Embroidery Sewing Machine Thread Color Grouping
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Solution Overview
Problem
Existing embroidery sewing machines face inefficiencies in thread color management, particularly when switching between designs with different color compositions, leading to increased thread spool replacements and reduced versatility, especially in single-needle machines.
Innovation Solution
An embroidery sewing machine with a thread color storage unit, comparison unit, and grouping unit that compares and groups thread colors based on their sewing order, allowing for efficient thread color management by identifying and grouping same-color threads, thereby minimizing thread spool replacements and enhancing versatility across various designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thread color grouping is performed based on sewing stacking order only, then sewing efficiency is improved for specific designs, but versatility is reduced when color order or number of colors differs
Solution Approach 1:
The patent implements dynamic thread color grouping that adapts to different design configurations. The system automatically adjusts grouping strategies based on the specific color composition and sewing order of each design, rather than applying a fixed stacking order approach. This enables the system to handle varying color orders and numbers of colors while maintaining high sewing efficiency.
Solution Approach 2:
The patent changes the parameters used for thread grouping from rigid sewing stacking order to flexible color matching criteria. By allowing thread colors to be grouped based on color identity rather than position in sewing order, the system achieves both high productivity for standardized designs and versatility for customized designs with different color compositions.
2Adaptability or versatility
If multiple thread spools are used to support multiple thread colors, then color variety is improved, but device complexity and operation complexity increase
Solution Approach 1:
The patent merges multiple thread spool operations into consolidated threading sequences by grouping identical thread colors across different designs. This allows the sewing machine to use fewer thread spools overall while maintaining the ability to produce multi-color embroidery designs, thereby reducing device complexity without sacrificing color variety.
Solution Approach 2:
The patent makes single thread spools serve multiple functions by reusing the same thread color across different design elements and designs. A single thread spool can supply thread for multiple stitching operations throughout the embroidery process, eliminating the need for dedicated spools for each color instance and simplifying the overall system.
3Ease of operation
If thread color grouping is performed without considering sewing order, then operation simplicity is improved, but manufacturing precision deteriorates due to incorrect color sequencing
Solution Approach 1:
The patent performs preliminary analysis of design color compositions and sewing orders before actual thread grouping is executed. The system pre-calculates the optimal grouping strategy that maintains correct color sequencing requirements, allowing simple automated execution during sewing while ensuring manufacturing precision is not compromised.
Solution Approach 2:
The patent implements feedback mechanisms that monitor the actual sewing progress and thread color usage against the planned color sequence. This ensures that even though the grouping operation is simple and automated, the system continuously verifies that color sequencing accuracy is maintained, preventing manufacturing defects.
Data Source
AI summary
A thread color comparison unit compares and judges whether or not a comparison target is the same as a comparison reference with a given thread color of a given design stored in a thread color storage unit as the comparison target and with a given thread color of another given design that differs from the given design as the comparison reference. A thread color grouping unit performs grouping for the comparison target and the comparison reference included in different designs when the comparison target and the comparison reference are the same color. When the thread color comparison unit has judged that the comparison target is the same as the comparison reference, the thread color storage unit stores information such that the comparison target is to be sewn together with the comparison reference that has been judged to be the same, and the sewing data for the comparison target is removed.