting the parameters modified in the parameter modification process to the sewing machine.

[0013] In the parameter display device according to claim 8 of the present invention, the control unit is configured to further perform a sewing defect data acquisition process that acquires sewing defect data representing the type of detected sewing defect, which is an actual sewing defect among the first sewing defect and the second sewing defect, and the timing of the defect occurrence in which the detected sewing defect occurred, and the graph includes the timing of the defect occurrence. The display control process of the parameter display device according to claim 8 contributes to the operator being able to compare and confirm the timing of the defect occurrence with the timing of the defect determination.

[0014] The parameter display method according to claim 9 of the present invention includes various processes performed by the control unit of the parameter display device described in any one of claims 1 to 8. The display control process of the parameter display method according to claim 9 is performed by the control unit of the parameter display device, which contributes to making it easier to confirm whether the parameters used for determining sewing defects are set appropriately compared to conventional methods.

[0015] The parameter display program according to claim 10 of the present invention includes instructions for causing the control unit of the parameter display device to execute various processes of the parameter display device according to any one of claims 1 to 8. The display control process of the parameter display program of claim 10 contributes to making it easier to confirm whether the parameters used for determining sewing defects are appropriately set than before, by being executed by the control unit of the parameter display device.

Brief Description of the Drawings

[0016] [Figure 1] It is a perspective view of the sewing machine 1. [Figure 2] It is a perspective view of the frame 7. [Figure 3] It is a block diagram showing the electrical configuration of the sewing machine 1, the parameter display device 2, and the server 3 included in the sewing system 5. [Figure 4] It is a flowchart of the main process executed by the parameter display device 2. [Figure 5] It is an explanatory diagram of the screen G1. [Figure 6] It is an explanatory diagram of the screen G20. [Figure 7] It is a flowchart of the log data display process. [Figure 8] It is an explanatory diagram of the screen G30. [Figure 9] It is a flowchart of the simulation display process. [Figure 10] It is an explanatory diagram of the screen G40. [Figure 11] (A) is an explanatory diagram of the column G45 before modification, and (B) is an explanatory diagram of the column G45 before modification. [Figure 12] It is a flowchart of the log information display process. [Figure 13] (A) is an explanatory diagram of the screen G50, (B) is an explanatory diagram of the column G51 of the second aspect, and (C) is an explanatory diagram of the column G52 of the second aspect.

Embodiments for Carrying Out the Invention

[0017] Referring to FIG. 3, the outline of the sewing system 5 will be described. The sewing system 5 includes a sewing machine 1, a parameter display device 2, and a server 3. The sewing system 5 is a system that enables the parameter display device 2 to confirm whether the parameters used for determining sewing defects in the sewing machine 1 are appropriately set.

[0018] Referring to FIGS. 1 and 2, the physical configuration of the sewing machine 1 will be described. In the following description, the left - right, front - back, and up - down directions indicated by arrows in the figures are used. As shown in FIG. 1, the sewing machine 1 is a portal - type sewing machine capable of sewing on a sewing material. The sewing machine 1 has a bed portion 21, a feeding mechanism 25, leg pillar portions 221, 222, a beam portion 23, an operation portion 27, a head portion 24, and a frame 7 shown in FIG. 2.

[0019] As shown in FIG. 1, the bed portion 21 has a base portion 211 and a frame body 212. The base portion 211 is in the shape of a rectangular parallelepiped. The base portion 211 includes a first holding plate 213, a second holding plate 214, and bellows 215, 216. Openings 217, 218 are formed in the base portion 211. The base portion 211 further includes a pair of first rails and a pair of second rails.

[0020] The first holding plate 213 forms the upper surface of the base portion 211 and is a plane extending in the horizontal direction. The second holding plate 214 is a rectangular plate arranged flush with the first holding plate 213 in front of the first holding plate 213.

[0021] The opening 217 extends in the front - back direction near the left end of the first holding plate 213. One of the pair of first rails extending in the front - back direction is arranged in the opening 217. The opening 218 extends in the front - back direction near the right end of the first holding plate 213. The other of the pair of first rails is arranged in the opening 218.

[0022] The bellows 215 covers the opening 217. The bellows 216 covers the opening 218. The bellows 215, 216 expand and contract in response to the reciprocating movement of the feeding mechanism 25 described later along the pair of first rails in the front - back direction.

[0023] The frame 212 is a lattice-like structure that supports the base 211 from below. A pair of second rails extend horizontally below the first retaining plate 213 and between the openings 217 and 218.

[0024] The feeding mechanism 25 includes a holding mechanism 26 and connecting parts 251 and 252. The holding mechanism 26 holds the sewn workpiece. The holding mechanism 26 includes an upper frame 260, a lower frame 261, and air cylinders 262 and 263. The upper frame 260 and the lower frame 261 are rectangular frames in plan view and clamp the sewn workpiece.

[0025] The upper frame 260 moves up and down by air cylinders 262 and 263. One end of the connecting part 251 is connected to the first rail located in the opening 217 of the bed section 21, and the other end of the connecting part 251 is connected to the left end of the holding mechanism 26. One end of the connecting part 252 is connected to the first rail located in the opening 218 of the bed section 21, and the other end of the connecting part 252 is connected to the right end of the holding mechanism 26.

[0026] The leg sections 221 and 222 are each rectangular prisms. The leg section 221 extends upward from the left end of the base 211 of the bed section 21, and from a position forward of the center in the front-to-back direction. The leg section 221 is located to the left of the bellows 215 in the left-to-right direction. The leg section 221 internally supports a synchronization mechanism that synchronously drives the needle bar mechanism 6 and the bobbin mechanism 12.

[0027] The leg column 222 extends upward from the right end of the base 211 of the bed 21 and from a position forward of the center in the front-to-back direction. The leg column 222 is located to the right of the bellows 216 in the left-to-right direction. The leg column 221 internally supports the X motor 132 shown in Figure 3, which moves the bobbin mechanism 12 and the needle bar mechanism 6 in a left-to-right direction parallel to the horizontal direction relative to the sewing work. The leg columns 221 and 222 are separated in the left-to-right direction.

[0028] The beam section 23 is erected between the column sections 221 and 222. The beam section 23 has a housing 231, a third rail, and a bellows 232. The housing 231 extends between the upper and rear ends of the column section 221 and the upper and rear ends of the column section 222.

[0029] The third rail is positioned in the space enclosed by the leg columns 221 and 222, the housing 231, and the bellows 232. The third rail is rod-shaped and is installed between the leg columns 221 and 222. The third rail supports the head 24, which will be described later, so that it can move in the left-right direction.

[0030] The bellows 232 extends from the front ends of the leg sections 221 and 222, the housing 231, and both the left and right ends of the head section 24, which will be described later. The bellows 232 covers the third rail that supports the head section 24 from the front. The bellows 232 expands and contracts in response to the head section 24 moving back and forth along the third rail in the left and right direction.

[0031] The control unit 27 is fixed to the front of the left end of the beam section 23. The control unit 27 includes a switch group 28 and a display unit 29. The switch group 28 receives various instructions according to the operator's actions. The display unit 29 is a liquid crystal display and can display various images.

