Embroidery Data Creation Using Layered Stitch Segmentation
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Solution Overview
Problem
Existing embroidery data creation devices struggle to accurately express tiny portions of images, such as photographs, due to limitations in stitch length, which prevents precise representation of pixel-level details.
Innovation Solution
A device and computer-readable medium that acquire image data, extract pixels with significant color differences, arrange and connect line segments corresponding to these pixels to create embroidery data, ensuring that subsequent stitches do not overlap, allowing for detailed expression of image details through controlled stitching order and thread colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stitch lengths are shortened to express image details, then image detail representation is improved, but manufacturing feasibility deteriorates due to needle and thread thickness limitations
Solution Approach 1:
The patent segments the embroidery pattern into multiple layers, with foreground objects represented by shorter stitches and background objects by longer stitches. This allows different stitch lengths to coexist in the same embroidery design, enabling both fine detail representation and manufacturing feasibility. The segmentation is achieved by analyzing image luminance values and assigning pixels to different layers based on their brightness characteristics.
Solution Approach 2:
The patent applies different stitch lengths to different regions of the embroidery pattern based on local requirements. Foreground regions requiring fine detail use shorter stitches, while background regions use longer stitches. This local differentiation resolves the contradiction by allowing short stitches where needed for precision while using longer stitches elsewhere for manufacturing efficiency.
2Manufacturing precision
If stitch lengths are shortened to represent tiny image portions, then pixel-level detail expression is improved, but device complexity increases due to multiple sewing passes
Solution Approach 1:
The patent performs preliminary classification of pixels into foreground and background layers before generating embroidery data. By pre-processing the image data to identify which pixels require short stitches versus long stitches, the system prepares the sewing path in advance, reducing the complexity of real-time decision-making during the embroidery process.
Solution Approach 2:
The patent introduces a new dimension of layering to the embroidery process, creating multiple sewing passes at different depths. This dimensional approach allows the system to manage complexity by organizing stitches into hierarchical layers, where foreground elements are sewn first with short stitches and background elements are sewn afterward with long stitches.
3Manufacturing precision
If multiple sewing passes are used to achieve detailed expression, then image fidelity is improved, but productivity decreases due to increased sewing time
Solution Approach 1:
The patent applies local quality by using short stitches only for foreground regions that require fine detail representation, while using long stitches for background regions where high precision is less critical. This selective approach maintains image fidelity in important areas while minimizing the overall sewing time, thus balancing productivity and precision.
Solution Approach 2:
The patent applies partial action by implementing multiple sewing passes only for the foreground layer that requires detailed expression, while the background layer uses a single pass with long stitches. This partial application of multi-pass sewing reduces the total sewing time compared to applying multiple passes to the entire image, thereby improving productivity while maintaining image fidelity where needed.
Data Source
AI summary
A device includes a processor and a memory configured to store computer-readable instructions that, when executed by the processor, cause the device to perform processes that include acquiring image data, extracting one or more first pixels, arranging one or more first line segments in one or more first positions, determining one or more first colors, connecting the one or more first line segments, arranging one or more second line segments in one or more second positions such that none of the one or more second line segments overlaps with any one of the one or more first positions, determining one or more second colors, connecting the one or more second line segments, and creating embroidery data based on the connected one or more first line segments and on the connected one or more second line segments.