Sewing machine management system and sewing machine management method

Abstract

A sewing machine management system (1) comprises: a data acquisition unit (61) that acquires operation history data of a sewing machine (2); a processing unit (62) that calculates a maintenance recommendation condition for the sewing machine (2) on the basis of the operation history data; and an output unit (63) that causes an output device to output the maintenance recommendation condition.

Description

Sewing machine management system and sewing machine management method

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

[0002] In the technical field related to sewing machine management systems, a sewing management system such as that disclosed in Japanese Patent Application Laid-Open No. 2003-122999 is known.

[0003] Japanese Patent Application Publication No. 2020-168056

[0004] Industrial sewing machines are installed in sewing factories and maintained by maintenance personnel. If maintenance is not performed properly, the performance of the sewing machine may deteriorate.

[0005] The technology disclosed in this specification aims to properly maintain a sewing machine.

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

[0007] According to the technology disclosed in this specification, the sewing machine is properly maintained.

[0008] FIG. 1 is a diagram schematically showing a sewing machine management system according to an embodiment. FIG. 2 is a hardware configuration diagram showing a management controller according to an embodiment. FIG. 3 is a functional block diagram showing a management device and a sewing machine according to an embodiment. FIG. 4 is a flowchart showing a sewing machine management method according to an embodiment. FIG. 5 is a diagram for explaining the processing of an output unit according to an embodiment. FIG. 6 is a diagram for explaining the processing of an output unit according to an embodiment.

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

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

[0011] In the sewing process, a sewing object is sewn by the sewing machine 2 to produce a sewn product. An example of the sewing object is fabric, and an example of the sewn product is clothing.

[0012] A sewing factory is equipped with multiple types of sewing machines 2 according to their intended use. A sewing factory is equipped with multiple types of sewing machines 2 corresponding to the multiple sewing processes for producing sewn products. Examples of the types of sewing machines 2 include a lockstitch sewing machine for sewing together body parts, a button sewing machine for attaching buttons to body parts, and a pocket sewing machine for attaching pockets to body parts. Many types of sewing machines 2 are installed in one sewing factory. For ease of explanation, three sewing machines 2 are shown in FIG. 1. A first sewing machine 2A is used in a first process for producing sewn products. A second sewing machine 2B is used in a second process for producing sewn products. A third sewing machine 2C is used in a third process for producing sewn products. A sewing factory may be equipped with multiple sewing machines 2 of the same type.

[0013] A sewing factory employs a manager, workers, and maintenance personnel. The manager manages the workers, maintenance personnel, and sewing machine 2. The workers sew items to be sewn using the sewing machine 2 in the sewing process. The maintenance personnel maintain the sewing machine 2. Each of the manager, workers, and maintenance personnel may be considered to be a user of the sewing machine 2. The manager may be one person or multiple people. The workers may be one person or multiple people. For example, one worker may operate multiple sewing machines 2. The maintenance personnel may be one person or multiple people.

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

[0015] The sewing machine 2 has an operation panel 7 and a sewing machine controller 8. The operation panel 7 generates operation data when operated by an operator. The operation panel 7 includes a touch panel (touch sensor) arranged on the display screen of the display. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 has at least one processor and a main memory that stores computer programs executable by the processor.

[0016] The maintenance technician performs maintenance on the sewing machine 2. The maintenance technician carries an information terminal 11. Examples of the information terminal 11 include a tablet terminal or a smartphone. The information terminal 11 includes a display, an input device such as a touch panel, and a computer system.

[0017] The management device 3 is shared by a plurality of sewing machines 2 and information terminals 11 in a sewing factory. The number of management devices 3 is smaller than the number of sewing machines 2. The management device 3 is capable of communicating with each of the sewing machines 2 and the information terminals 11. The management controller 6 of the management device 3 communicates with each of the sewing machine controllers 8 of the sewing machines 2 and the information terminals 11. The management controller 6, sewing machine controller 8, and information terminal 11 communicate wirelessly. The management controller 6, sewing machine controller 8, and information terminal 11 communicate wirelessly via a local area network (LAN). An example of a wireless LAN is Wi-Fi (registered trademark). The management controller 6, sewing machine controller 8, and information terminal 11 may also communicate wirelessly via a personal area network (PAN). An example of a wireless PAN is Bluetooth (registered trademark).

[0018] The management controller 6 transmits a control command to the sewing machine controller 8 of the sewing machine 2 based on input data generated by operating the input device 5 .

