Embroidery Design Software Continuous Underlay Graph
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Solution Overview
Problem
Current embroidery digitizing software requires manual re-entry and recalibration of design parameters and features when altering designs for different sizes or fabrics, lacks automatic underlay for grouped design elements, fails to account for thread stretching, and does not allow for automatic adjustment of tie-in and tie-off stitches during scaling.
Innovation Solution
The method involves identifying groups of design elements, creating a graph to determine the order for continuous underlay, generating a stitch pattern based on this order, and automatically selecting and adjusting stitch types and tie-in/tie-off stitches to maintain design integrity and stability during scaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual re-entry and recalibration of design parameters is performed when altering designs, then design accuracy can be maintained, but user time and expertise requirements increase significantly
Solution Approach 1:
The system automatically adjusts design parameters and features when a design is altered, allowing the software to serve itself rather than requiring manual user intervention. The computer automatically recalculates and modifies stitch patterns, underlay, and other design elements based on the altered design parameters.
Solution Approach 2:
The system automatically modifies multiple design parameters simultaneously when the design is altered, including stitch type selection, underlay parameters, stitch pattern density, and tie-in/tie-off stitch locations, rather than requiring manual adjustment of each parameter individually.
2Ease of operation
If separate underlay stitching is performed for each design element, then individual element control is maintained, but stitch stability decreases compared to continuous underlay
Solution Approach 1:
The system merges the underlay stitching of multiple design elements into a continuous stitch pattern that spans across element boundaries. The computer identifies adjacent design elements and generates continuous underlay stitches that connect them, eliminating gaps and improving overall stitch stability.
3Manufacturing precision
If width compensation is applied to account for thread stretching, then side distortion is corrected, but height distortion remains unaddressed
Solution Approach 1:
The system applies dimensional transformation parameters to pre-distort the digitized shape in both width and height directions. The computer calculates compensation values for both dimensions based on the stitch pattern and applies scaling transformations to the design data before stitching, correcting both side shrinkage and height expansion.
4Ease of manufacture
If tie-in and tie-off stitches are manually digitized each time, then custom stitch patterns can be created, but productivity decreases due to repetitive manual work
Solution Approach 1:
The system automatically identifies and places tie-in and tie-off stitches at appropriate locations on design elements before the main stitching process. The computer calculates optimal stitch locations and generates the tie stitches automatically, eliminating the need for manual digitization of these repetitive elements.
5Speed
If design elements are scaled without automatic parameter adjustment, then scaling speed is maintained, but design quality degrades due to inconsistent appearance
Solution Approach 1:
The system automatically adjusts multiple design parameters in response to scaling operations, including stitch density, underlay parameters, stitch length, and tie-in/tie-off stitch locations. The computer recalculates all these parameters based on the new design size to maintain consistent appearance and quality across different scales.
Data Source
AI summary
A method of generating continuous underlay for a group of design elements in an embroidery design, including identifying a group of design elements, creating a graph of the group of design elements, determining an order for sewing a continuous underlay for the group of design elements using the graph, and generating a stitch pattern for the group of design elements, the stitch pattern based at least in part on the order for sewing the continuous underlay for the group of design elements.