[0032] The head unit 24 is positioned in front of the beam unit 23. The head unit 24 includes a needle bar 31, a drive unit 50, a presser foot 32, a balance beam 33, a thread tension device 34, a secondary thread tensioner 35, and thread guides 36 and 37. The needle bar 31 extends vertically, and a sewing needle 30 can be attached to its lower end.

[0033] The drive unit 50 has a main shaft 52 and a rotary knob 51. The main shaft 52 rotates with the power of the main motor 131 shown in Figure 3, causing the needle bar 31 to reciprocate in the vertical direction. The rotary knob 51 is manually rotated by the operator when moving the needle bar 31 in the vertical direction. The presser foot 32 has a through hole through which the sewing needle 30 passes in accordance with the movement of the needle bar 31, and presses down on the sewn work from above.

[0034] The balance 33 operates in response to the vertical movement of the needle bar 31, pulling up the upper thread. The thread tension device 34 adjusts the tension of the upper thread. The auxiliary thread tensioner 35 wraps around the upper thread extending from the spool and guides the upper thread toward the thread tension device 34 below. The thread guides 36 and 37 each contact the upper thread extending from the thread tension device 34 and guide the upper thread toward the balance 33. The head 24 is movable left and right along the front end of the beam section 23.

[0035] As shown in Figure 2, the frame 7 is positioned below the head 24 and inside the base 211. The frame 7 includes a housing 70, a needle plate 74, legs 71 and 72, and a bobbin mechanism 12.

[0036] The housing 70 houses the boiler mechanism 12 inside. The housing 70 has a main part 701 and a protruding part 702. The main part 701 is box-shaped. The protruding part 702 protrudes to the left from near the front end of the left side surface of the main part 701.

[0037] The needle plate 74 is detachably fixed above the protruding portion 702. The needle plate 74 has a needle hole 73 through which the sewing needle 30 can be inserted. The needle hole 73 is located below the needle bar 31. Figure 2 shows the needle hole 73 and the needle plate 74 with dashed lines.

[0038] The leg portion 71 is located at the rear end of the main portion 701 and is supported by a second rail 75 that extends in the left-right direction. The rear end of the main portion 701 is the part behind the center of the main portion 701. The leg portion 72 is located at the front end of the main portion 701 and is supported by a second rail 76 that extends in the left-right direction. The boiler mechanism 12 can move in the left-right direction in synchronization with the head portion 24 as the legs 71 and 72 move along the second rails 75 and 76. The head portion 24 and frame 7 move in the left-right direction with the power of the X motor 132.

[0039] The bobbin mechanism 12 is housed within the casing 70 of the frame 7. The bobbin mechanism 12 has a vertical bobbin 82 in which the bobbin's rotation axis is positioned perpendicular to the direction of movement of the needle bar 31. The vertical bobbin 82 rotates in sync with the vertical movement of the needle bar 31, driven by the main motor 131.

[0040] Referring to Figure 3, the electrical configurations of the sewing machine 1, parameter display device 2, and server 3 of the sewing system 5 will be described in order. The control unit 110 of the sewing machine 1 includes a CPU 111, ROM 112, RAM 113, storage device 114, input / output interface (I / O) 115, drive circuits 121-126, etc.

[0041] The CPU 111 provides overall control over the operation of the sewing machine 1. The ROM 112 stores programs and other data for executing various processes. The RAM 113 can temporarily store various information generated during the execution of various processes. The storage device 114 is non-volatile and stores various setting values.

[0042] The drive circuits 121-126, encoders 141-143, switch group 28, thread tension sensor 38, and connector 39 are connected to I / O 115. Drive circuit 121 is connected to the main motor 131 and drives the main motor 131 with control commands from the CPU 111. Drive circuit 122 is connected to the X motor 132 of the transport mechanism and drives the X motor 132 with control commands from the CPU 111. Drive circuit 123 is connected to the Y motor 133 of the feed mechanism 25 and drives the Y motor 133 with control commands from the CPU 111.

[0043] The drive circuit 124 is connected to the air cylinder 262 and drives the air cylinder 262 according to the control commands of the CPU 111. The drive circuit 125 is connected to the air cylinder 263 and drives the air cylinder 263 according to the control commands of the CPU 111. The drive circuit 126 is connected to the display unit 29 and displays various information on the display unit 29 according to the control commands of the CPU 111.

[0044] The encoder 141 detects the rotation direction, rotation position, and rotation speed of the output shaft of the main motor 131 and outputs the detection results to the I / O 115. The detection results of the encoder 141 indicate the rotation direction, rotation position, and rotation speed of the shaft connected to the main shaft 52 and vertical spool 82 driven by the main motor 131.

[0045] Encoder 142 detects the rotational position of the output shaft of the X motor 132 and outputs the detection result to I / O 115. The detection result of encoder 142 indicates the direction of movement, left-right position, and movement speed of the needle bar 31 and the bobbin mechanism 12. Encoder 143 detects the rotational direction, rotational position, and rotational speed of the output shaft of the Y motor 133 and outputs the detection result to I / O 115. The detection result of encoder 143 indicates the direction of movement, front-back position, and movement speed of the holding mechanism 26.

[0046] The switch group 28 detects various instructions and outputs the detection results to I / O 115. The thread tension sensor 38 outputs a detection result indicating the tension of the upper thread to I / O 115. The thread tension sensor 38 may be configured using a magnetic sensor, or it may detect tension based on the output of an electrostrictive element that receives the force of the thread. The connector 39 is a USB standard connector and can be connected to USB devices such as a USB memory stick 19.

[0047] The electrical configuration of the parameter display device 2 will now be described. The parameter display device 2 in this embodiment is a general-purpose personal computer. The parameter display device 2 includes a CPU 41 that controls the parameter display device 2. The CPU 41 is electrically connected to the ROM 42, RAM 43, storage device 44, communication I / F 45, connector 48, display unit 49, and operation unit 46 via an input / output interface 47.

[0048] ROM 42 stores the boot program, BIOS, etc. RAM 43 can store timers, counters, flag data, and temporary data. Storage device 44 is a non-volatile storage medium such as a hard disk. Storage device 44 stores the programs, OS, and various tables for the processes executed by the CPU 41.

[0049] The communication interface 45 is an interface such as a LAN card for the parameter display device 2 to connect to the public network 4 via a wired connection. However, an interface for wireless connection by connecting to an access point, such as a Wi-Fi® communication module, may also be used as the communication interface 45. The CPU 41 transmits and receives data with other devices connected to the public network 4 via the communication interface 45. These other devices include the server 3.

[0050] The display unit 49 can display various types of information. The display unit 49 is, for example, a liquid crystal display. The operation unit 46 can input various types of information. The operation unit 46 includes, for example, a keyboard and a mouse.

[0051] Server 3 comprises a control unit, a storage unit, and a communication unit. The control unit is configured to execute various processes according to the program stored in the storage unit. The communication unit is a communication module for connecting to the public telephone network 4. Server 3 can send and receive data to and from the parameter display device 2 via the public telephone network 4.