[0019] The sewing machine controller 8 transmits operation history data indicating the operation history of the sewing machine 2 to the management controller 6. The operation history of the sewing machine 2 includes at least one of the operation date and time of the sewing machine 2, the operation time of the sewing machine 2, the type of sewing object sewn by the sewing machine 2, the number of stitches during sewing, information about an error that occurred in the sewing machine 2, and the operator who operated the sewing machine 2. The operation time of the sewing machine 2 includes at least one of the continuous operation time of the sewing machine 2 and the accumulated operation time of the sewing machine 2.

[0020] The sewing machine 2 has a needle bar, a thread take-up lever, and a sewing machine motor for operating the needle bar and the thread take-up lever. The operation history of the sewing machine 2 includes the operation history of the sewing machine motor. The sewing machine controller 8 inputs control commands to a sewing machine drive circuit that drives the sewing machine motor. The sewing machine drive circuit includes a switching element such as a field effect transistor (FET). The operation history data of the sewing machine 2 includes control commands transmitted from the sewing machine controller 8 to the sewing machine drive circuit. The control commands include at least one of a rotation speed command value that commands the rotation speed of the sewing machine motor and a current command value that commands the value of a current input to the sewing machine motor. The operation date and time of the sewing machine 2 includes the date and time when the control command was transmitted from the sewing machine controller 8 to the sewing machine drive circuit. The operation time of the sewing machine 2 includes the time when the control command was transmitted from the sewing machine controller 8 to the sewing machine drive circuit.

[0021] The operation history data of the sewing machine 2 may include detection data of a sensor 9 (see FIG. 3 ) provided in the sewing machine 2. The sensor 9 detects the operating conditions of the sewing machine 2. Examples of the sensor 9 include a stitch count sensor that detects the number of stitches during sewing, a tension sensor that detects the tension of the thread, and a presser foot pressure sensor that detects the pressure applied to the sewing object. The sewing machine controller 8 may transmit the detection data of the sensor 9 to the management controller 6 as the operation history data of the sewing machine 2.

[0022] Furthermore, the sewing machine controller 8 transmits usage environment history data indicating the usage environment history of the sewing machine 2 to the management controller 6. The usage environment history of the sewing machine 2 includes at least one of the atmospheric temperature and humidity of the environment in which the sewing machine 2 was used. If the sensor 9 provided in the sewing machine 2 is a temperature sensor, the sewing machine controller 8 can transmit the usage environment history data to the management controller 6 based on the detection data of the temperature sensor. If the sensor 9 provided in the sewing machine 2 is a humidity sensor, the sewing machine controller 8 can transmit the usage environment history data to the management controller 6 based on the detection data of the humidity sensor.

[0023] The information terminal 11 transmits maintenance history data indicating the maintenance history of the sewing machine 2 to the management controller 6. The maintenance of the sewing machine 2 includes at least one of inspection, adjustment, part replacement, and repair of the sewing machine 2. The maintenance history of the sewing machine 2 includes at least one of the date and time of maintenance of the sewing machine 2, the maintenance method of the sewing machine 2, the maintenance location of the sewing machine 2, the maintenance result of the sewing machine 2, and the maintenance technician who maintained the sewing machine 2. The maintenance method includes at least one of inspection, adjustment, part replacement, and repair of the sewing machine 2. The maintenance location refers to the part of the sewing machine 2 that has been maintained. The maintenance location includes the part of the sewing machine 2 that has been maintained. The maintenance result includes at least one of the inspection result, adjustment result, replaced part, and repair result. The inspection result indicates a record of the inspection of the sewing machine 2. The adjustment result indicates the state of the sewing machine 2 after adjustment. The repair result indicates the state of the sewing machine 2 after repair. The maintenance technician inputs maintenance data related to the maintenance of the sewing machine 2 performed by the maintenance technician into the information terminal 11. The information terminal 11 transmits maintenance history data to the management controller 6 based on the maintenance data.

[0024] The management controller 6 collects operation history data, usage environment history data, and maintenance history data of each of the plurality of sewing machines 2. The management controller 6 causes the display device 4 to display the operation history data, usage environment history data, and maintenance history data of each of the plurality of sewing machines 2.

[0025] [Computer System] FIG. 2 is a hardware configuration diagram showing a management controller 6 according to an embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a CPU (Central Processing Unit), a main memory 1002 including a nonvolatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 1003, and an interface 1004 including an input / output circuit. The functions of the management controller 6 are stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, loads it into the main memory 1002, and executes processing in accordance with the computer program. The computer program may be distributed to the computer system 1000 via a network.

