Embroidery System with Liquid Coloring and Density Control
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Solution Overview
Problem
Existing embroidery systems face challenges in creating multi-colored designs, as they require large apparatuses to manage multiple threads, and struggle to impart a visual roughness impression to embroidery designs, resulting in flat textures.
Innovation Solution
An embroidery system that includes a liquid discharge apparatus for coloring threads and an embroidery apparatus for performing embroidery designs and underlay stitching, using data creation and adjustment mechanisms to modify embroidery density and contrast based on roughness data, thereby imparting a visual roughness impression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large-sized embroidery apparatus holding multiple colored threads is used to create multi-colored designs, then color variety is improved, but device complexity and size increase
Solution Approach 1:
The invention extracts the coloring function from the embroidery apparatus itself and separates it into an independent liquid discharge apparatus. This allows the embroidery apparatus to focus on stitching while the liquid discharge apparatus handles color application, thereby reducing the complexity and size of the embroidery apparatus while maintaining multi-color capability
Solution Approach 2:
The liquid discharge apparatus serves as a universal coloring mechanism that can apply multiple colors to a single thread or different threads without requiring the embroidery apparatus to hold and manage multiple colored thread spools. This multi-functional approach enables color variety while keeping the embroidery apparatus compact
2Manufacturing precision
If traditional embroidery methods are used without underlay stitching optimization, then manufacturing simplicity is maintained, but visual roughness impression and three-dimensional effect are insufficient
Solution Approach 1:
The system performs preliminary actions by automatically creating optimized underlay stitching data and embroidery density adjustment data before the actual embroidery process. The image processing apparatus analyzes the design image and pre-calculates the optimal underlay stitching patterns and density adjustments, which simplifies the manufacturing process while achieving the desired visual roughness effect
Solution Approach 2:
The invention introduces an intermediary data processing layer that includes image processing apparatus and data creation units. This intermediary layer translates design images into optimized embroidery data with automatic underlay stitching generation and density adjustment, bridging the gap between simple manufacturing and high visual precision without requiring complex manual intervention
3Manufacturing precision
If uniform embroidery density is used throughout the design, then ease of operation is maintained, but visual roughness impression and texture depth are reduced
Solution Approach 1:
The invention applies local quality by varying the embroidery density at different regions of the design based on the underlying image characteristics. The system automatically identifies areas requiring different density levels and adjusts the stitching density locally, creating visual roughness and texture depth without requiring manual parameter adjustment by the operator
Solution Approach 2:
The embroidery system performs self-service by automatically analyzing the design image and determining the optimal density distribution pattern. The image processing apparatus and data creation units work autonomously to generate the density adjustment data, eliminating the need for operator intervention in parameter adjustment while achieving superior texture effects
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 colors threads and adjusts embroidery density and contrast to create designs with a visual roughness impression, enhancing the three-dimensional effect and texture of embroidery without the need for multiple thread colors.
Implementation Method 1
a liquid discharge apparatus (103) to discharge liquid according to color data
Implementation Method 2
a heating apparatus (104) to heat the thread (101) according to drying data
Data Source
AI summary
An embroidery system includes a coloring device to color a thread. The embroidery system includes an embroidery device to perform embroidery of an embroidery design and underlay stitching. The embroidery device uses the thread colored by the coloring device for at least one of the embroidery of the embroidery design or the underlay stitching. The embroidery system includes circuitry to: create data of the embroidery design and the underlay stitching according to embroidery image data; create color data for coloring the thread to be used for coloring the at least one of the embroidery of the embroidery design or the underlay stitching; acquire roughness data representing roughness impression of the embroidery image data; and change an embroidery density of the embroidery design according to the roughness data.