[0052] This section describes the various types of sewing defects that can be detected by sewing machine 1, and an overview of the criteria for determining each sewing defect. Sewing machine 1 in this embodiment can detect selected sewing defects from among several types of sewing defects, including skipped stitches, broken threads, poor thread tension detection, and fake stitches at the start of sewing, as selected by the operator. Each of the various types of sewing defects has different criteria for determining them.

[0053] Sewing machine 1 uses the results of the upper thread tension detection by the thread tension sensor 38 to detect skipped stitches, thread breakage, poor thread tension, and fake stitches at the start of sewing. During sewing, the upper thread tension and the height of the lower end of the sewing needle 30 fluctuate periodically according to the angle of the main shaft 52, with the sewing period as the unit period. The sewing period is the time required to sew one stitch. Hereinafter, the periodically fluctuating upper thread tension will be referred to as the fluctuating tension.

[0054] Skipped stitches are a defect in the bobbin's handling of the upper thread during sewing, resulting in the inability to form normal stitches on the sewn workpiece. When skipped stitches occur, the fluctuating tension during the balance lift period does not change significantly compared to normal conditions, but the fluctuating tension during the bobbin insertion period becomes extremely small compared to normal conditions. The memory device 44 stores a skipped stitch threshold for detecting skipped stitches. When the thread tension during the balance lift period is at a normal value, and the magnitude of the upper thread tension during the bobbin insertion period falls below the skipped stitch threshold, the CPU 41 determines that skipped stitches have occurred.

[0055] Thread breakage is a defect in which the upper thread comes out of the sewing needle 30. When thread breakage occurs, the tension of the upper thread becomes extremely low for the duration of one sewing cycle. The memory device 44 stores a thread breakage threshold for detecting thread breakage. The sewing machine 1 determines that thread breakage has occurred when the magnitude of the upper thread tension during the tension pull-up period falls below the thread breakage threshold.

[0056] Poor thread tension is an imbalance between the upper and lower threads that forms a seam in the fabric when the balance 33 pulls up the upper thread. For example, if the upper thread becomes too tightly entangled with the lower thread, the sewn material near the seam will shrink. When poor thread tension occurs, the fluctuating tension during the balance pull-up period is different from the fluctuating tension of the previous cycle. The phase and magnitude of the upper thread tension during the balance pull-up period in the Nth sewing cycle in which poor thread tension occurs are different from the phase and magnitude of the upper thread tension during the balance pull-up period in the (N-1)th sewing cycle in which poor thread tension does not occur. N is an integer of two or more.

[0057] The memory device 44 stores the thread tension failure threshold for thread tension failure. During the balance lifting period, when the difference between the first phase and the second phase becomes greater than or equal to the thread tension failure threshold, the CPU 41 determines that thread tension failure has occurred. The first phase is the phase when the magnitude of the upper thread tension begins to increase during the Nth sewing cycle. The second phase is the phase when the magnitude of the upper thread tension begins to increase during the (N-1)th sewing cycle.

[0058] A false stitch at the start of sewing is a defect in which the lower thread is not supplied properly, and a stitch-like pattern is formed using only the upper thread without the lower thread being intertwined with the upper thread. Sewing machine 1 detects a false stitch at the start of sewing based on a comparison of the thread tension of the upper threads of multiple stitches with the false stitch threshold, and whether or not the bobbin mounted in the vertical hook 82 is rotating.

[0059] This section describes the sewing motion data generated by sewing machine 1. The sewing motion data represents the detection results of each stitch during the sewing process in which sewing machine 1 forms stitches on the workpiece. The sewing motion data is used to determine whether or not there is a sewing defect selected by the operator from among several types of sewing defects. The CPU 111 of sewing machine 1 acquires the thread tension of the upper thread based on the detection result of the thread tension sensor 38 and the angle of the spindle 52 based on the detection result of the encoder 141.

[0060] During the sewing period for one stitch, with the top dead center of the sewing needle 30 as the reference point, the balance lifting period and the bobbin insertion period occur in sequence. The first peak of the fluctuating tension during the sewing period occurs during the balance lifting period. The second peak of the fluctuating tension during the sewing period occurs during the bobbin insertion period. The CPU 111 determines whether there is a sewing defect by judging the balance lifting period and the bobbin insertion period from the angle of the main spindle 52 based on the detection result of the encoder 141.

[0061] The CPU 111 stores the time, the detection result of the encoder 141, the detection result of the thread tension sensor 38, etc., associated with each sewing unit in the storage device 114 as part of the sewing operation data. The sewing unit can be set as appropriate; for example, sewing one item may be considered one unit.

[0062] The main process will be explained with reference to Figures 4 to 13. In the main process, the CPU 41 displays on the display unit 49 whether the parameters used to determine sewing defects in the sewing machine 1 are set appropriately. The operator stores the information stored by the sewing machine 1 in the storage device 114 in the USB memory 19 via the connector 39, and then uploads the information to the parameter display device 2. The main process is started when the operator specifies the start of the process by operating the operation unit 46 of the parameter display device 2. As an example, the case in which skipped stitches and thread breaks are selected by the operator as sewing defects to be detected from among several types of sewing defects will be explained.

[0063] The CPU 41 reads the parameter display program for the main process from the ROM 42 into the RAM 43 and executes the main process. The parameter display program contains instructions for the CPU 41 to perform the following processes. Hereafter, steps will be abbreviated as S.

[0064] As shown in Figure 4, the CPU 41 retrieves the history data stored in the storage device 114 (S1). The CPU 41 stores the log data uploaded during the main process as history data in the storage device 114, associating it with the upload date and time. In S11, the CPU 41 retrieves the history data stored in the storage device 114.

[0065] The CPU 41 displays the list screen G1 on the display unit 49 (S2). As shown in Figure 5, the list screen G1 includes key images G2 to G4 and columns G5 and G6. Key image G2 is selected when an instruction is entered to display log data in a list.

[0066] Key image G3 is selected when entering instructions to display account information. Account information includes, for example, the user ID. Key image G4 is selected when entering instructions to upload log data. Field G5 is where search criteria are entered when searching for files.

[0067] Column G6 displays a list of log data information. Column G6 includes columns G7 to G13. Column G7 displays the type of log data using an icon, corresponding to the log data file extension. If the extension is sddb, the log data type is binary data containing thread tension data during sewing. If the extension is sddb, the log data includes parameters used to determine sewing defects and sewing defect data indicating the timing of defect occurrence. If the extension is sdds, the log data type is standard deviation information calculated based on thread tension data for 50 workpieces.

[0068] Column G8 displays the file name. Column G9 displays the number of files included in the log data. Columns G10 and G11 display the actual number of detected sewing defects among multiple sewing defects that have been selected as the target for detection. Column G10 displays the actual number of detected skipped stitches. Column G11 displays the actual number of detected thread breaks. Column G12 displays the data size of the log data. Column G13 displays the date and time the log data was updated.

[0069] The CPU 41 determines whether a file has been selected from the list displayed in column G6 (S3). The operator operates the control unit 46 to input an instruction to select the desired file. If no file has been selected (S3: NO), the CPU 41 determines whether key image G4 has been selected (S21). If key image G4 has not been selected (S21: NO), the CPU 41 returns the process to S3.