[0026] Similarly, each of the sewing machine controller 8 and the information terminal 11 includes a computer system having a processor, a main memory, a storage, and an interface.

[0027] 3 is a functional block diagram showing the management device 3 and the sewing machine 2 according to the embodiment. As shown in FIG. 3, the sewing machine 2 has a sewing machine controller 8 and a sensor 9.

[0028] The management controller 6 includes a data acquisition unit 61 , a processing unit 62 , and an output unit 63 .

[0029] The data acquisition unit 61 acquires operation history data of the sewing machine 2 from the sewing machine controller 8. The data acquisition unit 61 acquires usage environment history data of the sewing machine 2 from the sewing machine controller 8. The data acquisition unit 61 acquires maintenance history data of the sewing machine 2 from the information terminal 11.

[0030] The processing unit 62 calculates recommended maintenance conditions for the sewing machine 2 based on the operation history data acquired by the data acquisition unit 61. The processing unit 62 may calculate the recommended maintenance conditions based on the operation history data and the usage environment history data acquired by the data acquisition unit 61. The processing unit 62 may calculate the recommended maintenance conditions based on the operation history data and the maintenance history data acquired by the data acquisition unit 61. The processing unit 62 may calculate the recommended maintenance conditions based on the operation history data, the usage environment history data, and the maintenance history data acquired by the data acquisition unit 61.

[0031] The recommended maintenance conditions include at least one of a recommended maintenance time, a recommended maintenance location, and a recommended maintenance method. The recommended maintenance time refers to the next time when the sewing machine 2 should be maintained. The recommended maintenance location refers to a part of the sewing machine 2 that should be maintained. The recommended maintenance location includes a recommended maintenance part. The recommended maintenance part refers to a part of the sewing machine 2 that should be maintained. The part of the sewing machine 2 that should be maintained includes a part of the sewing machine 2 that should be replaced. The recommended maintenance method refers to a method or procedure for maintaining the recommended maintenance location. The recommended maintenance method includes daily inspection, periodic inspection which is a more detailed inspection than daily inspection, adjustment of the part that should be maintained, repair of the part that should be maintained, adjustment of the part that should be maintained, and replacement of the part that should be maintained.

[0032] In the embodiment, correlation data indicating the relationship between the operation history data and the recommended maintenance conditions is derived in advance and stored in the processing unit 62. The processing unit 62 can calculate the recommended maintenance conditions based on the operation history data acquired by the data acquisition unit 61 and the correlation data that has been derived in advance.

[0033] Furthermore, correlation data indicating the relationship between the usage environment history data and the recommended maintenance conditions is derived in advance and stored in the processing unit 62. The processing unit 62 can calculate the recommended maintenance conditions based on the usage environment history data acquired by the data acquisition unit 61 and the correlation data that has been derived in advance.

[0034] Furthermore, correlation data indicating the relationship between the maintenance history data and the recommended maintenance conditions is derived in advance and stored in the processing unit 62. The processing unit 62 can calculate the recommended maintenance conditions based on the maintenance history data acquired by the data acquisition unit 61 and the correlation data that has been derived in advance.

[0035] For example, if correlation data between the number of stitches (operation history data) and the time to replace the sewing machine needle (recommended maintenance conditions) is derived in advance, and the data acquisition unit 61 acquires the number of stitches detected by the sewing machine needle sensor as operation history data, the processing unit 62 can determine the recommended time to replace the sewing machine needle (recommended maintenance conditions) based on the number of stitches acquired by the data acquisition unit 61 and the correlation data.

[0036] For example, if correlation data between atmospheric temperature (usage environment history data) and the time to replace a sewing machine needle (recommended maintenance conditions) is derived in advance, and the data acquisition unit 61 acquires the atmospheric temperature detected by a temperature sensor as usage environment history data, the processing unit 62 can determine the recommended time to replace the sewing machine needle (recommended maintenance conditions) based on the atmospheric temperature acquired by the data acquisition unit 61 and the correlation data.

[0037] For example, if correlation data between the most recent maintenance date and time (maintenance history data) and the time when a sewing machine needle should be replaced (recommended maintenance conditions) is derived in advance, and the data acquisition unit 61 acquires the most recent maintenance date and time as maintenance history data, the processing unit 62 can determine the recommended time to replace the sewing machine needle (recommended maintenance conditions) based on the most recent maintenance date and time acquired by the data acquisition unit 61 and the correlation data.

