Embroidery Data Generator Tapered Join Precision
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Solution Overview
Problem
Existing embroidery techniques suffer from inconsistencies in sewing length due to differences between test and real fabric, leading to overlaps or gaps at join portions, which are user-dependent and not effectively addressed by existing technologies.
Innovation Solution
An embroidery data generator and method that generates data for patterns with tapered profiles, allowing adjacent elements to be joined seamlessly without overlaps or gaps, by computing and applying specific taper angles and profiles based on the shape and dimensions of the patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If test sewing and real sewing are performed with manual adjustment, then the user can achieve the target length, but slight differences arise in the length of sewing due to differences between test sewing pieces and the real fabric
Solution Approach 1:
The patent replaces manual mechanical adjustment methods with an automated computer-based system. The embroidery data generator automatically calculates and generates precise embroidery data that accounts for fabric differences, eliminating the need for manual test sewing and real sewing adjustments. The system uses computational algorithms to determine optimal sewing parameters, substituting mechanical trial-and-error with digital precision.
Solution Approach 2:
The patent changes the parameters of embroidery data generation to automatically account for fabric variations. The system adjusts sewing length, taper angles, and other parameters based on detected fabric properties and pattern requirements. By dynamically modifying these parameters through computational algorithms, the system achieves consistent sewing results without manual intervention.
2Manufacturing precision
If taper angles are manually set and test sewing is performed, then the user can adjust the taper, but overlap or gaps may occur at the join portions due to the angle of taper not being freely settable
Solution Approach 1:
The patent implements dynamic taper angle adjustment where the system automatically calculates optimal taper angles based on the specific pattern geometry and fabric properties. Rather than requiring manual setting, the taper angles are dynamically determined through computational algorithms that consider the pattern's dimensional requirements and join portion specifications, enabling flexible adaptation to different patterns without increasing operational complexity.
Solution Approach 2:
The system incorporates feedback mechanisms where the generated embroidery data is validated against the original pattern requirements. The computer-based system detects and corrects potential overlaps or gaps by comparing the planned seam paths with the desired pattern geometry, automatically adjusting taper angles to ensure precise join portions.
3Stability of the object's composition
If the user operates the presser bar lifter and rotates the cloth at corner portions, then the continuity of stitching is secured, but overlapping at the corner portions still occurs
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-generating the complete embroidery data for the entire pattern before sewing begins. The system automatically determines the optimal paths and parameters for all sections including corner portions, eliminating the need for manual adjustments during sewing. The pre-generated data ensures both stitching continuity and precise corner alignment without requiring user intervention at corner portions.
Data Source
AI summary
An embroidery data generator generates embroidery data of a whole pattern of joined pattern-configuration-elements. The embroidery data generator includes a pattern-configuration-element generation section configured to generate the pattern-configuration-elements from array patterns configured from unit patterns and having tapered profiles imparted to end portions of the array patterns, and to place the pattern-configuration-elements so that adjacent of the pattern-configuration-elements are joined to each other at tapered portions having the tapered profile.