[0070] If key image G4 is selected (S21:YES), CPU 41 displays the upload screen (S22). The operator operates the control unit 46 to select the file to upload on the upload screen and enters the upload command. CPU 41 determines whether the upload has been completed based on whether it detected the upload command (S23). If the upload has not been completed (S23:NO), CPU 41 returns to processing S23.

[0071] If the data has not been uploaded (S23:YES), the CPU 41 retrieves the sewing operation data included in the uploaded log data (S24). The sewing operation data represents the detection result of each stitch during the sewing process in which the sewing machine 1 forms stitches on the workpiece. The sewing operation data in this embodiment includes thread tension data, which includes the upper thread tension detected by the thread tension sensor 38 of the sewing machine 1 as the detection result, the angle of the spindle 52, and the elapsed time from the start of sewing. The thread tension data includes multiple thread tensions within a sewing cycle, where one stitch constitutes one cycle. The thread tension data in this embodiment includes 256 thread tensions corresponding to the angle of the spindle 52 within a sewing cycle.

[0072] CPU41 retrieves the parameters contained in the uploaded log data (S25). In the parameter retrieval process, CPU41 retrieves a first parameter associated with the first sewing defect and a second parameter associated with the second sewing defect. In this embodiment, the first sewing defect is a skipped stitch, and the first parameter includes a skipped stitch threshold. In this embodiment, the second sewing defect is a broken thread, and the second parameter includes a broken thread threshold.

[0073] CPU 41 executes a sewing defect data acquisition process (S26) to acquire sewing defect data included in the uploaded log data. The sewing defect data represents the type of detected sewing defect, which is a sewing defect that actually occurred among the first and second sewing defects, and the timing at which the detected sewing defect occurred. The sewing defect data may be data generated based on the detection results of sewing defects at sewing machine 1, or it may be data that was directly or indirectly input to the parameter display device 2 regarding sewing defects discovered by the worker during inspection. If no sewing defect has actually occurred, CPU 41 may omit the process in S26, or may acquire data indicating that no sewing defect has occurred. In a specific example, CPU 41 acquires sewing defect data that represents the timing at which a skipped stitch occurred.

[0074] CPU 41 stores sewing operation data, parameters, and sewing defect data as history data in storage device 114, associating them with the upload date and time. Hereafter, sewing operation data, parameters, and sewing defect data will be collectively referred to as log data. CPU 41 adds the uploaded log data to list screen G1 and updates list screen G1 (S27). CPU 41 then executes the process described in S11 below.

[0075] In S3, the operator selects a log data file in which sewing defects were detected, for example, by referring to columns G10 and G11. If the file "4622.sddb" is selected from column G6 (S3:YES), CPU 41 displays a details screen G20 for "4622.sddb" (S4). As shown in Figure 6, the details screen G20 for "4622.sddb" includes columns G27 to G29 and key images G21 to G26.

[0076] Column G27 displays graph G60, which is created based on the selected log data. Graph G60 includes the thread tension of the upper thread for each stitch. Column G28 is used to change the range of the displayed graph. Column G29 displays the range of the displayed graph in terms of stitch count.

[0077] Graph G60 is a line graph showing the upper thread tension for each stitch from the 0th to the 10th stitch out of 85 stitches. The upper thread tension for each stitch includes 256 tension values ​​corresponding to the angle of the main shaft 52.

[0078] Key image G21 is selected when entering an instruction to return to the list screen. Key image G22 is selected when entering an instruction to display log data in a graph. Key image G23 is selected when entering an instruction to run a detection simulation that determines whether or not there is a sewing defect based on the sewing operation data and parameters in the log data.

[0079] Key image G24 is selected when entering instructions to display log information. Key image G25 is selected when entering instructions to change the display format of the graph displayed in column G27. Key image G26 is selected when entering instructions to download sewing operation data, parameters, and sewing defect data.

[0080] CPU41 determines whether log data has been selected based on whether key image G22 has been selected (S5). If log data has been selected (S5:YES), CPU41 executes the log data display process described below (S6).

[0081] If no log data is selected (S5:NO), or after processing S6, CPU41 determines whether simulation is selected based on key image G23 (S7). If simulation is selected (S7:YES), CPU41 executes the simulation display process described below (S8).

[0082] If simulation is not selected (S7:NO), or after processing S8, CPU41 determines whether log information has been selected using key image G24 (S9). If log information has been selected (S9:YES), CPU41 executes the log information display process described below (S10).

[0083] If no log information is selected (S9:NO), or after the processing in S10, the CPU 41 decides whether to terminate the main process (S11). If the main process is to be terminated, the operator operates the control unit 46 to input a termination command. If no termination command is detected (S11:NO), the CPU 41 returns the process to S3. If a termination command is detected (S11:YES), the CPU 41 terminates the main process.

[0084] Referring to Figure 7, the log data display process will be explained. The CPU 41 displays the initial log data screen on the display unit 49 (S31). The initial log data screen is the same screen as the detail screen G20. The CPU 41 determines whether the key image G23 is selected and whether simulation is selected (S32). If simulation is selected (S32: YES), the CPU 41 executes the simulation display process described later (S8).

[0085] If simulation is not selected (S32: NO), CPU 41 determines whether log information has been selected using key image G24 (S34). If log information has been selected (S34: YES), CPU 41 executes the log information display process described below (S10).

[0086] If no log information is selected (S34:NO), the CPU 41 determines whether key image G25 has been selected and whether an instruction to change the graph display format has been detected (S36). The CPU 41 in this embodiment can display a graph of the type selected by the operator from among several types of graphs. The multiple types of graphs may be set as appropriate according to the type of sewing defect.

[0087] The multiple types of graphs in this embodiment include the first graph and the second graph. The first graph is graph G60, shown in Figure 6, which shows the change in upper thread tension with respect to the number of needles. The second graph is graph G64, shown in column G27 of screen G30 in Figure 8, which shows the change in upper thread tension within one needle. The horizontal axis of graph G64 is the angle of the principal axis 52.

[0088] If an instruction to change the graph display format from the first graph to the second graph is detected (S36: YES), the CPU 41 displays screen G30 as shown in Figure 8 and changes the graph display format (S37). The CPU 41 then performs the process described in S44 below.

[0089] If no instruction to change the graph display format is detected (S36: NO), the CPU 41 determines whether an instruction to download log data has been detected by the key image G26 (S38). If an instruction to download log data is detected (S38: YES), the CPU 41 displays the file format selection screen (S39). The file format selection screen is for selecting the file format of the log data to be downloaded from the parameter display device 2. The operator operates the operation unit 46 to select the desired file format from among the multiple file formats displayed on the selection screen.

[0090] CPU 41 determines whether it has detected an instruction to select a file format (S40). If no instruction to select a file format has been detected (S40: NO), CPU 41 returns to S40. If an instruction to select a file format has been detected (S40: YES), CPU 41 outputs the selected log data in the selected file format (S41). CPU 41 may output the selected log data to, for example, the USB memory 19 connected to connector 48. CPU 41 then performs the processing described in S44 below.

