Dynamic Underlay Stitching for Textile Embroidery Position Accuracy

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Solution Overview

Problem

In embroidery systems with dyeing functions, positional deviations of embroidered colors on cloth can occur due to imbalances in thread consumption, cloth deflection, and variations in embroidery thickness, leading to exposure of color change points on the embroidery surface.

Innovation Solution

A textile-printing-and-embroidery system that includes a textile printing apparatus, an embroidery apparatus, a dyeing data processor, and an embroidery data processor. This system creates initial dyeing data with redundant data and turn-back markers at color change points, and inserts underlay stitching data to adjust thread consumption, ensuring that the color change point is hidden beneath the next color's embroidery region.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If underlay stitching of predetermined length is used to hide color change points, then color change points are concealed, but positional deviation accumulates when actual thread consumption differs from assumed amount

Engineering Contradiction:

Improvepositioning accuracy of color change pointsVSAvoidconsistency of thread consumption

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The underlay stitching length is made dynamic rather than fixed. The system calculates and adjusts the underlay stitching length in real-time based on the actual thread consumption amount detected during embroidery operation, allowing the stitching length to adapt to variations in thread usage and prevent positional deviation accumulation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements a feedback mechanism where the actual thread consumption amount is continuously monitored during embroidery operation. This feedback information is used to adjust the underlay stitching length dynamically, ensuring that color change points remain accurately positioned despite variations in thread consumption

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If thread consumption amount varies due to tension balance changes and cloth deflection, then embroidery position shifts, but fixed underlay stitching cannot compensate for accumulated deviation

Engineering Contradiction:

Improveadjustment capability to thread consumption variationsVSAvoidembroidery position accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the parameter of underlay stitching length based on detected thread consumption variations. By adjusting this parameter dynamically according to actual operating conditions, the system maintains embroidery position accuracy despite changes in tension balance and cloth deflection

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively prevents positional deviations of embroidered colors and accumulations of thread consumption deviations, ensuring that color change points are not exposed on the embroidery surface, thus maintaining the integrity of the embroidery pattern.

Implementation Method 1

an upper thread is dyed using an inkjet technology so as to impart a color that changes in a conveyance direction

Methodology Applied

Scientific EffectInkjet technology:

Data Source

PatentEP4151792B1Textile-printing-and-embroidery system, textile-printing-and- embroidery apparatus, and embroidery adjustment method for textile-printing-and-embroidery system

Publication Date: 2025.04.09 RICOH CO LTD

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AI summary

A textile-printing-and-embroidery system (3) includes a textile printing apparatus (1), an embroidery apparatus (2), a dyeing data processor (107), and an embroidery data processor (24). The textile printing apparatus (1) includes a dyeing device (103) to print a thread based on dyeing data including redundant data to which a turn-back marker is attached. The embroidery apparatus (2) includes an underlay stitching controller (25) to perform an underlay stitching operation for length adjustment such that underlay stitching is started at a timing at which an assumed embroidering position on embroidery data calculated from a number of stitches indicating how many times a needle is sewn reaches a color change point on the embroidery data, regardless of an actual embroidering position on the thread, and is turned back at the turn-back marker to move back and forth once, to consume a deviation between the assumed embroidering position and the actual embroidering position.