Embroidery apparatus, dyeing/embroidery system, and method for adjusting consumption amount of thread
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Solution Overview
Problem
Embroidery apparatuses face challenges in maintaining thread tension balance between needle and bobbin threads, leading to positional deviations of color changes during embroidery when actual thread consumption differs from predicted amounts, especially with continuous threads featuring color changes.
Innovation Solution
An embroidery apparatus equipped with a thread consumption amount calculator, detection mechanism, and adjuster, which calculates and adjusts the thread consumption based on the difference between assumed and actual consumption amounts to maintain balanced tension and correct positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If embroidery is performed using a continuous needle thread including color change, then productivity is improved by reducing thread breaks and repositioning operations, but manufacturing precision deteriorates due to positional deviations of color change points
Solution Approach 1:
The system detects the actual consumption amount of needle thread during embroidery operation and feeds this information back to the embroidery data editing mechanism. The mechanism then adjusts the embroidery data based on the difference between detected actual consumption and predicted consumption, thereby correcting positional deviations of color change points and maintaining manufacturing precision while using continuous threads for improved productivity
Solution Approach 2:
The embroidery data editing mechanism changes parameters in the embroidery data (such as stitch coordinates, stitch length, or stitch density) based on the detected thread consumption deviation. By dynamically adjusting these parameters, the system compensates for variations in thread consumption and ensures that color change points occur at the correct positions, thus maintaining manufacturing precision while benefiting from continuous thread embroidery
2Device complexity
If thread consumption amount is not adjusted during embroidery operation, then device complexity is reduced, but manufacturing precision deteriorates due to inability to correct positional deviations
Solution Approach 1:
A thread consumption amount detection mechanism is introduced to detect the actual consumption amount of needle thread during embroidery operation. This detected information is fed back to the embroidery data editing mechanism, which automatically adjusts the embroidery data to correct positional deviations of color change points, thereby maintaining manufacturing precision without significantly increasing device complexity
Solution Approach 2:
The embroidery data editing mechanism automatically adjusts the embroidery data based on the detected thread consumption deviation, without requiring external intervention. The system self-corrects the positional deviations by modifying embroidery parameters, maintaining manufacturing precision while keeping the control system relatively simple and automated
Data Source
AI summary
An embroidery apparatus is configured to perform an embroidery operation according to embroidery data. The embroidery apparatus includes a thread assumed consumption amount calculator configured to calculate an assumed consumption amount of a thread in the embroidery operation, based on initial embroidery data input in advance; a thread consumption amount detection mechanism configured to detect an actual consumption amount of the thread; and a thread consumption amount adjuster configured to adjust the actual consumption amount of the thread in the embroidery operation by adjusting output embroidery data to be output, based on a difference between the calculated assumed consumption amount of the thread and the detected actual consumption amount of the thread.