[0091] If no instruction to download log data is detected (S38: NO), CPU 41 determines whether an instruction to change the display range has been detected (S42). If the operator wants to change the display range of the graph, they operate column G28 to input an instruction to change the display range. If an instruction to change the display range of the graph is detected (S42: YES), CPU 41 displays the range indicated in column G28 and changes the display range of the graph (S43).

[0092] If no instruction to change the display range of the graph is detected (S42: NO), or immediately after S43, the CPU 41 determines whether an instruction to return to the list screen has been detected by the key image G21 (S44). If the user does not return to the list screen (S44: NO), the CPU 41 returns to processing S32. If the user returns to the list screen (S44: YES), the CPU 41 displays the list screen G1 on the display unit 49 (S45). The CPU 41 then terminates the log data display process and returns to the main processing.

[0093] The simulation display process will be explained with reference to Figures 9 to 11(B). The CPU 41 displays the initial simulation screen G40 on the display unit 49 (S51). The initial simulation screen G40 includes key images G21 to G24, G43, G44, and columns G41, G42, G45 to G47. Column G41 displays the type of sewing defect selected by the operator from among multiple sewing defects, and the settings. In this specific example, thread breakage and skipped stitches are selected as sewing defects.

[0094] Column G42 displays the current parameter setting for one of the sewing defects selected by the operator. In the parameter change process, CPU 41 displays the selected parameter corresponding to the selected sewing defect from the first and second parameters on the display unit 49 and accepts the change of the selected parameter. Figure 10 shows the case where skipped stitches are selected as the sewing defect for which parameters are to be displayed. CPU 41 may display parameters for each sewing defect, or it may display parameters for some or all of the selected sewing defects together.

[0095] Column G42 in Figure 10 displays the current settings for the skipped stitch parameters, including the skipped stitch threshold. The skipped stitch parameters include multiple items, including a first threshold and a second threshold. The first threshold is the upper thread tension threshold during the balance lift period, which is part of the sewing period for one stitch, and the second threshold is the upper thread tension threshold during the bobbin insertion period, which is also part of the sewing period for one stitch. Here, the first threshold may be entered as a percentage of the total thread tension detected during the balance lift period, for example, a value between 0 and 100%. The detection start speed may be entered as, for example, the rotational speed of the main motor 131 or spindle 52 per minute (rpm).

[0096] In this embodiment, the first and second threshold values ​​can be set to different values ​​for each of three conditions, A, B, and C, depending on the operating status of the main motor 131. The operating status of the main motor 131 may be, for example, the number of stitches since the start of operation, the number of items sewn, or the operating time. The operating status of the main motor 131 is determined, for example, based on the calculation results of the elapsed time since the start of sewing, the number of stitches, the number of items sewn, and the angle of the spindle 52, which are included in the sewing operation data. The graph in column G45 displays the sum of the thread tensions detected during each period defined by the angle of the spindle 52 as described above, and the values ​​of each threshold calculated by the input parameters.

[0097] Key image G43 is selected when an instruction is given to display the defect detection timing on a graph. The defect detection timing is the timing at which a selected sewing defect occurs, based on the detection result for each stitch and the comparison result with the parameters, for a first sewing defect and a second sewing defect that is different from the first sewing defect.

[0098] In this embodiment, the parameter display device 2 includes the failure detection timing in the graph after the key image G43 is selected. Therefore, the failure detection timing is not displayed on the initial simulation screen G40.

[0099] Key image G44 is selected when an instruction is given to output log data to an external device. The external device is, for example, a USB memory stick 19.

[0100] Column G45 displays a graph. As shown in Figure 11(A), the graph G61 on the initial simulation screen G40 includes the detection results for each stitch and the parameters. When the selected sewing defects are skipped stitches and thread breaks, the graph G61 includes, as the detection results for each stitch, the sum of the upper thread tension K1 during the balance lift period and the sum of the upper thread tension K2 during the bobbin insertion period. The graph G61 also includes the thread break threshold J1 and the skipped stitch threshold J2 as parameters.

[0101] Graph G61 is a line graph plotting the sum K1, sum K2, thread break threshold J1, and skipped stitch threshold J2 for each number of needles. Since the thread break threshold J1 and skipped stitch threshold J2 are calculated based on the tension of the previous needle, the thresholds also change in accordance with changes in thread tension.

[0102] The graph G61 of this embodiment further includes a defect occurrence timing G48 displayed based on sewing defect data. The defect occurrence timing G48 is the timing at which a sewing defect actually occurred. The defect occurrence timing G48 represents the type of sewing defect detected and the timing on the graph G61 at which the sewing defect occurred. By checking the graph G61, the user can easily confirm the setting status of the selected sewing defect parameters.

[0103] If the timing of a defect is not recorded in the log data, the timing of the defect may not be displayed on the graph, or a message indicating that the timing of the defect is not recorded in the log data may be displayed. The timing of the thread breakage defect is not displayed in graph G61. The absence of the thread breakage defect timing in graph G61 indicates that no thread breakage occurred.

[0104] Column G46 is used to change the range of the displayed graph. Column G47 displays the range of the displayed graph in terms of stitch count. Graph G61 in column G45 displays the thread tension of the upper thread for each stitch from stitch 0 to stitch 85 out of 5 stitches.

[0105] CPU41 determines whether log data has been selected based on key image G22 (S52). If log data has been selected (S52: YES), CPU41 executes the log data display process described above (S6).

[0106] If no log data is selected (S52: NO), CPU 41 determines whether log information has been selected using key image G24 (S54). If log information is selected (S54: YES), CPU 41 executes the log information display process described below (S10).

[0107] If no log information is selected (S54: NO), the CPU 41 determines whether a sewing defect displayed in column G41 has been selected (S56). The operator operates the control unit 46 to select a sewing defect from the items displayed in column G41 to be displayed in column G42.

[0108] If a sewing defect is detected (S56:YES), the CPU 41 displays the selected sewing defect as a display sewing defect from the items displayed in column G41 (S57). The CPU 41 displays the parameters of the display sewing defect in column G42 (S58). Column G42 in Figure 10 shows the case where skipped stitches are the display sewing defect. The CPU 41 then executes the process described in S72 below.

[0109] If no sewing defect is detected (S56: NO), the CPU 41 determines whether an instruction to perform a simulation based on the selection of key image G43 has been detected (S59). If an instruction to perform a simulation is detected (S59: YES), the CPU 41 performs a transmission process to send sewing operation data and parameters to server 3 (S60). Based on the comparison result between the sewing operation data and the parameters, the CPU 41 determines whether it has received the defect detection timing determined by server 3 (S61). If the defect detection timing has not been received (S61: NO), the CPU 41 returns to processing S61.

[0110] Server 3, having received sewing operation data and parameters from the parameter display device 2, determines the defect detection timing based on the comparison result between the sewing operation data and the parameters. The method for determining the defect detection timing may be appropriately changed depending on the type of sewing defect and the parameters. For example, Server 3 may determine that there is a sewing defect when the detection result for each stitch exceeds a threshold. Server 3 transmits the determination result to the parameter display device 2. Server 3 may store the determination result in association with the identification information of the parameter display device 2 or the sewing machine 1.

