Printing and embroidery system, printing and embroidery device, and embroidery adjustment method for printing and embroidery system

Abstract

To provide an apparatus which avoids misregistration of an embroidery color on cloth, and prevents deviation of a thread consumption amount from accumulating even if an actual consumed amount of the thread deviates from an estimate while performing embroidery using a thread whose color varies in a print embroidery system.SOLUTION: A print embroidery system includes: a dyeing data-processing part for inserting redundant data attached with a folding marker as a mark on a thread into a color change point where the color to dye by initial dying data changes; an embroidering data-processing part for inserting preliminary sewing data for sewing an under side of an embroidery region of a next color longer than the redundant data; a dying part for dying thread on the basis of a dying data containing the redundant data attached with the folding marker; and a preliminary sewing-controlling part for having a deviated amount between an estimated embroidery position and an actual embroidery position consumed by having preliminary sewing operation adjusted with a length so as to begin the preliminary sewing at a timing of reaching of estimated embroidery position on the embroidery data calculated from a stitch number to a color change point on the embroidery data, and make one reciprocation by returning at a returning marker as a mark performed.SELECTED DRAWING: Figure 11

Description

[Technical field]

[0001] The present invention relates to a printing and embroidery system, a printing and embroidery device, and an embroidery adjustment method for the printing and embroidery system. [Background technology]

[0002] In recent years, an embroidery system with a dyeing function has become known that uses inkjet technology to dye an upper thread so as to impart a color that changes in the transport direction, and embroiders using the dyed upper thread with an embroidery machine or sewing machine.

[0003] In the embroidery machine of this type of embroidery system, the balance between the tension of the upper and lower threads can be disrupted, the fabric can warp, or the thickness of the embroidery can vary, causing the balance between the consumption of the upper and lower threads to change, which can result in the embroidery being misaligned on the fabric.

[0004] Therefore, Patent Document 1 proposes inserting data for underlayment and adjusting the dyeing data so that the color change of the upper thread is positioned below the embroidery of the next color, in order to prevent the color change from being exposed on the surface of the embroidery. Summary of the Invention [Problem to be solved by the invention]

[0005] In Patent Document 1, the dyeing data is adjusted so that a predetermined length of understitching, including a color transition, is hidden in the area to be embroidered, but if the consumption of upper thread changes from the prediction during the embroidery operation, the position of the color transition will shift. If the actual consumption amount deviates significantly from the prediction and this positional shift accumulates, it is conceivable that even the predetermined length of understitching will not be able to cover the shift.

[0006] In view of the above circumstances, the present invention aims to provide a textile printing and embroidery system that prevents misalignment of the embroidery colors on the fabric and prevents accumulation of deviations in thread consumption even if the actual thread consumption deviates from expected during embroidery operation using continuous threads that change color. [Means for solving the problem]

[0007] In order to solve the above problems, in one aspect of the present invention, A printing device for printing the yarn; an embroidery device that uses the thread sent from the printing device to embroider on a cloth with a needle based on embroidery data, Create initial dyeing data that realizes the thread color of the embroidery data, and at the color change points where the dyeing color changes in the initial dyeing data, 、 a dyeing data processing unit for inserting redundant data with turn-back markers that serve as marks on the yarn; an embroidery data processing unit that inserts underlay data for sewing an underside of an embroidery area of ​​a planned next color at a color change point on the embroidery data, the underlay data being longer than the redundant data, at a position on the dyeing data where the redundant data has been inserted; The printing apparatus includes: A dyeing section is provided for printing yarn based on the dyeing data including the redundant data with the turnaround marker, The embroidery device includes: The understitching control unit starts understitching at a timing when an assumed embroidery position on the embroidery data, which is calculated from the number of stitches sewn by the needle, reaches a color change point on the embroidery data, regardless of the actual embroidery position on the thread, and performs an understitching operation with a length adjusted so that the understitching is turned back and forth using the turn marker as a marker, thereby consuming the deviation between the assumed embroidery position and the actual embroidery position. Textile printing and embroidery system to provide. Effect of the Invention

[0008] According to one embodiment, in a textile printing and embroidery system, even if the actual thread consumption deviates from the expected amount during embroidery operation using continuous threads of changing color, it is possible to avoid misalignment of the embroidery color on the fabric and prevent accumulation of deviations in the amount of thread consumption. [Brief description of the drawings]

[0009] [Figure 1] 1 is a schematic side view of a dyeing and embroidery system according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic side view of a dyeing unit in the dyeing apparatus according to one embodiment of the present invention. [Diagram 3] FIG. 2 is a schematic diagram of the underside of a dyeing unit according to one embodiment of the present invention. [Figure 4] FIG. 1 is a schematic block diagram of a dyeing and embroidery system according to a first embodiment. [Diagram 5] 1 is a schematic diagram showing an example of stitches on the upper and lower sides of a fabric using an upper thread and a lower thread; [Figure 6] Schematic cross-sectional views of various states of stitches made by upper and lower threads on a piece of fabric. [Figure 7] FIG. 4 is an explanatory diagram of a yarn consumption detection unit according to an embodiment of the present invention. [Figure 8] FIG. 2 is a functional block diagram of an embroidery data processing unit, an embroidery data processor, and a computing mechanism according to the first embodiment. [Figure 9] 13 is an example of dyeing data with turn-over markers dyed by the dyeing device of the present invention. [Figure 10] FIG. 1 is a sequence diagram showing the communication between devices in the dyeing and embroidery flow of the present invention. [Figure 11] 4 is a detailed flowchart showing an embroidery control operation of the present invention. [Figure 12] 11A-11C are diagrams illustrating examples of redundant dye areas and underlay distances on dyed threads in the embroidery control operation of the present invention. [Figure 13] 13A and 13B are diagrams illustrating a specific example of an embroidery pattern produced by performing the embroidery control operation of the present invention when the actual amount of upper thread consumption is less than expected. [Figure 14] 11A and 11B are diagrams illustrating a specific example of an embroidery pattern produced by implementing the embroidery control operation of the present invention when the actual amount of upper thread consumption is greater than expected. [Figure 15] FIG. 4 is a diagram showing a modified example of the embroidery device according to the first embodiment of the present invention. [Figure 16] FIG. 5 is a schematic side view of a dyeing and embroidery system according to a second embodiment of the present invention. [Figure 17] FIG. 11 is a functional block diagram relating to control of a host control device, a dyeing device, and an embroidery device according to a second embodiment. [Figure 18]FIG. 11 is a schematic side view of a dyeing and embroidery device according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the following drawings, the same components are denoted by the same reference numerals, and duplicated explanations may be omitted.

[0011] <Overall composition> First, a dyeing and embroidery system (textile printing and embroidery system) according to a first embodiment of the present invention will be described with reference to Figs. 1 to 4. Fig. 1 is a side schematic view of an example of the dyeing and embroidery system according to the first embodiment of the present invention. Fig. 2 is a side schematic view of a dyeing section in a dyeing device according to one embodiment of the present invention. Fig. 3 is a bottom schematic view of the dyeing section according to one embodiment of the present invention. Fig. 4 is a schematic block diagram of the dyeing and embroidery system according to the first embodiment.

[0012] 1, a dyeing and embroidery system 3 according to this embodiment includes a dyeing device 1 and an embroidery device 2. In this system, the dyeing device 1 is electrically connected to the embroidery device 2 via wired or wireless communication so as to be able to exchange information with the embroidery device 2.

[0013] The dyeing device 1 includes an upper thread spool 101 around which an upper thread N is wound, a dyeing section 103, a fixing section 104, and a post-processing section 105. The dyeing device 1 in this embodiment is a yarn coloring device that dyes yarn by liquid ejection.

[0014] In the dyeing device 1, a thread N unwound from an upper thread spool 101 is guided by a supply roller 102 and a transport roller 106, and is continuously wound up to the embroidery head 20 of the embroidery device 2.

[0015] The dyeing section 103 includes a plurality of ejection heads 30 (30K to 30Y) that eject and apply liquid of the required color to the yarn N that is pulled out from the upper thread spool 101 and transported, and a maintenance unit 35 that is composed of a plurality of individual maintenance units 36 (36K to 36Y) that perform maintenance on each of the ejection heads 30K to 30Y.

[0016] Hereinafter, the width direction of the dyeing and embroidery system 3 will be referred to as X, the depth direction of the dyeing and embroidery system 3 as Y, and the height direction (vertical direction) as Z.

[0017] Referring to FIG. 2, the multiple ejection heads 30K to 30Y are dyeing means (yarn printing means) and are ejection heads (dyeing heads) that eject different colors from each other. For example, 30K is a head that ejects black (K) droplets (ink), 30C is a head that ejects cyan (C) droplets, 30M is a head that ejects magenta (M) droplets, and 30Y is a head that ejects yellow (Y) droplets. The order of colors shown in FIG. 2 is an example, and the colors may be arranged in an order different from that described here. Although not shown, the dyeing unit 103 may include, at the most downstream, an ejection head that ejects colorless droplets for coating the upper thread after dyeing.

