Sewing management system and sewing management method

Abstract

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

Description

Sewing management system and sewing management method

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

[0002] In the technical field related to the stitching management system, a stitching management system such as that disclosed in Japanese Patent Application Laid-Open No. 2003-122266 is known.

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

[0004] Sewing machines operate based on electricity. In order to manage the power consumption of sewing machines, it is possible to install a power sensor on the sewing machine. However, when managing the power consumption of many industrial sewing machines in a sewing factory, installing a power sensor on every industrial sewing machine would be costly.

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

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

[0007] According to the technology disclosed in this specification, it is possible to manage the power consumption of a sewing machine.

[0008] FIG. 1 is a diagram schematically showing a sewing 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 management method according to an embodiment. FIG. 5 is a diagram showing an example of display data displayed on a display device according to an embodiment. FIG. 6 is a diagram showing an example of display data displayed on a display device according to an embodiment. FIG. 7 is a diagram for explaining 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 Management System] FIG. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages the production process of 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 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 manager and workers work in a sewing factory. The manager manages the workers and the sewing machine 2. The workers sew items to be sewn using the sewing machine 2 in the sewing process. Each of the manager and the worker may be considered to be a user of the sewing machine 2. There may be one manager or multiple managers. There may be one worker or multiple workers. For example, one worker may operate multiple sewing machines 2.

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

[0016] The management device 3 is shared by a plurality of sewing machines 2 in a sewing factory. The number of management devices 3 is smaller than the number of sewing machines 2. The management device 3 is capable of communicating with the sewing machines. The management controller 6 of the management device 3 communicates with the sewing machine controller 8 of the sewing machine 2. The management controller 6 and the sewing machine controller 8 communicate wirelessly. The management controller 6 and the sewing machine controller 8 communicate wirelessly via a local area network (LAN). An example of the wireless LAN is Wi-Fi (registered trademark). The management controller 6 and the sewing machine controller 8 may also communicate wirelessly via a personal area network (PAN). An example of the wireless PAN is Bluetooth (registered trademark).

[0017] 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 .

[0018] The sewing machine controller 8 transmits operation data of the sewing machine 2 to the management controller 6. The operation data of the sewing machine 2 includes the operating conditions of the sewing machine 2. The operating conditions of the sewing machine 2 include the number of stitches, stitch length, stitch pitch, stitch pattern, feed speed of the sewing object, thread tension, and presser foot pressure on the sewing object. The sewing machine controller 8 monitors the operating conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor 7 (see FIG. 3 ) that detects the operating conditions of the sewing machine 2. Examples of the sensor 7 include a stitch number sensor that detects the number of stitches, a tension sensor that detects thread tension, and a presser foot pressure sensor that detects presser foot pressure on the sewing object. The sewing machine controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring the detection data of the sensor 7.

[0019] The sewing machine 2 also has a sewing machine motor for operating the needle bar and thread take-up lever. The operation data of the sewing machine 2 includes operating conditions 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 data of the sewing machine 2 includes control commands input 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 sewing machine motor rotates at a rotation speed determined based on the rotation speed command value. The rotation speed command value may be an average rotation speed command value while the sewing machine motor is operating or a maximum rotation speed command value. The rotation speed of the sewing machine motor may be the average rotation speed while the sewing machine motor is operating or the maximum rotation speed. A current value determined based on the current command value is input to the sewing machine motor.

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

[0021] [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 non-volatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 1003, and an interface 1004 including an input / output circuit. The functions of the management controller 6 are stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, 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.

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

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

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

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

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

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

[0028] As described above, the operation data of the sewing machine 2 includes control commands input to the sewing machine drive circuit from the sewing machine controller 8. 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.

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

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

[0031] The operation data may also be the number of stitches of the sewing machine 2. The number of stitches refers to the number of times the sewing machine needle (needle bar) moves back and forth up and down due to the sewing machine motor. The sensor 7 described above includes a stitch number sensor that detects the number of stitches. The correlation data indicates the relationship between the number of stitches and power consumption. The greater the number of stitches, the greater the power consumption. The smaller the number of stitches, the less the power consumption. The processing unit 62 can calculate the power consumption of the sewing machine 2 based on the number of stitches acquired by the data acquisition unit 61 and the correlation data.

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

[0033] The output unit 63 displays the power consumption calculated by the processing unit 62 on the display device 13. The display device 13 is an example of an output device that outputs the power consumption calculated by the processing unit 62.

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

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

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

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

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

[0039] [Abnormality Detection] The processing unit 62 can determine whether or not an abnormality has occurred in the sewing machine 2 based on the calculated power consumption of the sewing machine 2. If the calculated power consumption changes suddenly, the processing unit 62 can determine that an abnormality has occurred in the sewing machine motor or the motor drive circuit. If the calculated power consumption increases or decreases suddenly, the processing unit 62 can determine that an abnormality has occurred in the sewing machine motor or the motor drive circuit. A sudden change in power consumption means that the amount of change (rate of change) in power consumption per unit time is equal to or greater than a predetermined threshold. If the calculated rate of change in power consumption is equal to or greater than a predetermined threshold, the processing unit 62 determines that an abnormality has occurred in the sewing machine motor or the motor drive circuit.

