Multi-Needle Sewing Head Layout for Direct Overhead Needle Imaging
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Solution Overview
Problem
In multi-needle sewing machines, existing image capture devices are often positioned obliquely relative to the needle drop position, preventing a clear overhead image capture due to structural constraints, which can lead to image distortion and hinder precise needle position detection.
Innovation Solution
A multi-needle sewing machine design that includes a needle bar case and a moving mechanism to position the image capture device directly above the needle drop position, allowing for straight overhead imaging without additional mechanisms, and an adjustable image capture system to minimize distortion, ensuring accurate needle position alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the image capture device is disposed obliquely overhead in relation to the needle drop position, then the device can be positioned within the structural constraints of the sewing machine, but the image capture quality deteriorates due to distortion and inability to capture from a straight overhead position
Solution Approach 1:
The needle bar case is made movable in the horizontal direction, allowing the image capture device to dynamically change its position from an initial oblique position to a final position directly above the needle drop position. This dynamic adjustment enables the system to overcome fixed structural constraints and achieve optimal imaging conditions.
Solution Approach 2:
The solution introduces horizontal movement capability to the needle bar case, adding a degree of freedom in the horizontal dimension. This allows the image capture device to reach positions that were previously inaccessible from fixed vertical mounting points, enabling straight overhead imaging.
2Measurement precision
If a separate mechanism is provided to move the image capture device to a position straight above the needle drop position, then clear overhead imaging is achieved, but the device complexity and space requirements increase
Solution Approach 1:
The image capture device is integrated with the needle bar case, which already has movement functionality for needle bar positioning. By combining these functions, the system achieves dual purpose: needle positioning and image capture positioning, without requiring a separate mechanism for the image device.
Solution Approach 2:
The needle bar case is designed to serve multiple functions: supporting and positioning the needle bars for sewing operations, and simultaneously positioning the image capture device for imaging. This multi-functionality eliminates the need for dedicated positioning mechanisms for each component.
3Volume of moving object
If the image capture device is positioned within the needle bar case structure, then the moving mechanism can be made more compact, but the device may interfere with the needle bars during operation
Solution Approach 1:
The needle bar case moves horizontally to position the image capture device directly above the needle drop position only when imaging is required. During sewing operations, the case returns to its normal position, dynamically adjusting to prevent interference while enabling imaging when needed.
Solution Approach 2:
The image capture device is positioned at the outer side of the needle bars in the needle bar case, extracting it from the central operational area. This placement minimizes potential interference with needle bar movements while still allowing the entire assembly to be positioned for imaging when required.
Data Source
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AI summary
A multi-needle sewing machine (1) is provided with a needle bar case (21) that is movable to the right and to the left. Six needle bars (31) are lined up on the frame (24) that is provided in a needle bar case (21). A needle bar case moving mechanism (40) moves the needle bar case (21) in a direction in which the six needle bars (31) are lined up. Sewing is performed by using one of the six needle bars (31) that is positioned straight above a needle drop position. On the right side of the frame (24), an image sensor holding mechanism (51) that holds an image sensor (52) is provided such that the image sensor (52) is aligned with the six needle bars (31). The image sensor (52) is moved to a position that is straight above the needle drop position by moving the needle bar case (21).