[0018] In addition, the maintenance units 36K to 36Y are provided below the ejection heads 30K to 30Y of each color, and perform maintenance and recovery operations such as capping the heads when not in use, receiving empty droplets from the ejection heads 30, performing suction and circulation operations for the nozzles with the empty ejection receivers close to the heads, and wiping operations for the nozzles.

[0019] Here, as shown in Fig. 3, each of the ejection heads 30K to 30Y has a nozzle surface 33 on which a nozzle row 32 is formed, in which a plurality of nozzles 31 for ejecting droplets are arranged. Each of the ejection heads 30 is arranged such that the extension direction of the nozzle row 32, which is the arrangement direction of the nozzles 31, coincides with the transport direction of the yarn N. Note that, although only one nozzle row 32 is shown on the nozzle surface 33 in Fig. 3, a plurality of nozzle rows 32 may be arranged on the nozzle surface 33.

[0020] Returning to Fig. 1, the fixing unit 104 performs a fixing process (drying process) on the yarn N to which the liquid discharged from the dyeing unit 103 has been applied. The fixing unit 104 includes a heating means such as an infrared irradiation means or a hot air blowing means, and heats and dries the yarn N.

[0021] The post-treatment section 105 includes, for example, a cleaning means for cleaning the yarn N, a lubricant applying means for applying a lubricant to the surface of the yarn N, and the like.

[0022] In the dyeing device 1 of the present invention, it is sufficient to have at least the dyeing section 103 that applies a colored liquid to the yarn N, and the fixing section 104 and the post-treatment section 105 may not be provided.

[0023] Note that the dyeing section 103 in the dyeing device 1 shown in Figures 1 to 3 shows an example of a liquid ejection type configuration in which the upper thread N is dyed by ejecting ink from the ejection heads 30Y to 30K. However, the dyeing section 103 may also be a dyeing section of an application type in which the upper thread N is printed by applying ink by clamping the upper thread N with rollers or the like.

[0024] 1 includes a needle 21, a lower thread rotating body 22, a stage 23, and an embroidery head 20. The needle 21 has an upper thread N passed through a needle hole at the tip of the needle, and can be driven to move up and down relative to the fabric C.

[0025] The lower thread rotating body 22 has a lower thread bobbin 221 around which the lower thread B is wound, and a hook 222, and the lower thread bobbin 221 and the hook 222 rotate in conjunction with the movement of the needle 21. Although not shown, the lower thread rotating body 22 is also provided with a cylindrical inner hook that houses the lower thread bobbin 221, a cylindrical outer hook with a bottom, a cylindrical case integrated with the hook 222, and the like. Note that, although FIG. 1 shows an example of the lower thread bobbin 221 being of a vertical rotation type (vertical full rotary hook type, vertical half rotary hook type) in which the rotation direction is vertical, the lower thread bobbin 221 may also be of a horizontal rotation type (horizontal hook type) in which the rotation direction is horizontal.

[0026] The stage 23 is a platform that holds the cloth C, and is formed with a hole 23O (see FIG. 7) through which the needle passes. The stage 23 is movable in the X direction and the Y direction for feeding the cloth.

[0027] The embroidery head 20 is provided with a calculation mechanism 25 (see Figure 4), which controls the movement (needle movement) of the needle 21 through which the upper thread N passes, and the movement of the stage 23, so that the embroidery device 2 uses the upper thread N and the lower thread B, which is fed in accordance with the feeding of the upper thread N, to embroider on the cloth C, thereby forming an embroidery pattern (embroidery design) on the cloth C.

[0028] In addition, the term "thread" refers to glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer, or metal, yarn, filament, or a linear member (continuous substrate) to which a liquid can be applied, and also includes braided cord, flat cord, etc.

[0029] 4, the embroidery device 2 according to this embodiment includes, as drive control related parts, an embroidery data processing unit 24, a calculation mechanism 25, a stitch counter 26, a color measurement sensor 27, a driver 28, a drive motor 29, a needle up / down drive unit 291, a lower thread rotation drive unit 2922, an X-axis drive unit 293, and a Y-axis drive unit 294. Of these, at least the driver 28, the drive motor 29, and the needle up / down drive unit 291 are built into the embroidery head 20 above the needle 21. The embroidery data processing unit 24 and the calculation mechanism 25 may also be built into the embroidery head 20. Meanwhile, the drive units 293 and 294 that move the stage 23 and the lower thread rotation drive unit 292 are provided below the stage 23.

[0030] The dyeing device 1 also includes, as parts related to dyeing control, a dyeing data processing unit 107 and a calculation mechanism 108. The calculation mechanism 108 controls the head driver 39 that drives the discharge heads 30 (30K to 30Y) to control the dyeing operation, and also controls the inlet side motor 60 that drives the inlet side drive motor (yarn supply roller) 106 to rotate, thereby adjusting the yarn transport speed.

[0031] The embroidery data processing unit 24 acquires an embroidery image (embroidery file) that is the source of the embroidery data, and creates embroidery data (initial embroidery data) based on the embroidery image. Furthermore, the embroidery data processing unit 24 adds underlay data to the color change position of the created initial embroidery data, and outputs the embroidery data and underlay data to the driver 28.

[0032] Here, the embroidery image is image data (embroidery design) that is the original of the embroidery pattern on the fabric. The initial embroidery data creation unit 402 (see FIG. 8) of the embroidery data processing unit 24 breaks down the embroidery image into colors (RGB values), and based on the size of the embroidery pattern on the fabric, determines the colors of thread to be used and the continuation length of each color on the thread so that the stitches can be sewn in a smooth order, and creates embroidery data so that stitches are formed on the fabric using threads of the determined colors.

[0033] More specifically, the embroidery data is "data that combines data on the coordinates to which the needle moves and the items to be performed at those coordinates." The items to be performed at those coordinates are specifically, (1) To insert the needle into the fabric, intertwine it with the bobbin thread, bring the needle back to the front of the fabric, and then move the needle to the next position to insert the fabric. (2) Ending or interrupting embroidery (including switching to another needle or cutting the thread to move to a separate location where embroidery is not continuous); (3) moving to the initialization position (alignment position); The embroidery data files are generally in the format of ".dst", ".pes", etc. The initial embroidery data is the data that is set first, and is the embroidery data before editing according to the amount of thread consumption.

[0034] The calculation mechanism 25 drives and controls the driver 28 so as to execute a main embroidery operation for forming an embroidery pattern on the cloth based on the embroidery data, and an understitching operation for adjusting the amount of thread consumption in accordance with the understitching data, the progress status of the number of stitches advanced detected by the stitch counter 26 or the like, and a turn-back instruction detected by the colorimetric sensor 27.

[0035] The stitch counter 26 is a sensor that detects the up and down movement of the needle 21 and is provided, for example, on a needle bar that holds the needle 21. The stitch counter 26 detects the number of times the needle 21 has risen and fallen, i.e., the number of stitches that have been advanced.

[0036] The color measurement sensor 27 is a sensor that detects the color of the thread at the needle drop position, and detects the color of the underlay turn marker and the start of embroidery. Note that the color measurement sensor 27 does not necessarily have to be provided (see the modified example in FIG. 15).

[0037] The driver 28 controls the drive of the drive motor 29 based on the understitching embroidery data.

[0038] The needle up-down drive unit 291 is a so-called thread take-up lever, and drives the up-down movement of the needle 21 through which the upper thread N is passed by converting the rotational motion of an upper shaft connected to the drive motor 29 into up-down motion.

[0039] The lower thread rotation drive unit 292 rotates the lower thread rotor 22 in conjunction with the up and down movement of the needle 21 by the rotational movement of the lower shaft which is connected to the upper shaft via a belt, cam, and crank.

[0040] The X-axis drive unit 293 and the Y-axis drive unit 294 are a stage movement drive unit (cloth feed unit), and drive the movement of the stage 23 on which the cloth C is placed in the X and Y directions by the rotational movement of the lower shaft in conjunction with the up and down movement of the needle 21 and the rotation of the lower thread rotor 22. At this time, as a method of feeding the cloth C, the entire stage 23 may be moved, or a feed dog provided in a hole 23O (see FIG. 7) formed in the stage 23 may be moved.

[0041] The needle up / down drive unit 291, the lower thread rotation drive unit 292, the X-axis drive unit 293, and the Y-axis drive unit 294 form a drive mechanism that is driven in conjunction with one drive motor 29. Therefore, the rotation of the drive motor 29 generates up / down movement of the needle 21, rotational movement of the lower thread rotor 22, and XY movement of the cloth C on the stage 23. For example, one up / down movement of the needle 21 is linked with one or an integer number of rotational movements of the lower thread rotor 22.