[0040] When the processing unit 62 determines that the sewing machine 2 is abnormal, the output unit 63 causes the display device 13 to display that the sewing machine 2 is abnormal. This allows the manager to quickly recognize the abnormality of the sewing machine 2. The output unit 63 may also cause the display device 13 to display that there is a sign of an abnormality in the sewing machine 2.

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

[0042] 7 is a diagram illustrating the processing of the output unit 63 according to the embodiment. As shown in FIG. 7 , when the processing unit 62 determines that the sewing machine 2 is abnormal, the output unit 63 may output a message indicating that the sewing machine 2 is abnormal to, for example, the information terminal 11 carried by a maintenance technician of the sewing machine 2. This allows the maintenance technician to quickly recognize the abnormality in the sewing machine 2 and perform maintenance on the sewing machine 2 promptly. The output unit 63 may also output a message indicating that the sewing machine 2 is showing signs of an abnormality to the information terminal 11.

[0043] If the sewing machine 2 is provided with a vibration sensor as the sensor 7 that detects vibrations of the sewing machine 2, the processing unit 62 may determine whether or not there is an abnormality in the sewing machine 2 based on the detected value of the vibration sensor. If the detected value of the vibration sensor increases suddenly, the processing unit 62 can determine that an abnormality has occurred in at least a part of the sewing machine 2. The output unit 63 may output to the display device 13 or the information terminal 11 that there is an abnormality in the sewing machine 2 or that there is a sign of an abnormality in the sewing machine 2.

[0044] If the sewing machine 2 is provided with a temperature sensor as the sensor 7 for detecting the temperature of the sewing machine 2, the processing unit 62 may determine whether or not there is an abnormality in the sewing machine 2 based on the value detected by the temperature sensor. If the value detected by the temperature sensor increases suddenly, the processing unit 62 may determine that an abnormality has occurred in at least a part of the sewing machine 2. The output unit 63 may output to the display device 13 or the information terminal 11 that there is an abnormality in the sewing machine 2 or that there is a sign of an abnormality in the sewing machine 2.

[0045] [Effects] As described above, in the embodiment, the sewing management system 1 includes a data acquisition unit 61 that acquires operation data of the sewing machine 2, a processing unit 62 that calculates the power consumption of the sewing machine 2 based on the operation data, and an output unit 63 that outputs the power consumption to the display device 13, which is an output device.

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

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

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

[0049] The processing unit 62 can determine whether or not there is an abnormality in the sewing machine 2 based on the power consumption of the sewing machine 2. The output unit 63 outputs a signal indicating that there is an abnormality in the sewing machine to the display device 13 or the information terminal 11. This allows the manager or maintenance person to recognize the abnormality in the sewing machine 2 at an early stage.

[0050] The present disclosure includes the following aspects. (1) A sewing management system comprising: a data acquisition unit that acquires operation data of a sewing machine; a processing unit that calculates power consumption of the sewing machine based on the operation data; and an output unit that outputs the power consumption to an output device. (2) The sewing management system described in (1), in which correlation data indicating a relationship between the operation data and the power consumption is obtained in advance, and the processing unit calculates the power consumption based on the operation data acquired by the data acquisition unit and the correlation data. (3) The sewing management system described in (1), in which the operation data includes at least one of a rotation speed command value of a sewing machine motor and a current command value of the sewing machine motor. (4) The sewing management system described in (1), in which the processing unit determines whether the sewing machine is abnormal based on the power consumption, and the output unit outputs a signal that the sewing machine is abnormal. (5) The sewing management system described in (4), in which the processing unit determines that an abnormality has occurred in the sewing machine motor or a motor drive circuit when the power consumption changes suddenly. (6) The sewing management system according to (4), wherein, when the processing unit determines that the sewing machine is abnormal, the output unit causes a display device to display that the sewing machine is abnormal. (7) The sewing management system according to (4), wherein, when the processing unit determines that the sewing machine is abnormal, the output unit causes an information terminal of a maintenance technician to output that the sewing machine is abnormal. (8) A sewing management method comprising: acquiring operation data of a sewing machine; calculating power consumption of the sewing machine based on the operation data; and outputting the power consumption to an output device.

[0051] This application is based on Japanese Patent Application No. 2023-222432, filed on December 28, 2023, the contents of which are incorporated herein by reference.

Claims

1. A sewing management system comprising: a data acquisition unit that acquires operation data of a sewing machine; a processing unit that calculates power consumption of the sewing machine based on the operation data; and an output unit that causes the output device to output the power consumption.

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

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

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

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

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

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

8. A sewing management method including: acquiring operation data of a sewing machine; calculating power consumption of the sewing machine based on the operation data; and causing an output device to output the power consumption.

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