[0038] The output unit 63 displays the recommended maintenance conditions calculated by the processing unit 62 on the display device 4 or the display of the information terminal 11. The display device 4 and the display of the information terminal 11 are examples of output devices that output the recommended maintenance conditions calculated by the processing unit 62.

[0039] 4 is a flowchart showing a sewing machine management method according to an embodiment. The data acquisition unit 61 acquires operation history data of the sewing machine 2 from the sewing machine controller 8 (step S1). The data acquisition unit 61 acquires maintenance history data of the sewing machine 2 from the information terminal 11 (step S2). The data acquisition unit 61 acquires usage environment history data of the sewing machine 2 from the sewing machine controller 8 (step S3).

[0040] The processing unit 62 calculates recommended maintenance conditions based on the operation history data, the maintenance history data, the use environment history data, and the correlation data (step S4).

[0041] The output unit 63 displays the recommended maintenance conditions calculated by the processing unit 62 on the display device 4 or the display of the information terminal 11 (step S5).

[0042] 5 is a diagram illustrating the processing of the output unit 63 according to the embodiment. As shown in FIG. 5, the output unit 63 may transmit the recommended maintenance conditions to the information terminal 11 carried by the maintenance technician. The maintenance technician can perform maintenance on the sewing machine 2 based on the recommended maintenance conditions displayed on the display of the information terminal 11.

[0043] 6 is a diagram illustrating the processing of the output unit 63 according to the embodiment. As shown in FIG. 6, the output unit 63 may transmit the recommended maintenance conditions to the sewing machine controller 8 of the sewing machine 2. The sewing machine controller 8 displays the recommended maintenance conditions on the operation panel 7 of the sewing machine 2. The recommended maintenance conditions include recommended cleaning conditions for the sewing machine 2. The operator can clean the sewing machine 2 based on the recommended cleaning conditions displayed on the operation panel 7.

[0044] [Effects] As described above, according to the embodiment, the sewing machine 2 is provided with a data acquisition unit 61 that acquires operation history data of the sewing machine 2, a processing unit 62 that calculates recommended maintenance conditions for the sewing machine 2 based on the operation history data, and an output unit 63 that outputs the recommended maintenance conditions to the information terminal 11, which is an output device.

[0045] According to the embodiment, the sewing machine 2 is properly maintained based on the operation history data. A sewing machine 2 operated under harsh operating conditions needs to be maintained frequently or using a thorough maintenance method in order to prevent a decrease in the performance of the sewing machine 2. On the other hand, if a sewing machine 2 operated under less harsh operating conditions is maintained frequently or using a thorough maintenance method, the operation rate of the sewing machine may decrease, and the productivity of the sewing factory may decrease. Furthermore, when maintenance is performed on a part that does not require maintenance, the operation rate of the sewing machine may also decrease. According to the embodiment, recommended maintenance conditions for the sewing machine 2 are determined based on the operation history data, and therefore a decrease in the performance of the sewing machine 2 is prevented, and a decrease in the operation rate of the sewing machine 2 is prevented. The sewing machine 2 is properly maintained.

[0046] In the embodiment, the sewing machine 2 is properly maintained based on the usage environment history data. A sewing machine 2 operated in a harsh usage environment needs to be maintained frequently or using a thorough maintenance method in order to prevent a decline in the performance of the sewing machine 2. On the other hand, if a sewing machine 2 operated in a less harsh usage environment is maintained frequently or using a thorough maintenance method, the availability rate of the sewing machine may decrease. According to the embodiment, recommended maintenance conditions for the sewing machine 2 are determined based on the usage environment history data, so the sewing machine 2 is properly maintained.

[0047] In the embodiment, the sewing machine 2 is appropriately maintained based on the maintenance history data. If maintenance is performed again even though the time since the last maintenance is short and the next maintenance is not necessary, the availability of the sewing machine 2 may decrease. Furthermore, if a part of the sewing machine 2 was carefully maintained in the previous maintenance and the same part is carefully maintained again, the availability of the sewing machine 2 may decrease. Furthermore, replacing a part that has just been replaced again will incur replacement costs. According to the embodiment, the recommended maintenance conditions for the sewing machine 2 are determined based on the maintenance history data, so the sewing machine 2 is appropriately maintained.