[0042] (Upper and lower thread tension) Fig. 5 is a schematic diagram showing an example of a stitch on the top and bottom sides of the upper and lower threads of the fabric. In Fig. 5, (a) is a top view, and (b) is a bottom view. Fig. 6 is a diagram explaining the balance of the upper and lower threads in a stitch on the fabric. In Fig. 6, (a) shows a case where the tension balance between the upper and lower threads is appropriate, (b) shows a case where the tension of the upper thread is high, and (c) shows a case where the tension of the lower thread is high.

[0043] In the embroidery device 2, when the needle 21 descends and penetrates the cloth C, the upper thread N is also drawn into the back side of the cloth C together with the needle 21. Thereafter, when the needle 21 ascends and is removed from the cloth C and returns to the front side of the cloth C, the upper thread N forms a loop on the back side of the cloth C and remains there due to friction between the cloth C and the upper thread N. At this time, the hook 222 gets caught on the looped upper thread N due to the rotation of the lower thread rotating body 22, and the lower thread B passes through the loop of the upper thread N. Furthermore, when the needle 21 ascends above the cloth C, the position where the upper thread N and the lower thread B intersect is pulled up to the cloth C, forming a stitch on the cloth C.

[0044] An example of a stitch formed in this way is shown in Figure 5. Figure 5 is an enlarged view of a stitch embroidered with a decorative stitch (satin stitch) that fills the surface from top to bottom. Note that in Figure 5(b) on the back side, the hooked part between the upper thread N and the lower thread B is shown loosely surrounded by a dotted line to clearly explain the relationship between the threads, but in reality, the upper thread N and the lower thread B are in contact with each other and pull each other at the hooked part.

[0045] Fig. 6 is a cross-sectional view of the area indicated by the dashed line in Fig. 5. When the tension balance between the upper thread and the lower thread is appropriate in the cross section of the stitch in Fig. 5, the cross section will be as shown in Fig. 6(a).

[0046] In the stitch formed in this way, when the tension of the upper thread N is high, the upper thread N pulls the lower thread B as shown in Fig. 6(b), so the amount of the upper thread N wrapping around to the back side of the fabric C is less than in the case of the proper balance in Fig. 6(a). In other words, the length BL of the lower thread on the back side is longer and the length NL of the upper thread is shorter. Therefore, if the tension of the upper thread remains high for a long time, the consumption (usage) of the upper thread becomes less than predicted, and the consumption speed of the upper thread N becomes slower.

[0047] On the other hand, when the tension of the upper thread is low, the upper thread N is pulled by the lower thread B as shown in Fig. 6(c), so the upper thread N wraps around the back side of the fabric C more than in the case of the proper balance in Fig. 6(a). In other words, the lower thread length BL on the back side is shorter and the upper thread length NL is longer. Therefore, if the tension of the upper thread remains low for a long time, the consumption of the upper thread N becomes larger than expected, and the consumption speed of the upper thread N becomes faster.

[0048] In this way, the consumption speed of the upper thread N depends on the amount of wraparound to the back of the fabric C. In a situation where the wraparound amount differs from the prediction as in Figures 6(b) and 6(c), as embroidery continues, a large difference will arise between the predicted amount of upper thread consumption and the actual cumulative amount of thread consumed. In this invention, the upper thread is dyed in the dyeing device 1 upstream of the embroidery at the predicted position of thread consumption, so if the colored thread is not positioned correctly, the color position after embroidery will be shifted, and the image of the embroidery pattern on the fabric will be distorted.

[0049] Therefore, in the present invention, at the change of thread color, understitching is started from an assumed position, and understitching is performed by turning back at the position of the detected turn marker on the thread and making a round trip, thereby adjusting the amount of thread consumption by performing an understitching operation with an adjusted length to absorb the deviation between the assumed embroidery position and the actual embroidery position. The method of detecting the turn marker (actual thread consumption) of the upper thread N color will be described below with reference to FIG. 7.

[0050] (Detection means) Fig. 7 is an explanatory diagram of the detection means of the present invention. Note that the embroidery head 20 and the lower thread rotating body 22 are omitted in Fig. 7. In Fig. 7, (a) shows an example in which the colorimetric sensor and the stitch counter are separate, and (b) shows an example in which the detection means is integrated.

[0051] The separate detection means shown in FIG. 7(a) is composed of a stitch counter 26 that counts the number of stitches and a color measurement sensor 27 that detects the color of the thread, and these two components are used to detect the current position within the embroidery data and the amount of thread consumed.

[0052] The colorimetric sensor 27 is an optical sensor, such as a color laser sensor, that is capable of detecting at least the color of the thread. A color laser sensor is a type of photoelectric sensor that emits light from a light-projecting section and detects the light reflected by a detected object with a light-receiving section. The color laser sensor can detect the amount of received light of red, blue, and green, respectively, and is therefore capable of distinguishing the color of the object (the color of the needle and thread), and is therefore capable of detecting the fold marker that serves as a landmark during underlay.

[0053] In this configuration, an independent stitch counter 26 is provided to count the number of stitches in order to grasp the current position during embroidery operation and detect the expected position of the color change point. The stitch counter 26 is a sensor that detects the up and down movement of the needle 21 and is provided, for example, on the needle bar that holds the needle 21, and detects the number of stitches, which corresponds to how many times the needle 21 has gone up and down, i.e., how many stitches it has advanced.

[0054] In this configuration, the color measurement sensor 27, which is a color laser sensor, detects the color at the needle drop timing when the needle 21 pierces the fabric C detected by the stitch counter 26, so that the number of stitches and the color of the thread at the position of the needle hole can be detected simultaneously.

[0055] The integrated detection means 270 shown in Fig. 7(b) is, for example, a color laser sensor with a memory function. As shown in Fig. 7(b), the detection means 270 sets the needle drop position where the needle N pierces the fabric C as the target irradiation range, and detects the time and color at the moment when the needle 21 pierces the fabric C. In this way, the integrated detection means 270 can detect the number of stitches by counting the number of needle drops, and can simultaneously detect the color of the thread at the timing used to form a stitch on the fabric.

[0056] 7 shows an example in which a stitch number detection means is provided whether it is a separate type or an integrated type, but the colorimetric sensor 27 consisting of one color laser sensor may be used only for color detection, and the stitch number corresponding to the current position may be retrieved from the driver 28, which is driven based on the embroidery data, without providing a stitch counter function. At the timing when the needle 21 pierces the fabric C, the number of stitches corresponding to the expected color change point may be counted inside the downstream calculation mechanism 25 in conjunction with the operation of the driver 28.

[0057] As a result, whichever detection method is used, the turn marker on the thread, which is the change in thread color for the needle 21 used for embroidery, and the current position during embroidery operation for counting the color change point can be grasped in real time without any time error.

[0058] (Function Block) FIG. 8 is a functional block diagram of a dyeing data processing unit, an embroidery data processing unit, and a computing mechanism related to the dyeing and embroidery operations of the first embodiment.

[0059] In this embodiment, an example will be described in which the embroidery data processing unit is provided in the embroidery device, and the dyeing data processing unit is provided in the embroidery device.

[0060] The dyeing data processing unit 107 of the dyeing device 1 has an embroidery image / embroidery data acquisition unit 701, an initial dyeing data creation unit 702, a redundant data presence / absence determination unit 703, a color difference threshold memory unit 704, a continuation length threshold memory unit 705, a redundant data / turn marker setting unit 706, and a redundant data / turn marker-included dyeing data creation unit 707 that are executable.

[0061] The embroidery data processing unit 24 of the embroidery device 2 includes an embroidery image acquisition unit 401 , an initial embroidery data creation unit 402 , an underlay data creation unit 403 , and an underlay embroidery data creation unit 404 .

[0062] The calculation mechanism 25 of the embroidery device 2 has a stitch position calculation unit 501, a current position grasping unit 502, an understitching start position memory unit 503, an understitching start instruction unit 504, an understitching forward pass count unit 505, a forward pass stitch number memory unit 506, an understitching return pass count unit 507, an understitching turn-back instruction unit 508, a turn-back marker color memory unit 509, an embroidery start instruction unit 510 and an embroidery start color memory unit 511.

[0063] The calculation mechanism 25 functions as an underlay control section.

[0064] The embroidery image acquisition unit 401 of the embroidery data processing unit 24 of the embroidery device 2 acquires an embroidery image (embroidery file) which is image data.

[0065] The initial embroidery data creation unit 402 creates embroidery data (initial embroidery data) based on the acquired embroidery image. As described above, the embroidery data is a pair of data on the coordinates to which the needle 21 is moved and what to do at that position. Note that while Fig. 8 shows an example in which the embroidery data is created in the embroidery data processing unit 24 based on the embroidery image, the embroidery data (initial embroidery data) may also be input directly from outside.