[0111] If a defect detection timing is received (S61:YES), the CPU 41 displays a graph in column G45 that includes the detection result for each stitch, parameters, and defect detection timing for the selected sewing defect, which is chosen from the first sewing defect and the second sewing defect which is different from the first sewing defect (S62). In the specific example shown in Figure 11(A), no sewing defect is detected based on the comparison result between the sewing operation data and the parameters, so the defect detection timing based on the simulation result is not added to graph G61. In the specific example shown in Figure 11(A), the judgment result from the simulation and the defect occurrence timing G48 read from the sewing defect data on the log data do not match.

[0112] If no instruction to run the simulation is detected (S59: NO), the CPU 41 determines whether an instruction to select key image G44 and download log data including sewing operation data, parameters, and sewing defect data has been detected (S63). If an instruction to download log data is detected (S63: YES), the CPU 41 displays a selection screen to select the file format of the log data to be downloaded (S64). The operator operates the control unit 46 to select the desired file format from among the multiple file formats displayed on the selection screen.

[0113] CPU 41 determines whether it has detected an instruction to select a file format (S65). If no instruction to select a file format has been detected (S65: NO), CPU 41 returns to S65. If an instruction to select a file format has been detected (S65: YES), CPU 41 executes parameter output processing that allows the modified parameters to be output to an external device (S66). For example, CPU 41 outputs the selected log data to the USB memory 19 in the selected file format. CPU 41 then performs the processing described in S72 below.

[0114] The output log data may be uploaded to the sewing machine via the USB memory 19, and the parameters stored in the sewing machine may be updated based on the uploaded log data. In this case, the sewing machine may be sewing machine 1 that generated the log data, or it may be another sewing machine of the same model as sewing machine 1 that generated the log data. In this case, the sewing system 5 can reflect the changed parameters in sewing machine 1 using the parameter display device 2.

[0115] If no instruction to download log data is detected (S63: NO), CPU 41 determines whether an instruction to change the display range has been detected (S67). If the operator wants to change the display range of the graph, they operate column G46 to input an instruction to change the display range. If an instruction to change the display range of the graph is detected (S67: YES), CPU 41 displays the range indicated in column G46 and changes the display range of the graph (S68).

[0116] If no instruction to change the display range of the graph is detected (S67: NO), it is determined whether to change the parameters of the indicated sewing defect displayed in column G42 (S70). If the operator changes the parameters of the indicated sewing defect, they operate the operation unit 46 to change the parameters in column G42. In the specific example in Figure 11(A), the judgment result on server 3 and the defect occurrence timing G48 do not match, so the operator inputs an instruction to change the skipped stitch threshold so that the two match.

[0117] If an instruction to change a parameter is detected (S70: YES), the CPU 41 executes a parameter change process to accept the parameter change (S71). The CPU 41 changes the parameter according to the instruction entered by the operator and updates the history data in the storage device 114. The CPU 41 updates the parameter displayed in column G42 and the graph parameter displayed in column G45. The CPU 41 then executes the process described in S72 below.

[0118] If, after changing the skipped stitch parameters, an instruction to run a simulation is entered in S59, the CPU 41 displays graph G62 in Figure 11(B) based on the judgment result from server 3 (S60, S61: YES, S62). Graph G62 includes parameters such as the thread breakage threshold J1 and the changed skipped stitch threshold J3, the detection result for each stitch, the defect judgment timing G49, and the defect occurrence timing G48. In this embodiment, the CPU 41 highlights the defect judgment timing G49 with a background where the sum of the thread tension K2 of the upper thread during the bobbin insertion period falls below the changed skipped stitch threshold J3. After the operator changes the skipped stitch parameters and performs the process in S62, the defect judgment timing G49 and the defect occurrence timing G48 coincide.

[0119] If no instruction to change parameters is detected (S70: NO), the CPU 41 determines whether to return to the list screen based on whether key image G21 has been selected (S72). If it does not return to the list screen (S72: NO), the CPU 41 returns to processing S52. If it returns to the list screen (S72: YES), the CPU 41 displays list screen G1 on the display unit 49 (S73). The CPU 41 then terminates the simulation display processing and returns to processing the main process.

[0120] The log information display process will be explained with reference to Figures 12 and 13(A) to 13(C). The CPU 41 displays the initial log information screen G50 on the display unit 49 (S51). As shown in Figure 13(A), the initial log information screen G50 includes key images G21 to G24 and fields G51 to G54.

[0121] Column G51 displays general information about sewing machine 1 included in the log data (S81). Column G52 displays the detection settings, including the selection status of multiple types of sewing defects. Column G53 displays various count values ​​for detected sewing defects. Column G54 displays ID information. The ID information includes information such as the time the log data was created, the parameter change history, and comments entered by the user.

[0122] Each of the columns G51 to G54 can be switched between a first mode that displays information and a second mode that displays only the item name without displaying any information. In the initial log information screen G50, columns G51 to G54 are displayed in the second mode.

[0123] The CPU 41 determines whether log data has been selected based on whether key image G22 has been selected (S82). If log data has been selected (S82: YES), the CPU 41 executes the log data display process described above (S6).

[0124] If no log data is selected (S82: NO), CPU 41 determines whether key image G23 is selected and whether simulation is selected (S84). If simulation is selected (S84: YES), CPU 41 executes the simulation display process described above (S8).

[0125] If simulation is not selected (S84: NO), the CPU 41 determines whether to change the display mode of the general information based on whether it has detected a selection in field G51 (S86). If the display mode of the general information is to be changed (S86: YES), the CPU 41 changes the display mode of the general information (S87). If the general information was displayed in the first mode, the CPU 41 displays the general information in the second mode in S87, as shown in Figure 13(B). The CPU 41 then executes the process in S94 described below.

[0126] If the display method for general information is not changed (S86: NO), the CPU 41 determines whether to change the display method for the detection settings based on whether it has detected a selection in column G52 (S88). If the display method for the detection settings is changed (S88: YES), the CPU 41 changes the display method for the detection settings in column G52 (S89). If the detection settings were displayed in the first method, the CPU 41 displays the detection settings in the second method in S89, as shown in Figure 13(C).

[0127] The process of selecting specific sewing defects from among multiple types is performed using column G52. The operator sets the value of the sewing defects to be selected for detection to ON and the value of the sewing defects to be excluded to OFF. The operator can check the currently selected sewing defects using column G52.

[0128] If the display method for the detection settings is not changed (S88: NO), the CPU 41 determines whether to change the display method for the counter value based on whether it has detected a selection in column G53 (S90). The counter value is the value at which sewing defects are detected, and it is possible to display the counted value for each type of sewing defect, the sum of the count values ​​for all sewing defects, or the counter value within a specified range such as judgment period, time, number of stitches, and number of sewn pieces. In column G53, the CPU 41 can change the types that are allowed to be displayed, change the display order, or switch and display counter values ​​for different judgment periods. If the display method for the counter value is changed (S90: YES), the CPU 41 changes the display method for the counter value in column G53 (S91). The CPU 41 then executes the process in S94 described below.

