Dynamic Unit Region Sizing for Embroidery Data Processing
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Solution Overview
Problem
Conventional embroidery data processing methods degrade sewing quality by unnecessarily dividing embroidery patterns into unit regions of uniform size, leading to suboptimal fit within the embroidery frame's maximum sewing size.
Innovation Solution
An embroidery data processing apparatus and program that dynamically set and modify unit embroidery regions based on the size and position of partial patterns to ensure they fit within the maximum sewing region, allowing for the creation of complete or partial patterns without division, thereby optimizing the sewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If unit embroidery regions are set with uniform size to fit within maximum sewing region, then embroidery data can be created for patterns larger than maximum sewing size, but patterns are unnecessarily divided leading to degraded sewing quality
Solution Approach 1:
The patent applies dynamics by making the unit embroidery region size variable rather than fixed. The control device dynamically adjusts the size of unit embroidery regions based on the actual dimensions of partial patterns, allowing regions to expand or contract as needed. This resolves the contradiction by enabling large patterns to be embroidered without unnecessary division (maintaining quality) while still fitting within the maximum sewing region constraints.
Solution Approach 2:
The patent applies local quality by allowing different unit embroidery regions to have different sizes tailored to their specific partial patterns. Instead of forcing uniform sizing across all regions, each region's size is optimized locally to match its contained pattern elements. This prevents unnecessary divisions in regions with small or compact patterns while efficiently utilizing space in regions with larger patterns.
2Adaptability or versatility
If original pattern is divided into several patterns to fit maximum sewing size, then embroidery data can be created for large patterns, but the number of divisions increases leading to more labor and cloth changes
Solution Approach 1:
The control device dynamically determines the optimal number and size of unit embroidery regions based on the partial patterns' characteristics. This dynamic approach minimizes the number of regions needed, thereby reducing the number of cloth changes and labor required, while still enabling processing of patterns larger than the maximum sewing size through strategic division only when necessary.
Solution Approach 2:
The patent applies preliminary action by having the control device analyze the original pattern and pre-determine the optimal division strategy before embroidery begins. The device calculates the minimum number of unit embroidery regions needed and their appropriate sizes in advance, ensuring that divisions are made only when absolutely necessary and that the embroidery process proceeds efficiently with minimal interruptions for cloth changes.
3Ease of manufacture
If uniform size unit embroidery regions are used, then setting process is simple, but pattern division cannot be optimized leading to degraded sewing quality
Solution Approach 1:
The patent applies self-service by enabling the control device to automatically perform the complex task of optimizing unit embroidery region sizes based on partial pattern characteristics. The system self-adjusts region sizes without requiring manual intervention or complex user configuration, thereby maintaining ease of operation while achieving optimized pattern division that prevents quality degradation.
Data Source
AI summary
An embroidery data processing apparatus and an embroidery data processing program that creates embroidery data usable by an embroidery sewing machine to sew an embroidery pattern that includes a plurality of partial patterns. The embroidery data processing apparatus and program store a maximum sewing region; set a plurality of unit embroidery regions; and modify a size of each of the plurality of unit regions based on the size of the maximum sewing region and a position and a size of each of the plurality of partial patterns contained within the plurality of unit embroidery regions. The embroidery data processing apparatus and program create the embroidery data of a part or a whole of the embroidery pattern being contained within the modified plurality of unit embroidery regions and output the embroidery data.