Embroidery Frame Deviation Detection Using Optical Reference Points
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Solution Overview
Problem
The existing sewing machine systems fail to accurately identify deviations in the positional relationship between the inner frame and the outer frame of the embroidery frame, leading to misalignment of embroidery patterns due to variations in sewing object thickness and manufacturing errors.
Innovation Solution
A sewing system equipped with an image sensor, processor, and memory that captures images of the embroidery frame, identifies reference point coordinates, and calculates the relative movement amount to align the inner frame with the outer frame, allowing for the determination of positional deviations and correction of embroidery pattern placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sewing machine holds and moves the outer frame of the embroidery frame, then the embroidery pattern can be sewn on the sewing object, but the positional relationship between the inner frame and outer frame deviates due to sewing object thickness and manufacturing errors
Solution Approach 1:
The patent replaces the purely mechanical positioning system with an optical measurement system. An image sensor captures images of the inner frame and outer frame, and a processor calculates their positional relationship based on these images, substituting mechanical measurement methods with optical ones to achieve higher precision.
Solution Approach 2:
The patent creates a digital copy of the physical frames through imaging. The image sensor captures visual information of the inner frame and outer frame, creating digital representations that can be analyzed computationally to determine positional deviations without physically measuring the frames.
2Adaptability or versatility
If the distance between inner frame and outer frame changes due to sewing object thickness, then different thicknesses can be accommodated, but the positional relationship becomes inaccurate
Solution Approach 1:
The patent uses optical imaging instead of mechanical measurement to determine positional relationships. The image sensor and processor combination replaces physical measurement tools, enabling accurate measurement of frame positions regardless of the sewing object thickness between them.
Solution Approach 2:
The patent introduces an intermediary measurement approach by imaging the frames rather than directly measuring their physical distance. The image sensor acts as an intermediary that captures visual information about frame positions, allowing the system to calculate positional relationships without direct physical contact or measurement through the sewing object.
3Device complexity
If the sewing machine does not identify positional deviation, then the system remains simple, but the embroidery pattern cannot be sewn at the correct position
Solution Approach 1:
The patent replaces complex mechanical deviation detection mechanisms with a simpler optical system. Instead of using mechanical sensors or complex measurement devices, the system uses an image sensor and computational processing to identify positional deviations, reducing mechanical complexity while maintaining or improving measurement capability.
Solution Approach 2:
The patent implements a feedback mechanism where the image sensor continuously monitors the positional relationship between frames, and the processor uses this information to identify deviations. This feedback loop enables the system to detect and correct positional inaccuracies automatically, ensuring accurate embroidery pattern placement.
Data Source
AI summary
The sewing system includes a device and a sewing machine including a movement mechanism to move an embroidery frame. The device identifies reference point coordinates representing a position of a reference point provided in a range prescribed by an inner frame of the embroidery frame and transmits the reference point coordinates to the sewing machine. The sewing machine notifies a notification position, using a notification portion, with respect to the range prescribed by the inner frame and acquires a relative movement amount of the embroidery frame with respect to the notification portion, for aligning the notification position and the reference point provided in the range prescribed by the inner frame. The sewing machine decides, on the basis of a relationship between the movement amount and the reference point coordinates, a deviation from a prescribed state of a positional relationship between the inner frame and the movement mechanism.