Multi-needle Embroidery Machine Cutting via Needle Holes
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Solution Overview
Problem
Existing embroidery cutting devices are large and cumbersome due to their reliance on heat cutters for cutting out embroidery patterns, which limits their efficiency and versatility.
Innovation Solution
A multi-needle sewing machine equipped with a processor and memory that creates embroidery data to form objects by sewing and cutting along an embroidery pattern without the need for a heat cutter, using a combination of sewing and cutting needles to form holes and stitches that define the pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a heat cutter is used to cut the work cloth along the outline of the embroidery pattern, then the cutting function is achieved, but the device size becomes large and cumbersome
Solution Approach 1:
The invention extracts the cutting function from the heat cutter and implements it using the sewing machine's needle and thread combination. The needle creates holes along the outline while the thread forms stitches that define the pattern boundary, eliminating the need for a separate heat cutter component and reducing device size.
Solution Approach 2:
The sewing machine is designed to perform multiple functions: it both sews the embroidery pattern and cuts the work cloth to form the final object. By using the same machine for both sewing and cutting operations, the invention eliminates the need for separate cutting devices, thereby reducing overall device size while maintaining manufacturing capability.
2Ease of manufacture
If a heat cutter is used to cut the embroidery pattern, then cutting is achieved, but the embroidery pattern is subjected to heat processing which may affect quality
Solution Approach 1:
The invention removes the heat-based cutting mechanism entirely and replaces it with a mechanical needle-punching method. The needle creates physical holes through the work cloth along the pattern outline without applying heat, thereby preserving the embroidery pattern from thermal damage while still achieving the cutting function.
Solution Approach 2:
The invention replaces the thermal cutting system with a mechanical system. Instead of using heat to melt and separate the material, the system uses a needle to mechanically punch holes and thread to form stitches that define the cut edges, eliminating harmful thermal effects on the embroidery.
3Reliability
If multiple holes are formed along the outline to connect inner and outer regions, then the connection reliability is improved, but the number of stitches and processing steps increases
Solution Approach 1:
The invention divides the continuous outline into multiple discrete hole positions spaced at predetermined intervals. By forming holes at these segmented locations rather than creating one continuous cut, the system reliably connects inner and outer regions while maintaining manageable processing steps through automated needle positioning.
Solution Approach 2:
The system pre-calculates and stores the positions of multiple holes along the outline pattern before actual sewing begins. This preliminary preparation of hole position data allows the sewing machine to efficiently execute the multi-hole formation process without real-time complex calculations, thereby maintaining productivity while achieving reliable regional connection.
Data Source
AI summary
An apparatus includes a processor and a memory. The memory is configured to store computer-readable instructions that, when executed by the processor, instruct the processor to perform processes including acquiring pattern data, specifying an outline of the embroidery pattern based on the pattern data, creating hole data for causing the sewing machine to form a plurality of holes including one or more first holes and one or more second holes, creating first stitch data for causing the sewing machine to sew one or more stitches for the one or more first holes, and creating embroidery data for causing the sewing machine to form one or more first holes, and sew the one or more stitches for the one or more first holes, and causing the sewing machine to form the one or more second holes, before causing the sewing machine to sew an outline pattern.