[0129] If the display method of the counter value is not changed (S90: NO), the CPU 41 determines whether to change the display method of the ID information based on whether it has detected the selection of column G54 (S92). In column G54, the CPU 41 can change whether or not to display the ID information by type and the order in which it is displayed. If the display method of the ID information is changed (S92: YES), the CPU 41 changes the display method of the ID information in column G54 (S93). The CPU 41 then executes the process described in S94 below.

[0130] If the display method of the ID information is not changed (S92: NO), the CPU 41 determines whether to return to the list screen based on whether key image G21 was selected (S94). If the system does not return to the list screen (S94: NO), the CPU 41 returns to processing S82. If the system returns to the list screen (S94: YES), the CPU 41 displays the list screen G1 on the display unit 49 (S95). The CPU 41 then terminates the log information display process and returns to the main processing.

[0131] In the above embodiment, sewing machine 1 is an example of a sewing machine of the present invention. Parameter display device 2 is an example of a parameter display device of the present invention. Server 3 is an example of a server of the present invention, and display unit 49 is an example of a display unit of the present invention. Thread tension sensor 38 is an example of a thread tension sensor of the present invention, and CPU 41 is an example of a control unit of the present invention.

[0132] The process in S24 is an example of the data acquisition process of the present invention, and the process in S25 is an example of the parameter acquisition process of the present invention. The process in S62 is an example of the display control process of the present invention, and the process in S60 is an example of the transmission process of the present invention. The process in S61 is an example of the reception process of the present invention. The process in S71 is an example of the parameter change process of the present invention, and the process in S26 is an example of the sewing defect data acquisition process of the present invention. The processes in S41 and S66 are examples of the parameter output process of the present invention.

[0133] The parameter display device 2 of the above embodiment comprises a display unit 49 and a CPU 41. The CPU 41 performs a data acquisition process to acquire sewing operation data representing the detection result of each stitch during the sewing process in which the sewing machine 1 forms stitches on the sewn work (S24). The CPU 41 also performs a parameter acquisition process to acquire parameters (S25).

[0134] The CPU 41 performs a display control process (S62) to display a graph on the display unit 49 that includes the detection result for each stitch, the parameters, and the defect judgment timing for the selected sewing defect. The selected sewing defect is a sewing defect selected from among the first sewing defect and a second sewing defect that is different from the first sewing defect. The defect judgment timing is the timing at which it is determined that a selected sewing defect has occurred based on the comparison result between the sewing operation data and the parameters. The display control process performed by the CPU 41 of the parameter display device 2 contributes to making it easier to confirm whether the parameters used for determining sewing defects are set appropriately compared to conventional methods.

[0135] With conventional sewing machines, operators could not view the log data. Therefore, operators could not understand how sewing defects were being detected. In contrast, the parameter display device 2 makes the log data, which was previously a black box, easily viewable by operators. Thus, the display control processing of the parameter display device 2 contributes to increasing the potential for detecting sewing defects and improving the value of sewing defect detection.

[0136] In the parameter display device 2, the CPU 41 performs a transmission process to send sewing operation data and parameters to the server 3 (S60). The CPU 41 also performs a reception process to receive the defect judgment timing determined by the server 3 based on the comparison result between the sewing operation data and the parameters (S61). The graph includes the defect judgment timing received from the server 3. The transmission and reception processes performed by the CPU 41 of the parameter display device 2 contribute to simplifying the processing performed by the parameter display device 2 for executing display control processing.

[0137] In the parameter display device 2, the sewing operation data is thread tension data that includes the upper thread tension detected by the thread tension sensor 38 of the sewing machine 1 as the detection result. The graph includes the upper thread tension for each stitch. The display control processing of the parameter display device 2 contributes to making it easier than before to confirm whether the parameters for selected sewing defects detected based on the upper thread tension are set appropriately.

[0138] In the parameter display device 2, the thread tension data includes multiple thread tensions within a sewing cycle where one stitch constitutes one cycle. The thread tension of the upper thread for each stitch is the thread tension of the upper thread for a predetermined period within the sewing cycle. The display control processing of the parameter display device 2 contributes to making it easier than before to confirm whether the parameters for selected sewing defects, which are detected based on the thread tension of the upper thread for a predetermined period, are set appropriately.

[0139] In the parameter display device 2, the CPU 41 executes a parameter change process to accept parameter changes (S71). The graph includes the timing of the defect determination when a selected sewing defect is determined to have occurred based on the comparison result between the sewing operation data and the changed parameters. The parameter change process of the parameter display device 2 contributes to making it easier to confirm whether the parameters for selected sewing defects after the change are set appropriately compared to conventional methods.

[0140] In the parameter display device 2, the CPU 41 acquires a first parameter and a second parameter as parameters in the parameter acquisition process (S25). The first parameter is the parameter associated with the first sewing defect. The second parameter is the parameter associated with the second sewing defect. In the parameter change process, the CPU 41 displays the selected parameter from the first and second parameters that corresponds to the selected sewing defect on the display unit 49 (S58) and accepts the change of the selected parameter (S71). The parameter change process of the parameter display device 2 contributes to improving the convenience of the operator when changing the selected parameter compared to when the first and second parameters are displayed in the parameter change process.

[0141] In the parameter display device 2, the CPU 41 is configured to perform parameter output processing that allows the modified parameters to be output to an external device (S41, S66). The parameter output processing of the parameter display device 2 contributes to improving the convenience of the operator when setting the parameters changed in the parameter change processing to the sewing machine.

[0142] In the parameter display device 2, the CPU 41 is configured to execute a sewing defect data acquisition process that acquires sewing defect data representing the type of detected sewing defect (which is a sewing defect that actually occurred) and the timing of the defect occurrence when the detected sewing defect occurred (S26). The graph includes the timing of the defect occurrence. The display control process of the parameter display device 2 helps the operator to compare and confirm the timing of the defect occurrence with the timing of the defect judgment.

[0143] The parameter display device, parameter display method, and parameter display program of the present invention are not limited to the embodiments described above, and various modifications are possible. For example, the present invention can also be realized in the form of a sewing system 5, a program executed by the sewing system 5, a storage medium storing the parameter display program, etc.

[0144] The configuration of the sewing machine 1 may be modified as appropriate; for example, it may be a sewing machine that does not hold the workpiece with the holding mechanism 26. The sewing machine 1 may be a two-needle sewing machine with two sewing needles attached to the needle bar 31, or a sewing machine with three or more sewing needles. The configuration, arrangement, detection method, etc. of the thread tension sensor 38 may be modified as appropriate. The sewing machine 1 may also be equipped with the function of a parameter display device 2.

[0145] The types of sewing defects detected by sewing machine 1 and the sewing operation data may be changed as appropriate. The sensors for detecting sewing operation data may be changed as appropriate depending on the type of sewing defect. For example, sewing machine 1 may detect an abnormality in the thickness of the sewn material as a sewing defect based on a height sensor that detects the height of the presser foot 32. In this case, the height sensor only needs to be able to detect the height of the presser foot 32 and may be an optical sensor, a magnetic sensor, or a camera.

