Embroidery Sewing Control for Object-Based Bobbin Thread Use
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Solution Overview
Problem
The increasing complexity and variety of sewable patterns lead to higher bobbin thread requirements, resulting in frequent bobbin thread replacements and waste, as conventional sewing machines lack efficient management of bobbin thread usage during embroidery sewing.
Innovation Solution
A sewing machine with a pattern data acquisition unit, bobbin thread remaining amount acquisition unit, determination unit, and decision unit that assesses the required bobbin thread amount for each object within a pattern and determines if it is sewable based on the remaining thread, allowing for targeted thread usage and reduction of unnecessary replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bobbin thread remaining amount is compared with the required amount on a pattern basis, then the warning display can be issued, but the bobbin thread replacement frequency increases and waste increases due to inability to sew complete objects
Solution Approach 1:
The patent segments the pattern into multiple objects and further divides each object into sub-objects. Instead of treating the entire pattern as a single unit for thread quantity calculation, the system calculates required thread amounts for each individual object and sub-object. This segmentation enables precise determination of which specific objects can be completed with the remaining bobbin thread, allowing the system to selectively sew only those objects that can be fully completed, thereby preventing thread waste while maintaining reliable warning functionality.
2Reliability
If the bobbin thread remaining amount is compared with the required amount on a pattern basis, then the warning display can be issued, but the operation complexity increases due to manual intervention requirements
Solution Approach 1:
The patent implements self-service functionality by enabling the sewing machine to automatically determine which objects can be completed with the remaining bobbin thread and automatically select and sew only those objects. The system autonomously calculates thread requirements for each object, compares them with the remaining thread amount, and makes decisions about which objects to sew without requiring manual user intervention. This automation reduces operation complexity while maintaining the reliability of thread sufficiency monitoring.
3Adaptability or versatility
If complex patterns with multiple objects are sewn, then the design versatility is improved, but the bobbin thread consumption increases requiring more frequent replacements
Solution Approach 1:
The patent segments complex patterns into multiple independent objects and sub-objects, enabling the system to calculate thread requirements for each individual component. This segmentation allows the sewing machine to selectively process only those objects that can be completed with the available bobbin thread, rather than requiring replacement after each object in a complex pattern. The system can identify and sew complete objects within a complex pattern using the remaining thread, thereby reducing overall thread consumption and replacement frequency while maintaining the ability to handle versatile, complex pattern designs.
4Productivity
If the entire pattern is attempted to be sewn with remaining thread, then the productivity is maintained, but the manufacturing precision decreases due to incomplete objects
Solution Approach 1:
The patent applies preliminary action by calculating the required bobbin thread amount for each object and sub-object before actual sewing begins. The system performs advance determination of which objects can be fully completed with the remaining thread, and pre-selects the appropriate objects for sewing. This preliminary calculation and selection process ensures that only objects that can be completely finished are chosen for sewing, guaranteeing manufacturing precision (complete objects) while maintaining productivity by automatically identifying the maximum number of completable objects within the thread constraint.
Data Source
AI summary
A sewing machine includes: a pattern data acquisition unit that acquires pattern data in which information on an object corresponding to a unit from a sewing start point to a ravel preventing point or a thread trimming point and information related to a required bobbin thread amount required for sewing the object are associated with each other and registered; a bobbin thread remaining amount acquisition unit that acquires a bobbin thread remaining amount; a determination unit that determines whether or not the object is sewable, based on a difference between a required bobbin thread amount of the object according to the pattern data and the bobbin thread remaining amount; and a decision unit that, based on a determination result of the determination unit, decides whether or not the object is set as a sewing target.