[0048] The recommended maintenance conditions include recommended cleaning conditions for the sewing machine 2. In cases where only maintenance personnel are allowed to inspect, adjust, replace parts, and repair the sewing machine 2, the recommended cleaning conditions are provided to the worker, allowing the worker to properly clean the sewing machine 2.

[0049] The present disclosure includes the following aspects. (1) A sewing machine management system comprising: a data acquisition unit that acquires operation history data of a sewing machine; a processing unit that calculates recommended maintenance conditions for the sewing machine based on the operation history data; and an output unit that outputs the recommended maintenance conditions to an output device. (2) The sewing machine management system according to (1), wherein the recommended maintenance conditions include at least one of a recommended maintenance time, a recommended maintenance location, and a recommended maintenance method. (3) The sewing machine management system according to (1), wherein the operation history data includes at least one of an operation history of a sewing machine motor, a control command transmitted from a sewing machine controller to a sewing machine drive circuit, detection data of a sensor provided in the sewing machine, operation date and time of the sewing machine, operation time of the sewing machine, a type of sewing object sewn by the sewing machine, the number of stitches during sewing, information on errors that have occurred in the sewing machine, and an operator who operated the sewing machine. (4) The sewing machine management system according to (1), wherein the data acquisition unit acquires maintenance history data of the sewing machine, and the processing unit calculates the recommended maintenance conditions based on the operation history data and the maintenance history data. (5) The sewing machine management system according to (4), wherein the maintenance history data includes at least one of a maintenance date and time for the sewing machine, a maintenance method for the sewing machine, a maintenance location for the sewing machine, a maintenance result for the sewing machine, and a maintenance technician who performed the maintenance on the sewing machine. (6) The sewing machine management system according to (1), wherein the data acquisition unit acquires usage environment history data for the sewing machine, and the processing unit calculates the recommended maintenance conditions based on the operation history data and the usage environment history data. (7) The sewing machine management system according to (6), wherein the usage environment history data includes at least one of an atmospheric temperature and a humidity of an environment in which the sewing machine is used. (8) The sewing machine management system according to (1), wherein the recommended maintenance conditions include recommended cleaning conditions for the sewing machine. (9) A sewing machine management method comprising: acquiring operation history data for a sewing machine; calculating recommended maintenance conditions for the sewing machine based on the operation history data; and outputting the recommended maintenance conditions to an output device.

[0050] This application is based on Japanese Patent Application No. 2023-217881 filed on December 25, 2023, the contents of which are incorporated herein by reference.

Claims

1. A sewing machine management system comprising: a data acquisition unit that acquires operation history data of a sewing machine; a processing unit that calculates maintenance recommendation conditions for the sewing machine based on the operation history data; and an output unit that outputs the maintenance recommendation conditions to an output device.

2. The sewing machine management system according to claim 1, wherein the maintenance recommendation conditions include at least one of a maintenance recommendation timing, a maintenance recommendation location, and a maintenance recommendation method.

3. The sewing machine management system according to claim 1, wherein the operation history data includes at least one of an operation history of a sewing machine motor, a control command transmitted from a sewing machine controller to a sewing machine drive circuit, detection data of a sensor provided in the sewing machine, an operation date and time of the sewing machine, an operation time of the sewing machine, a type of sewing target sewn by the sewing machine, a number of stitches during sewing, error information generated in the sewing machine, and an operator who operated the sewing machine.

4. The sewing machine management system according to claim 1, wherein the data acquisition unit acquires maintenance history data of the sewing machine, and the processing unit calculates the maintenance recommendation conditions based on the operation history data and the maintenance history data.

5. The sewing machine management system according to claim 4, wherein the maintenance history data includes at least one of a maintenance date and time of the sewing machine, a maintenance method of the sewing machine, a maintenance location of the sewing machine, a maintenance result of the sewing machine, and a maintenance person who maintained the sewing machine.

6. The sewing machine management system according to claim 1, wherein the data acquisition unit acquires usage environment history data of the sewing machine, and the processing unit calculates the maintenance recommendation conditions based on the operation history data and the usage environment history data.

7. The sewing machine management system according to claim 6, wherein the usage environment history data includes at least one of an atmospheric temperature and a humidity of an environment in which the sewing machine is used.

8. The sewing machine management system according to claim 1, wherein the maintenance recommendation conditions include cleaning recommendation conditions for the sewing machine.

9. A sewing machine management method including: acquiring operation history data of a sewing machine; calculating maintenance recommendation conditions for the sewing machine based on the operation history data; and outputting the maintenance recommendation conditions to an output device.

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