[0146] The sewing defects detected by the sewing machine 1 may include abnormalities in the distance between the sewing needle 30 and the tip of the vertical bobbin 82 when the needle bar 31 is at its bottom dead center, i.e., abnormalities in the needle gap. In this case, the sewing machine 1 may generate sewing operation data from the detection results of the needle gap sensor for each individual stitch.

[0147] The parameter display device 2 may be a dedicated device or a general-purpose device such as a PC. The parameter display device 2 may also be a mobile terminal such as a smartphone. The parameter display device 2 may perform some or all of the processing that was performed by the server 3.

[0148] The display unit 49 can be any device capable of displaying images, such as an organic EL display, plasma display, plasma tube array display, or electronic paper display using electrophoresis. The operation unit 46 can be a keyboard, mouse, touchscreen, joystick, or the like.

[0149] The parameter display program only needs to be stored in the storage device of the parameter display device 2 before the CPU 41 executes the program. Therefore, the method of acquiring the parameter display program, the acquisition path, and the device that stores the program can each be changed as appropriate. The parameter display program executed by the CPU 41 may be received from another device via cable or wireless communication and stored in a storage device such as flash memory. Other devices include, for example, a PC and a server connected via a network.

[0150] Some or all of the processing performed by the parameter display device 2 may be performed by an electronic device other than the CPU 41, such as an ASIC. The processing performed by the parameter display device 2 may be distributed among multiple electronic devices, such as multiple CPUs. Each step of the processing performed by the parameter display device 2 can be rearranged, omitted, or added as needed. The scope of the present invention also includes embodiments in which an operating system (OS) running on the parameter display device 2 performs some or all of the processing at the command of the CPU 41. The parameter display device 2 may be modified as appropriate in the above embodiment, for example.

[0151] The methods for acquiring sewing motion data, parameters, and sewing defect data may be modified as appropriate. For example, sewing motion data may be acquired via a wired or wireless network. Some or all of the parameters may be common to the first sewing defect and the second sewing defect.

[0152] The methods for acquiring sewing operation data, parameters, and sewing defect data may be the same or different. For example, the operator's input via the operation unit 46 may be acquired as sewing defect data. Sewing defect data may also be acquired from a device that inspects the sewn product. The process of acquiring sewing defect data in S26 may be omitted. For example, sewing operation data, parameters, and sewing defect data may be included in a single log data, or each data may exist separately as a separate data file and be acquired individually.

[0153] The type and display method of the graph may be changed as appropriate. The selected sewing defect may be one type of sewing defect or multiple types of sewing defects. If the selected sewing defect includes multiple types of sewing defects, the graph may include all types of sewing defects, or a separate graph may be generated for each sewing defect. The graph does not need to include the timing of defect occurrence.

[0154] The method of displaying the timing of defect occurrence and the timing of defect detection may be changed as appropriate. The method of displaying the timing of defect occurrence and the timing of defect detection may be represented by marks of a color or shape corresponding to the sewing defect. CPU 41 may display a graph including the defect detection timing on screen G40 in S51. CPU 41 may perform processing to display a graph including the defect detection timing between the processing in S71 and the processing in S72.

[0155] CPU41 may display a warning if the timing of failure occurrence and the timing of failure detection do not coincide. If the timing of failure occurrence and the timing of failure detection do not coincide, CPU41 may display candidate parameters to make them coincide.

[0156] Sewing operation data may be modified as appropriate in response to sewing defects. The number of thread tensions included in one sewing cycle may be modified as appropriate. The upper thread tension for each stitch may be the sum of the upper thread tensions for the entire sewing cycle, or a representative value for the sewing cycle. The representative value may be the average value of multiple thread tensions for the entire sewing cycle or a specified period, the median value, or the angle value of a predetermined main axis 52.

[0157] CPU41 does not need to accept parameter changes. The graph does not need to include the defect detection timing at which a sewing defect was determined to have occurred based on the comparison result with the changed parameters. The graph may include information indicating that no defect detection timing was detected. In this case, the operator can easily understand, based on the information, that no defect detection timing was detected.

[0158] The CPU 41 may display each of the first and second parameters on the display unit 49 during the parameter change process. The method by which the CPU 41 outputs the changed parameters to an external device may be changed as appropriate. For example, the changed parameters may be output to an external device, including the sewing machine 1, via a wired or wireless network. [Explanation of Symbols]

[0159] 1: Sewing machine 2: Parameter display device 3: Server 29:Display section 38: Thread tension sensor 41: CPU

Claims

1. Display unit and It includes a control unit, The control unit, A data acquisition process that acquires sewing motion data representing the detection result of each stitch during the sewing process in which a sewing machine forms stitches on a sewn workpiece, The parameter retrieval process for obtaining parameters, Regarding the first sewing defect and the second sewing defect which is different from the first sewing defect, The detection result for each needle, The aforementioned parameters, Based on the comparison result between the sewing operation data and the parameters, the defect determination timing at which it was determined that the selected sewing defect occurred, A display control process that displays a graph including the graph on the display unit. A parameter display device characterized by being configured to perform the following.

2. The control unit, A transmission process that sends the sewing operation data and the parameters to a server, A receiving process that receives the defect detection timing determined by the server based on the comparison result between the sewing operation data and the parameters, Configured to perform further, The parameter display device according to claim 1, characterized in that the graph includes the failure determination timing received from the server.

3. The sewing operation data is thread tension data that includes the upper thread tension detected by the thread tension sensor of the sewing machine as the detection result. The parameter display device according to claim 1, characterized in that the graph includes the thread tension of the upper thread for each stitch.

4. The aforementioned thread tension data includes multiple thread tensions within a sewing cycle where one stitch constitutes one cycle. The parameter display device according to claim 3, characterized in that the thread tension of the upper thread for each stitch is the thread tension of the upper thread for a predetermined period within the sewing cycle.

5. The control unit, It is configured to further perform a parameter change process that accepts changes to the aforementioned parameters, The parameter display device according to claim 1, characterized in that the graph includes the defect determination timing at which it was determined that a selected sewing defect occurred based on the comparison result between the sewing operation data and the modified parameters.

6. The control unit, In the parameter acquisition process described above, the parameters acquired are a first parameter associated with the first sewing defect and a second parameter associated with the second sewing defect. The parameter display device according to claim 5, characterized in that, in the parameter change process, the selected parameter corresponding to the selected sewing defect among the first parameter and the second parameter is displayed on the display unit, and the change of the selected parameter is accepted.

7. The control unit, The parameter display device according to claim 5 or 6, further configured to perform parameter output processing that enables outputting the modified parameters to an external device.

8. The control unit, The system is configured to further execute a sewing defect data acquisition process that acquires sewing defect data representing the type of detected sewing defect that actually occurred among the first sewing defect and the second sewing defect, and the timing at which the detected sewing defect occurred. The parameter display device according to claim 1, characterized in that the graph includes the timing of the failure occurrence.

9. A parameter display method characterized by including various processes performed by the control unit of the parameter display device according to any one of claims 1 to 8.

10. A parameter display program characterized by including instructions for the control unit of the parameter display device to execute various processes of the parameter display device described in any one of claims 1 to 8.

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