[0066] The embroidery image / embroidery data acquisition unit 701 of the dyeing device 1 acquires the embroidery image and embroidery data from the embroidery device 2 .

[0067] The initial dyeing data creation unit 702 creates dyeing data (initial dyeing data) based on the embroidery image and embroidery data. In more detail, the initial dyeing data creation unit 702 creates dyeing data that includes information on the blending amounts of each of the K, C, M, and Y colors used for dyeing to realize the thread color included in the embroidery data, and the dyeing duration of each color in the K, C, M, and Y discharge heads 30K to 30Y.

[0068] A redundant data presence / absence determining unit 703 determines whether or not redundant data is to be inserted into the color change position of the created dyeing data.

[0069] The color difference threshold storage unit 704 stores a color difference threshold value of two adjacent colors for which redundant data is required. The continuation length threshold storage unit 705 stores a threshold value of the continuation length of two adjacent colors for which redundant data is required.

[0070] The redundant data presence / absence determination unit 703 selects a color transition where redundant data is inserted (inserted) from among a plurality of color transitions based on the color difference between two adjacent colors at the color transition (color change point) in the dyeing data. For example, when the color difference is very small or there is a gradation, the positional deviation of the thread colors in the embroidery on the fabric is not noticeable. Therefore, the redundant data presence / absence determination unit 703 determines whether to insert redundant data when the color difference between two adjacent colors at the color change point exceeds a certain threshold stored in the color difference threshold storage unit 704, and not to insert redundant data when the color difference is equal to or less than the certain threshold.

[0071] The redundant data presence / absence determination unit 703 selects whether or not to insert redundant data in the dyeing data based on the continuation length of the dyeing of two adjacent colors at the color change point. In the present invention, the thread consumption is adjusted by understitching the bottom side of the embroidery area of ​​the planned next color, so the understitching cannot be concealed by the main embroidery unless the next thread color continues for a certain length. In addition, the difference between the calculated thread consumption and the actual thread consumption becomes larger the more embroidered, so in embroidery of a very short distance, the positional deviation between the embroidery and the thread color is small and not noticeable. Therefore, the redundant data presence / absence determination unit 703 determines whether to insert redundant data when the lengths of the two adjacent colors at the color change point both exceed a certain threshold stored in the continuation length threshold storage unit 705, and whether to not insert redundant data when the lengths are below the certain threshold.

[0072] The redundant data / turn marker setting unit 706 sets the turn marker position in the redundant data. The position of the turn marker, which serves as a turn mark on the thread, is set to the midpoint of the redundant marker. In addition, since the turn marker is a direction adjustment stitch in the underlay, it is preferable to set the length of the turn marker to about one stitch of the direction adjustment stitch, but less than two stitches, taking into account misalignment and turning.

[0073] A redundant data / turn marker-included dyeing data generating unit 707 generates dyeing data by adding redundant data including turn markers to the color change points of the initial dyeing data as necessary.

[0074] Here, the processing of dyeing data in the dyeing device 1 of the present invention will be described with reference to the schematic diagram of Fig. 9. In Fig. 9, (a) shows initial dyeing data, and (b) shows dyeing data including redundant data and turnaround markers.

[0075] In detail, Fig. 9(a) shows the initial dyeing data before the redundant data is inserted, and the initial dyeing data corresponds to the dyeing data calculated on the assumption that the thread is consumed ideally. In this case, the embroidery start point is A, the color change point on the embroidery design is B, and the embroidery end point is C, and AB and BC are dyed in the desired colors, as shown in Fig. 9(a). However, in actual embroidery, the amount of thread consumption changes from moment to moment due to the sagging and thickness variations of the fabric to be embroidered, the variations in the tension of the lower thread and upper thread as shown in Fig. 6, the external environment, etc.

[0076] Therefore, in the present invention, taking into consideration the case where the yarn consumption is greater than expected, dyeing is performed so that redundant data is inserted into the dyeing data in an amount sufficient to absorb the next shortage due to the variation in yarn consumption.

[0077] Fig. 9(b) shows the edited dyeing data after the redundant data has been inserted, with redundant data of BB' inserted at the position corresponding to point B before the insertion in Fig. 9(a). As will be described later, in the present invention, the amount of thread consumed is adjusted by basting back and forth to consume the amount of thread for the redundant dyed area dyed according to the redundant data and for the amount of thread consumption variation. A fold marker D is inserted at the midpoint of BB' as a mark for this basting fold.

[0078] 9(b), the redundant data inserted into the dyeing data has a first half that is the same color as the color before the color change, and a second half that is the same color as the color after the color change, with the turnaround marker as the boundary. The first and second halves are approximately equal in length.

[0079] In addition, in the dyed data, the turnaround markers inserted at the color boundaries are a different color than the two adjacent colors at the color change. By using a turnaround marker that serves as a landmark and is a different color than the two adjacent colors at the color change, the boundary can be clearly recognized even when the boundary is difficult to distinguish due to the adjacent colors.

[0080] In the present invention, the turn marker on the thread serves as a mark to be detected by the colorimetric sensor 27 or by the user's visual inspection, and the turn marker serves as the starting point for the underlay turn timing. By detecting the turn marker on the thread at the needle drop point, the actual amount of thread consumed up to the turn marker on the thread is detected, which is not affected by the progress of the embroidery data.

[0081] The redundant data / turn marker-inclusive dyeing data creating unit 707 outputs the edited dyeing data, which is the dyeing data including the redundant data and turn markers, created in this manner to the calculation mechanism 108 and the underlay data creating unit 403 of the embroidery device.

[0082] Returning to FIG. 8, the calculation mechanism 108 of the dyeing device 1 drives and controls the head driver 39 to cause each of the discharge heads 30K to 30Y of the dyeing section 103 to discharge dyeing liquid at a predetermined conveying speed in accordance with the dyeing data so as to dye the upper yarn.

[0083] The underlay data creation unit 403 in the embroidery data processing unit 24 of the embroidery device 2 creates underlay data based on the dyeing data including turn-back markers and redundant markers created by the dyeing data including redundant data and turn-back markers creation unit 707. The underlay data is set so that the underlay is hidden under the area to be embroidered with the thread of the next color by a distance sufficiently longer than the length of the redundant dyed area dyed along the redundant data. Note that in the present invention, since the length of the underlay increases or decreases to adjust the consumption of the upper thread, it is preferable that the underlay data is set so that it is hidden under the embroidery pattern of the next color even if it is understitched longer than the redundant dyed area on the thread to adjust the consumption of the upper thread.

[0084] In the underlay data, the paths are set to be the same for the outward and return passes, and the stitch lengths of the stitches in the return pass are set to be in the reverse order of the outward pass. Also, when the underlay outward pass is being executed, the underlay outward pass data is interrupted midway and turned back, and the start position of the underlay return pass data when the underlay return pass is started is the position corresponding to the interruption point of the underlay outward pass data. In other words, the underlay return pass data is cut from the original turn point to the position corresponding to the interruption point, and the underlay return pass is embroidered based on the underlay return pass data that follows the stitched portion of the underlay outward pass that has already been painted.

[0085] The underlay embroidery data creation unit 404 inserts the created underlay data into the embroidery data.

[0086] In the computing mechanism 25 of the embroidery device 2, the stitch position calculation unit 501 acquires in real time stitch data (cumulative stitch count) which is data on how many stitches have been advanced, i.e., which stitch is currently being sewn, output from the stitch counter 26. Note that the stitch position calculation unit 501 may calculate the current embroidery position in the embroidery data based on information from the driver 28, instead of the stitch counter.

[0087] A current position determining unit 502 calculates the current embroidery position, that is, how far the embroidery has progressed in the embroidery data, from the embroidery data and the stitch data, and determines the progress of the embroidery.

[0088] The underlay start position storage unit 503 stores in advance the start position of the underlay data inserted at the color change point of the embroidery data.

[0089] When the current embroidery position data calculated from the number of stitches reaches the color change position and the understitching data exists at the color change position, the understitching start instruction unit 504 notifies the driver 28 to stop the main stitching operation and start the understitching operation.

[0090] The underlay outward pass counting section 505 counts the number of underlay outward pass stitches simultaneously with the start of underlay.

[0091] The colorimetric sensor 27 that detects a change in color of the upper thread surface is connected to an underlay turn-back instruction unit 508 and an embroidery start instruction unit 510 .

[0092] The embroidery start color storage unit 511 stores the embroidery color at which embroidery (lock stitching) is to be started.

[0093] When the color measurement sensor 27 detects the color for starting embroidery, the embroidery start instruction unit 510 notifies the driver 28 to start the lock stitching operation.

