Embroidery Data Generation for Large Pattern Arrangement

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Solution Overview

Problem

Existing sewing machines lack flexibility in arranging sub patterns relative to sewing areas when embroidering patterns larger than the sewing area, requiring manual adjustments and leading to potential errors in positioning and stitching quality.

Innovation Solution

A computer-readable medium and method that allows for the virtual arrangement and relative position adjustment of sewing areas, generating embroidery data with needle drop coordinates to optimize the placement of sub patterns within each sewing area, enabling flexible and precise arrangement of sub patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If an embroidery pattern larger than the sewing area is split into sub patterns, then the pattern can be embroidered within the sewing area, but the arrangement of sub patterns relative to sewing areas lacks flexibility

Engineering Contradiction:

Improvearrangement flexibility of sub patternsVSAvoidcomplexity of arranging sub patterns

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by making the arrangement of sewing areas adjustable and reconfigurable. The system allows dynamic modification of the relative positions of multiple sewing areas on the workpiece, enabling flexible arrangement of sub patterns to accommodate different embroidery patterns and user requirements, rather than using fixed predetermined arrangements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent introduces a virtual arrangement dimension by setting virtual arrangements of both the pattern and multiple sewing areas relative to the workpiece. This virtual positioning layer allows for flexible planning and adjustment of sub pattern arrangements before actual embroidery, adding a planning dimension that enhances arrangement flexibility without increasing physical device complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the relative position of sewing areas is fixed, then the device complexity is reduced, but the flexibility in setting arrangement of sub patterns is limited

Engineering Contradiction:

Improveflexibility in setting arrangementVSAvoidease of arranging sub patterns

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent applies preliminary action by establishing virtual arrangements of the pattern and sewing areas relative to the workpiece before actual embroidery begins. This pre-positioning allows users to plan and adjust the arrangement of sub patterns in advance, making the subsequent embroidery process simpler and more efficient, thus improving ease of operation

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If manual adjustments are made for positioning sub patterns, then flexibility is increased, but positioning accuracy and stitching quality may deteriorate due to human error

Engineering Contradiction:

Improvearrangement flexibilityVSAvoidpositioning accuracy of sub patterns

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces manual mechanical positioning with an automated computer-based system that calculates and determines the relative positions of multiple sewing areas and sub patterns. This substitution of manual operation with automated computation eliminates human error in positioning, ensuring high precision while maintaining arrangement flexibility through software-based adjustments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a virtual copy or digital representation of the workpiece with pattern and sewing areas positioned in virtual space. This virtual model allows for precise calculation and adjustment of positions before physical embroidery, ensuring accurate positioning of sub patterns without relying on manual measurement and adjustment

Inventive Principle:

Principle #26Copying

Data Source

PatentUS11473228B2Non-transitory computer-readable medium and embroidery data generation method

Publication Date: 2022.10.18 BROTHER KOGYO KK

AI summary

A non-transitory computer-readable medium stores computer-readable instructions, when executed by a computer, causing the computer to execute a process. The process and a method of generating embroidery data each includes: obtaining a pattern to be sewn on a workpiece by a sewing machine; obtaining a size of a sewing area to be set inside an embroidery hoop attachable to the sewing machine; setting a virtual arrangement of a plurality of the sewing areas relative to the workpiece; setting a virtual arrangement of the pattern relative to the workpiece; changing a relative position of the sewing areas; and generating embroidery data including needle drop data, the needle drop data representing a plurality of coordinates of needle drop points to form a plurality of stitches for the pattern located in each of the sewing areas in the relative position changed.