[0094] The turn-around marker color storage unit 509 stores the color of the turn-around marker provided in the redundant data.

[0095] When the colorimetric sensor 27 detects the color of the turn marker stored in the turn marker color memory unit 509, the understitching turn instruction unit 508 notifies the driver 28 to turn the understitching operation, and also notifies the turn instruction to the forward stitch number memory unit 506 and the understitching return pass count unit 507.

[0096] When the driver 28 receives the turn back command, it interrupts the underlay outward pass and starts the underlay return pass. In the underlay return pass, the stitches are moved along the outward pass stitching so that the path is the same as in the outward pass (so that the stitch lengths of the stitches are reversed from those in the outward pass) until the underlay returns to the start point.

[0097] When an underlay turn-back instruction by the turn-back marker is received, the outward stitch number memory unit 506 stores the number of underlay outward stitches counted from the start of underlay to the turn-back marker.

[0098] The underlay return pass count unit 507 counts the number of stitches in the underlay return pass from the next step following the underlay turn-back instruction, and when the number of stitches reaches the same number as in the underlay forward pass, it notifies the driver 28 to end the underlay and start the main embroidery of the next color. Since the stitch length of each stitch in the sewing part in the return pass is the same as the stitch length of the sewing part in the adjacent parallel forward pass according to the underlay data, by making the number of stitches in the return pass the same as in the forward pass, the underlay lengths in the forward and return passes become equal.

[0099] In this example, the current position during underlayment is determined by counting the number of stitches, and the lengths of the forward and return passes are aligned. However, the current position may be determined from progress information from the driver 28, and the lengths of the forward and return passes may be aligned.

[0100] In this invention, in a dyeing and embroidery system that embroiders while dyeing in changing colors, dyeing data is created so that redundant data with turn-back markers are inserted for the required length at color change points as necessary, and when the understitch reaches the turn-back marker at the midpoint of the redundant dyed area dyed according to the redundant data during embroidery, the understitch is turned back regardless of the length of the outward path of the understitch, so that the consumption of the upper thread can be adjusted with the understitch whose length has been adjusted.

[0101] In this embodiment, the fact that the embroidery position has reached the turn marker on the thread is detected by the colorimetric sensor 27, which is a thread color detection device that detects the thread color and is disposed near the needle 21 of the embroidery head 20 as shown in Fig. 7. In this manner, in this embodiment, the underlay turn signal is generated based on the colorimetric sensor 27, so that the underlay can be completed accurately within the device during the flow of the embroidery operation without the user having to check it.

[0102] (Embroidery position adjustment operation) FIG. 10 is a sequence diagram showing the communication between devices in the dyeing and embroidery flow of the present invention.

[0103] When an embroidery image is input in step S101, embroidery data (initial embroidery data) is created in the embroidery device in step S102.

[0104] In step S103, the embroidery image and embroidery data are transmitted to the dyeing device 1.

[0105] In step S104, the dyeing device 1 creates dyeing data (initial dyeing data) for dyeing with colors that change according to the respective continuous lengths in accordance with the initial embroidery data.

[0106] In step S105, it is determined whether or not redundant data needs to be inserted at the color change point of the dyeing data, based on the color difference before and after the color change point of the dyeing data and the duration of the colors before and after the color change point.

[0107] In step S106, if redundant data is necessary, the length of the redundant data to be inserted at the color change point and the color of the turnaround marker are set based on the length of continuation of the color before and after the color change point.

[0108] In step S107, staining data (edited staining data) is created in which the redundant data with the set turnaround marker is inserted.

[0109] In step S108, the dyeing data including the redundant data and the turnaround markers is transmitted to the embroidery device 2.

[0110] In step S109, embroidery data including underlay data (edited embroidery data) is created.

[0111] In step S110, the embroidery start color and the color of the turn marker are stored, and the underlay start position within the edited embroidery data is also stored.

[0112] In step S111, the needle 21, stage 23, etc. of the embroidery device 2 are set to the embroidery start position.

[0113] When the embroidery device 2 notifies that the embroidery preparation is completed in step S112, the dyeing device 1 starts dyeing and thread transport operations in step S113.

[0114] Then, in the embroidery device 2, when the embroidery start color of the dyed and supplied thread is detected, the embroidery operation is started in step S114.

[0115] Then, in step S115, an embroidery control operation is carried out, the details of which will be described later with reference to FIG.

[0116] In step S116, when the edited dyeing data is completed, the dyeing device and the upper thread transport operation are terminated.

[0117] Furthermore, when the editing of the embroidery data is completed in step S117, the embroidery operation ends.

[0118] As can be seen from FIG. 10, before the dyeing / embroidery operation starts, information is exchanged between the dyeing device 1 and the embroidery device 2. However, after the start of embroidery, the understitching control is completed by the embroidery device 2 alone. Therefore, the embroidery adjustment operation by understitching of the present invention can be performed without complicating the control during the operation of the dyeing / embroidery system 3.

[0119] 11 is a detailed flowchart of the control during embroidery operation in the present invention, which is a detailed flowchart of step S115 in FIG.

[0120] When the embroidery device 2 detects that the supplied upper thread of the embroidery start color has arrived, the embroidery operation is started and this flow is started (Step S114 in FIG. 10).

[0121] When the embroidery operation is started, the embroidery device 2 starts the actual embroidery operation that is visible on the outermost surface of the fabric in accordance with the embroidery data in step S501.

[0122] In this embroidery operation, if there is no color change in the embroidery data in step S502 (NO), i.e., if embroidery is to be performed to the end with one color, the process proceeds to S512 without carrying out any further control, and the embroidery operation continues until the embroidery data is completed.

[0123] If it is determined in step S502 that there is a color change in the embroidery data (YES), the process proceeds to S503, and the subsequent embroidery operations are carried out.

[0124] In step S503, if the calculation mechanism 25 of the embroidery device 2 detects that the current embroidery position (assumed embroidery position) on the embroidery data calculated from the number of stitches has reached the color change point on the embroidery data, the process proceeds to step S504 and it is confirmed whether underlay data has been inserted at the color change position.

[0125] If no underlay data has been inserted in step S504 (NO), no further underlay operation is performed and the process proceeds to step S511. After the main embroidery of the current color is completed, the main embroidery of the next color is started without underlay.

[0126] If underlay data has been inserted in step S504 (YES), the flow proceeds to step S505 to proceed with the underlay operation of the present invention.

[0127] In step S505, after the main embroidery based on the embroidery data of the current color is completed, the underlay outward pass is started and the number of stitches for the underlay outward pass is counted. If underlay data has been inserted, the underlay operation is started in step S505 at the timing when the embroidery position calculated from the stitch count and assumed in the embroidery data reaches the color change point of the embroidery data based on the stitch count in S503. Therefore, if there is no deviation in the amount of thread consumption, the underlay outward pass is started when the embroidery reaches the redundant dyeing area. Also, if the amount of thread consumption is slow, the underlay outward pass is started even if the embroidery has not yet reached the redundant dyeing area, and if the amount of thread consumption is fast, the underlay outward pass is started after the embroidery reaches the redundant dyeing area.

[0128] When the colorimetric sensor 27 detects the turn marker in step S506, the underlay outward pass is ended in step S507, a course adjustment stitch which is the turn point is sewn, and counting of the number of stitches in the underlay outward pass is ended and the number of counted outward pass stitches is stored.

[0129] If there is no deviation in the amount of thread consumed, the embroidery distance of the underlay outward pass will be the same length as the redundant dyed area of ​​the outward pass in Figure 9(b), and the number of stitches of the underlay outward pass will be the number of stitches as assumed in the created underlay data.

[0130] Furthermore, if the thread consumption rate is slow, the embroidery distance of the underlay outward pass will be longer than the outward pass redundant dyed area, and the number of outward pass stitches will be greater than the number of stitches assumed in the underlay data.

[0131] On the other hand, if the thread is consumed quickly, the embroidery distance of the underlay outward pass will be shorter than the outward pass redundant dyed area, and the number of outward pass stitches will be fewer than the number assumed in the underlay data.

[0132] After sewing one path adjustment stitch, in step S508, the understitching return pass is started by turning back from the understitching forward pass and tracing the same path as the understitching forward pass, and counting the number of stitches for the understitching return pass is started. When forming a sewing portion on the understitching return pass so as to trace the path of the understitching forward pass, the stitch lengths of each stitch on the understitching return pass are in the reverse order to the forward pass so that the stitch length of each stitch on the sewing portion on the understitching return pass is the same as the stitch length of the sewing portion on the adjacent forward pass that moves in parallel, and the understitching is sewn to return to the understitching start point by the same distance as on the forward pass.

[0133] In step S509, when the number of underlay stitches in the homeward direction that is being counted reaches the number of stitches in the forward direction that is stored, it is determined that the underlay has returned to the starting position, and in step S510 the underlay ends and the main embroidery in the next color begins.

[0134] By doing this, it is possible to sew the return path with the same number of stitches as the outward stitch, and since the stitching is done by going back and forth once during the underlay, the needle returns to the color change point, which is the start point of the underlay.

[0135] If there is no deviation in the amount of thread consumed, the total embroidery distance of the underlay embroidery will be the same length as the redundant dyed area in Figure 9(b), the number of stitches required for the underlay will be the number of stitches assumed in the created underlay data, and the main embroidery of the next color will start from the end position of the return redundant area and the beginning position of the next color dyed according to the initial dyeing data.

[0136] Also, if the amount of thread consumed is small and the start is slower than expected, the total embroidery distance of the understitch embroidery will be longer than the redundant dyeing area, and the main embroidery of the next color will start a little later than the start position of the next color dyed according to the initial dyeing data after the return redundant area is finished. This allows the adjustment distance at the next color change point to be shortened by consuming more upper thread in advance at the start of the next color, which tends to be delayed.

[0137] Also, if the amount of thread consumed is large and is faster than expected, the total embroidery distance of the understitch embroidery will be shorter than the redundant dyeing area, and the main embroidery of the next color will start earlier than the starting position of the next color dyed according to the initial dyeing data before the return redundant area ends.

[0138] In step S511, it is determined whether there is a color change (underlay data) in the subsequent embroidery data. If there is, the process returns to before S503, and steps S503 to S511 are carried out in the same manner as in the current underlay period, and underlay operation using the turnaround point is performed and reflected, and this loop is repeated. Then, if the color change point has not been reached, in step S513, the current embroidery operation continues until the end of the embroidery data.

[0139] (Example of consumption adjustment by underlay) Next, the effect of dyeing areas according to redundant data (redundant dyeing areas) and underlay using turn markers will be described with reference to the schematic diagrams of Figs.

[0140] Fig. 12 is a diagram showing a specific example of the underlay length in the embroidery control operation of the present invention. In Fig. 12, (a) shows a diagram when there is no deviation in the embroidery position, (b) shows a diagram when the estimated thread consumption is less than the actual thread consumption, and (c) shows a diagram when the estimated thread consumption is greater than the actual thread consumption.

[0141] First, as shown in FIG. 12(a), when there is no deviation in the embroidery position, i.e., when the estimated thread consumption = the actual thread consumption, the timing when the embroidery position calculated from the number of stitches reaches the color change point E on the embroidery data, which is the timing to start understitching, is the same as the timing ts when the embroidery position moves from the dyed area based on the upper thread dyeing data to the redundant dyed area.

[0142] When the colorimetric sensor 27 detects the turn marker, the underlay outward pass is ended, a course adjustment stitch is sewn as the turn point, and the count of the underlay outward pass stitches is ended and the number of counted outward pass stitches is stored. In Fig. 12(a), the embroidery distance ED of the underlay outward pass is the same length as the outward pass redundant dyed area BD (ED = BD), and the number of outward pass stitches is the number of stitches expected from the underlay data.

[0143] Then, the stitch at point D where the turn marker is detected at the needle drop position is sewn as a course adjustment stitch at the position where the direction is bent in order to turn back from the underlay outward path.

[0144] After the course adjustment stitch, the underlay return pass begins and the count of the underlay return stitches begins. When the number of counted underlay return stitches reaches the memorized number of stitches for the forward pass, the underlay ends and the main embroidery of the next color begins. In this way, the return pass is sewn with the same number of stitches as the number of stitches for the forward pass, and the return pass is underlayed with the thread of the next color for the same distance as the outward pass with the thread of the current color, with the turn marker as the boundary (BD=DB´).

[0145] In this example, the timing when the embroidery position reaches the underlay end point E' on the embroidery data is the same as the timing te when the embroidery position reaches the redundant dyed area of ​​the upper thread. Therefore, the embroidery distance DE' of the underlay outward path is the same length as the redundant dyed area DB' in the outward path (DE' = DB'), and therefore the underlay distance, i.e., the amount of upper thread consumed by the underlay in Figure 12(a) is equal to the length of the redundant dyed area (EE' = BB').

[0146] 12(b), when the estimated thread consumption is less than the actual thread consumption, the embroidery position calculated from the number of stitches reaches the color change point E on the embroidery data (the estimated color change point) before the timing ts at which the actual embroidery position reaches the tip B of the redundant dyed area of ​​the upper thread. In other words, the redundant dyed area on the actual thread is reached later than predicted.

[0147] The color change starts from the assumed color change point E, which is before the leading edge B of the actual redundant dyed area, and the outward pass of the understitching is performed until the color measurement sensor 27 detects the turn marker. Therefore, in this example, the embroidery distance ED of the outward pass of the understitching consumes more upper thread than the outward pass redundant dyed area BD by the embroidery length corresponding to position E to position B.

[0148] Then, after the course adjustment stitch at the turn marker detection point D, underlay is performed for the same distance as the outward path. Therefore, in this example, the timing at which the embroidery position calculated from the number of stitches reaches the underlay end point E' on the embroidery data is later than the timing te at which the actual embroidery position ends the redundant dyed area of ​​the upper thread and reaches the dyed area according to the dyeing data of the next color. Therefore, the amount of upper thread consumed by underlay in Figure 12(b) is longer than the length BB' of the redundant dyed area by the embroidery length corresponding to position E to position B and the embroidery length corresponding to position B' to position E'.

[0149] Therefore, when the understitching is completed, the length of the next main embroidery corresponding to position E' to position B' has already been consumed, so that the amount of thread consumed is subtracted from the amount of thread consumed in the continuous length of the next color, and the consumption of the upper thread can be adjusted to eliminate or reduce delays in the next color change.

[0150] 12(c), when the assumed thread consumption is greater than the actual thread consumption, the embroidery position calculated from the stitch count reaches the color change point E on the embroidery data (the assumed color change point) after the timing ts at which the actual embroidery position reaches the tip B of the redundant dyed area of ​​the upper thread. In other words, the redundant dyed area on the actual thread is reached earlier than predicted.

[0151] The color change starts at the assumed color change time E, which is after the leading edge B of the actual redundant dyed area, and the outward pass of the understitching is performed until the color measurement sensor 27 detects the turn marker. Therefore, the embroidery distance ED of the outward pass of the understitching in this example consumes less upper thread than the outward pass redundant dyed area BD by the embroidery length corresponding to position B to position E.

[0152] Then, after the course adjustment stitch at the turn marker detection point D, underlay is performed for the same distance as the outward path. Therefore, in this example, the timing at which the embroidery position calculated from the number of stitches reaches the underlay end point E' on the embroidery data is earlier than the timing te at which the actual embroidery position ends the redundant dyed area of ​​the upper thread and reaches the dyed area according to the dyeing data of the next color. Therefore, the amount of upper thread consumed by underlay in Figure 12(c) is shorter than the length BB' of the redundant dyed area by the embroidery length corresponding to position B to position E and the embroidery length corresponding to position E' to position B'.

[0153] Therefore, at the time when the understitching is completed, the redundant dyed area of ​​the length corresponding to position E' to position B' has not yet been consumed, so that the amount of thread consumed is added to the amount of thread consumed in the continuous length of the next color, and therefore the consumption of the upper thread can be adjusted to eliminate or reduce the advance in the color change of the next color.

[0154] This underlay control ensures that the upper thread near the end of the dyeing area of ​​the current color is consumed before the dyeing area of ​​the next color begins, and by adjusting the thread length near the dyeing area of ​​the next color, the consumption can be adjusted to avoid misalignment at the next color change point. This avoids misalignment of the embroidery color on the fabric and prevents the accumulation of misalignment in the thread consumption, preventing the upper thread from being exposed on the embroidery surface at the color change and the image of the embroidery pattern on the fabric from being distorted.

[0155] Here, since the first and second halves of the redundant dyeing area, which corresponds to the understitching to be turned back, are equal in length, the adjustment of the upper thread consumption amount of the present invention is more effective when the length AB of the dyeing area of ​​the current color is equal to the length B'C of the dyeing area of ​​the next color.

[0156] 13 is a diagram showing a specific example of an embroidery pattern produced by implementing the embroidery control operation of the present invention when the actual upper thread consumption is less than expected. Here, as an example, the color of the thread currently being embroidered is blue, and the color of the thread to be embroidered next after the color change is red.

[0157] In Figure 13, (a) is a diagram showing the desired embroidery image, (b) is a diagram showing the state of the current blue thread when the actual main embroidery is completed, (c) is a diagram showing the state of the understitch turnaround point, (d) is a diagram showing the state when the understitching is completed, and (d) is a diagram showing the state after the next red main embroidery begins.

[0158] Time points t1 to t4 in FIG. 13 correspond to time points t1 to t4 in FIG. 12(b).

[0159] At the end of the current main embroidery with blue thread at t1 in Figure 13(b), the consumption of the blue thread of the upper thread dyed according to the dyeing data is small, and there is surplus upper thread, so if the main embroidery continues as is, the tip of the next red embroidery area will be sewn with blue thread.

[0160] Therefore, understitching is started below the red embroidery area (area to be embroidered), and the outward understitching is performed with the blue thread up to the turn marker. At this time, the outward understitching is performed with the blue thread, which is the current thread color, using the blue thread dyed according to the dyeing data and the blue thread dyed according to the redundant data.

[0161] As shown in FIG. 13(c), at t2, when the underlay reaches the turn marker, one course adjustment stitch is sewn, the underlay is turned back, and the return pass of the underlay is started.

[0162] Then, from the turn marker, the red thread is used to undersew the return path for the same distance as the blue thread. At this time, the red thread dyed according to the redundant data and the red thread dyed according to the dyeing data are used to undersew the return path with the red thread, which will be the next thread color.

[0163] As shown in FIG. 13(d), when the understitching reaches the original position at t3, i.e., when the number of stitches in the return path becomes the same as the number of stitches in the forward path, the main embroidery is performed with the next thread color, red. In the understitching return path, as shown in FIG. 13(d), the stitches are moved along the sewing part in the forward path so that the stitch length of each stitch is in the reverse order to that in the forward path, so that the path is the same as that in the forward path, until the understitching starts at the understitching start position. Therefore, the understitching lengths in the forward path and the return path are equal, and the consumption amounts of blue thread and red thread in the understitching are equal, so in this example, the understitching is performed using the dyed area according to the redundant data and the dyed area according to the dyeing data. Therefore, at t3 in this example, as shown in FIG. 13(d), the main embroidery is started with a certain amount of red thread for the main embroidery consumed in the understitching.

[0164] Then, as shown in FIG. 13(e), the main embroidery of the next color is continued while using the dyed area according to the dyeing data that has been consumed and shortened by the underlay for the main embroidery.

[0165] In this example, the extra upper thread is consumed in the underlay, and the amount of deviation is absorbed, so the deviation in the amount of thread consumption at the end point is also reduced. Even if the main embroidery and the underlay at the color change point are repeated after this, the consumption amount can be adjusted to the end by repeating the same underlay.

[0166] FIG. 14 is a diagram showing a specific example of an embroidery pattern produced by implementing the embroidery control operation of the present invention when the actual amount of upper thread consumption is greater than expected.

[0167] In Figure 14, (a) is a diagram showing the desired embroidery image, (b) is a diagram showing the state at the end of the main embroidery in blue thread predicted from the number of stitches, (c) is a diagram showing the state of the turnaround point of the understitching, (d) is a diagram showing the state at the end of the understitching, and (d) is a diagram showing the state after the next main embroidery in red begins.

[0168] The time point corresponding to B in FIG. 14 indicates a state slightly before time point t1 in FIG. 12(c), and times t2 to t4 correspond to times t2 to t4 in FIG. 12(c).

[0169] At the start position B of the redundant dyed area in Figure 14(b), the consumption of the blue top thread dyed according to the dyeing data is large, and without understitching, the end of the blue embroidery area would be sewn with the next red thread.

[0170] At this point, underlay is started and the outward underlay is performed with blue thread up to the turn marker, with the blue thread being dyed according to the redundant data, being the current thread color, blue, being used to underlay the outward underlay.

[0171] As shown in FIG. 14(c), at t2, when the underlay reaches the turn marker, one course adjustment stitch is sewn, the underlay is turned, and the return pass of the underlay is started.

[0172] Then, from the turn marker, the red thread is used to undersew the return path for the same distance as the blue thread, using the red thread dyed according to the redundant data to undersew the return path with the red thread that will be the next thread color.

[0173] As shown in Fig. 14(d), when the underlay reaches the original position at t3, i.e., when the number of stitches in the return path becomes the same as the number of stitches in the forward path, the main embroidery is performed with the next thread color, red. In the return path of the underlay, as shown in Fig. 14(d), the stitches are moved along the sewing part of the forward path until the underlay returns to the start point, so that the stitch length of each stitch is in the reverse order to that of the forward path, so that the path is the same as that of the forward path. Therefore, the underlay length of the forward path and the return path are equal, and the consumption of blue thread and red thread in the underlay are equal, so in this example, underlay is performed only in the dyed area according to the redundant data.

[0174] Then, as shown in Fig. 14(e), the main embroidery of the next color is continued while also using the area dyed according to the redundant data for the main embroidery. In this example, the main embroidery of the red embroidery area is started using the red thread dyed according to the redundant data for the underlay before reaching the red thread dyed according to the dyeing data.

[0175] In this example, less upper thread is consumed in the understitching, and the amount of deviation is absorbed, so the deviation in thread consumption at the end point is also reduced. Even if main embroidery and understitching at the color change point are repeated thereafter, the consumption amount can be adjusted to the end by repeating the same understitching.

[0176] In this way, in the present invention, underlay is performed by going back and forth once based on the inserted turn-back point at the bottom of the next sewing part (embroidery area) that does not appear in the embroidery design, thereby adjusting the difference between the calculated thread consumption and the actual thread consumption, and correcting the embroidery color shift. This makes it possible to adjust the embroidery position at the current color change, as well as to prevent embroidery position shifts at the next and subsequent color change points.

[0177] (Modification) FIG. 15 is a diagram showing a modified example of the embroidery device according to the first embodiment of the present invention.

[0178] Although an example has been described above in which the underlay turn marker is detected by the color measurement sensor, the underlay turn marker may be arbitrarily selected by the user.

[0179] In this modified example, when the user visually detects that the turn-back marker has reached the needle drop position, the user operates, for example, button 201 shown in FIG. 15 to issue a turn-back signal for underlay.

[0180] In this modified example, the operator visually detects that the embroidery position has reached the turn-back marker. Therefore, in the existing embroidery device 2A, the upper thread consumption adjustment by the understitching adjustment of the present invention can be realized without adding a color measurement sensor.

[0181] <Second embodiment> 16 is a schematic side view of a dyeing and embroidery system (textile printing and embroidery system) according to a second embodiment of the present invention. In this embodiment, a host control device 4, which is a host device, is connected to the dyeing and embroidery system 3B. The host control device 4 is an information processing device such as a computer.

[0182] 17 is a functional block diagram of the control unit 4, the dyeing unit 1B, and the embroidery unit 2B according to the third embodiment. Description of the same parts as those in FIG. 8 will be omitted.

[0183] In this embodiment, the functions of the dyeing data processing unit of the dyeing device 1 and the embroidery data processing unit of the embroidery device 2 in FIG.

[0184] The upper control device 4 has an input unit 410, a dyeing data processing unit 420, and an embroidery data processing unit 430 which are executable.

[0185] The input unit 410 has an embroidery image input unit 411 and, if necessary, an underlay amount selection unit 412. In the above example, the dyeing data processing unit determines whether or not to insert redundant data and the length of the redundant data, but the presence or absence of an underlay amount, the length, etc. may be selected externally in response to instructions from the user.

[0186] The dyeing data processing unit 420 is executable to include an initial dyeing data creation unit 421, a redundant data presence / absence determination unit 422, a color difference threshold memory unit 423, a continuation length threshold memory unit 424, a redundant data / turn marker setting unit 425, and a dyeing data creation unit 426 including redundant data and turn marker.

[0187] The embroidery data processing unit 430 includes an initial embroidery data creating unit 431 , an underlay data creating unit 432 , and an underlay data inserting unit 433 .

[0188] Since the upper control device 4 has a dyeing data processing unit for dyeing and an embroidery data processing unit for embroidery within the same device, a communication unit and an acquisition unit for data exchange are not required.

[0189] In the dyeing and embroidery system configured as above, before the start of the embroidery operation, the upper control device 4 creates the dyeing data and the embroidery data, transmits the dyeing data to the dyeing device 1B, and transmits the embroidery data to the embroidery device 2B. After the start of the embroidery operation, the dyeing device 1B and the embroidery device 2B execute their operations independently.

[0190] In this system, too, in the dyeing data based on the embroidery data, a redundant marker with a turn marker is inserted as necessary, and if understitching data exists at the color change point in the embroidery data, understitching is started from the expected embroidery position, and understitching is performed by turning back at the turn marker on the thread and going back and forth, thereby performing an understitching operation with the length adjusted to absorb the deviation between the expected embroidery position and the actual embroidery position. This makes it possible to avoid deviation in the color of the embroidery on the fabric at the current color change point even if the actual thread consumption deviates from the expected amount during embroidery operation using continuous color-changing threads, and to prevent accumulation of deviation in thread consumption at the next and subsequent color change points. This makes it possible to prevent the upper thread from being exposed on the embroidery surface at the color change point and the image of the embroidery pattern on the fabric from collapsing.

[0191] <Third embodiment> FIG. 18 is a schematic side view of a dyeing and embroidery device according to a third embodiment of the present invention.

[0192] The dyeing and embroidery device (textile printing and embroidery device) 5 of this embodiment is an in-line integrated device having a dyeing unit 51, an embroidery unit 52, and a computing mechanism 53 in one housing.

[0193] In this embodiment, since the dyeing unit 51 and the embroidery unit 52 are provided in the same apparatus, the functions of the computing mechanisms 108 and 25 shown in FIGS.

[0194] In this device, understitching is started from the expected embroidery position, and the understitching is performed by turning back at the turn marker on the thread and going back and forth, so that the understitching operation is adjusted in length to absorb the deviation between the expected embroidery position and the actual embroidery position. This makes it possible to avoid deviation in the color of the embroidery on the fabric at the current color change point even if the actual thread consumption deviates from the expected amount during embroidery operation using continuous color-changing threads, and to prevent the accumulation of deviation in thread consumption at subsequent color change points. This makes it possible to prevent the upper thread from being exposed on the embroidery surface at the color change point and the image of the embroidery pattern on the fabric from being distorted.

[0195] Although the preferred embodiments and examples of the present invention have been described above, the present invention is not limited to the above-described embodiments and examples. Furthermore, the present invention can be modified or changed in various ways in light of the scope of the appended claims. [Explanation of symbols]

[0196] 1,1B Dyeing equipment (textile printing equipment) 2,2A,2B Embroidery device 3,3B Dyeing and embroidery system (textile printing and embroidery system) 4. Upper control device 5 Dyeing and embroidery equipment (textile printing and embroidery equipment) 21 needles 22 Lower thread rotating body 23 Stage 24 Embroidery data processing section 25, 25B Calculation mechanism (understitch control section) 26 Stitch Counter 27 Colorimetric Sensor 28 Driving Driver 30 Discharge head (dyeing head) 51 Dyeing unit (Textile printing unit) 52 Embroidery unit B Lower thread C Cloth N Upper thread [Prior art documents] [Patent documents]

[0197] [Patent Document 1] JP 2008-289522 A

Claims

1. A printing device for printing the yarn; an embroidery device that uses the thread sent from the printing device to embroider on a cloth with a needle based on embroidery data, a dyeing data processing unit that creates initial dyeing data that realizes the thread color of the embroidery data, and inserts redundant data with turn-around markers that serve as marks on the thread at color change points where the dyeing color changes in the initial dyeing data; an embroidery data processing unit that inserts underlay data for sewing an underside of an embroidery area of ​​a planned next color at a color change point on the embroidery data, the underlay data being longer than the redundant data, at a position on the dyeing data where the redundant data has been inserted; The textile printing apparatus includes: A dyeing section is provided for printing yarn based on the dyeing data including the redundant data with the turnaround marker, The embroidery device includes: The understitching control unit starts understitching at a timing when an assumed embroidery position on the embroidery data, which is calculated from the number of stitches sewn by the needle, reaches a color change point on the embroidery data, regardless of the actual embroidery position on the thread, and performs an understitching operation with a length adjusted so that the understitching is turned back and forth using the turn marker as a marker, thereby consuming the deviation between the assumed embroidery position and the actual embroidery position. Printing and embroidery system.

2. The embroidery data processing unit includes: if the actual consumption of the thread is less than expected, and the expected embroidery position calculated from the number of stitches reaches the color change point on the embroidery data before the actual embroidery position reaches the redundant dyed area on the thread that is dyed in accordance with the redundant data, At that timing, the understitching is started, and when the turn marker reaches the needle position, the understitching is stopped and turned back to perform the understitching in a round trip, thereby performing the understitching over a distance longer than the redundant dyeing area. The textile printing and embroidery system according to claim 1 .

3. The embroidery data processing unit includes: an actual consumption amount of thread is greater than the assumed amount, and the assumed embroidery position reaches a color change point on the embroidery data after the actual embroidery position reaches a redundant dyed area on the thread that is dyed in accordance with the redundant data; Understitching is started at the timing when the assumed embroidery position reaches the color change point on the embroidery data, and when the turn marker reaches the needle position, the understitching is stopped and turned back and understitched in a round trip, thereby performing understitching over a distance shorter than the redundant dyeing area. The textile printing and embroidery system according to claim 1 .

4. The embroidery device includes: a forward pass counter that counts the number of stitches from the timing when the assumed embroidery position reaches a color change point on the embroidery data to the timing when the turn marker on the thread reaches the needle position as an underlay forward pass; a return pass counter that counts the number of stitches after the turn marker on the thread reaches the needle position, In the understitching return path, a sewing portion is formed so as to follow the path of the understitching forward path, and the stitch length of each stitch of the sewing portion in the understitching return path is set to be the same as the stitch length of the sewing portion of the adjacent forward path moving in parallel, When the number of stitches being counted by the return pass counter reaches the same number as the number of stitches in the underlay outward pass, the underlay operation is ended and main embroidery is performed to form an embroidery pattern on the cloth in the next color. The textile printing and embroidery system according to claim 2 or 3.

5. The embroidery device includes: A thread color detection means is provided for detecting the thread color and thereby detecting when the turn marker on the thread has reached the needle position.

5. The textile printing and embroidery system according to claim 2, 3 or 4.

6. and an input unit for inputting information of detection by a user that the turn marker on the thread has reached the needle position.

5. The textile printing and embroidery system according to claim 2, 3 or 4.

7. The redundant data includes an area before the turnaround marker that is the same color as the color before the color change point on the dyeing data, and an area after the turnaround marker that is the same color as the color after the color change point, The turnaround marker is set to a color different from two adjacent colors at a color change point on the dyeing data. The textile printing and embroidery system according to any one of claims 1 to 6.

8. The staining data processing unit includes: At a color change point on the dyeing data, it is determined whether or not to insert redundant data based on the color difference between two adjacent colors. The textile printing and embroidery system according to any one of claims 1 to 7.

9. The staining data processing unit includes: At a color change point on the dyeing data, it is determined whether or not to insert redundant data based on the continuation length of each of two adjacent colors. The textile printing and embroidery system according to any one of claims 1 to 8.

10. The staining data processing unit includes: The length of the redundant data to be inserted is set based on the continuation length of each of the two colors adjacent to each other at the color change point on the dyeing data. The textile printing and embroidery system according to claim 9.

11. The dyeing data processing unit and the embroidery data processing unit are mounted on a host control device that can be connected to the printing device, the embroidery device, or the printing and embroidery system. The textile printing and embroidery system according to any one of claims 1 to 10.

12. a printing unit for printing the yarn; an embroidery unit that uses the thread sent from the printing unit to embroider on a cloth with a needle based on embroidery data, a dyeing data processing unit that creates initial dyeing data that realizes the thread color of the embroidery data, and inserts redundant data with turn-around markers that serve as marks on the thread at color change points where the dyeing color changes in the initial dyeing data; an embroidery data processing unit that inserts underlay data for sewing an underside of an embroidery area of ​​a planned next color at a color change point on the embroidery data, the underlay data being longer than the redundant data, at a position on the dyeing data where the redundant data has been inserted; A dyeing unit that prints yarn based on the dyeing data including redundant data with a turnaround marker; The understitching control unit starts understitching at a timing when an assumed embroidery position on the embroidery data, which is calculated from the number of stitches sewn by the needle, reaches a color change point on the embroidery data, regardless of the actual embroidery position on the thread, and performs an understitching operation with a length adjusted so that the understitching is turned back and forth using the turn marker as a marker, thereby consuming the deviation between the assumed embroidery position and the actual embroidery position. Printing and embroidery equipment.

13. An embroidery adjustment method for a printing and embroidery system including a printing device and an embroidery device, comprising: A dyeing data processing step of creating initial dyeing data that realizes the thread color of the embroidery data, and inserting redundant data with turn-around markers that serve as marks on the thread at color change points where the dyeing color changes in the initial dyeing data; an embroidery data processing step of inserting underlay data for sewing an underside of an embroidery area of ​​a planned next color, the underlay data being longer than the redundant data, at a color change point on the embroidery data, the position where the redundant data on the dyeing data has been inserted; A dyeing step of printing the yarn based on the dyeing data including the redundant data with the turnaround marker; and an understitching control step of starting understitching at a timing when an assumed embroidery position on the embroidery data, which is calculated from the number of stitches sewn by the needle, reaches a color change point on the embroidery data, regardless of the actual embroidery position on the thread, and performing an understitching operation with a length adjusted so that the understitching is turned back and forth using the turn marker as a marker, thereby consuming the deviation between the assumed embroidery position and the actual embroidery position. How to adjust embroidery.

Images