Multi-Sensor Sewing Machine Automatic Needle Speed Control
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Solution Overview
Problem
Conventional sewing machines face difficulties in maintaining uniform stitch length due to non-uniform movement of fabric and machine, making it challenging for users to achieve consistent stitch lengths during relative movement.
Innovation Solution
A multi-sensor sewing machine with a processor-controlled motor system that uses multiple sensors emitting electromagnetic radiation at different frequencies to detect and adjust needle speed based on translational and rotational movements of the fabric and frame, ensuring uniform stitch length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a given needle speed is used, then the sewing machine operates efficiently, but the stitch length becomes non-uniform when fabric or machine moves at non-uniform rates
Solution Approach 1:
The patent employs optical sensors to detect fabric movement and provides real-time feedback to the processor, which automatically adjusts needle speed to maintain uniform stitch length. This closed-loop feedback system eliminates the need for users to manually control movement uniformity.
Solution Approach 2:
The sewing machine performs self-adjustment of needle speed based on detected fabric movement variations. The system serves itself by automatically compensating for non-uniform movement without requiring external user intervention or manual control.
2Manufacturing precision
If manual speed adjustment is used, then the system remains simple, but the stitch length uniformity deteriorates during non-uniform movement
Solution Approach 1:
The patent replaces manual mechanical speed adjustment with an automated electronic control system using optical sensors and a processor. This substitution of mechanical control with sensor-based electronic control achieves precise stitch uniformity while managing system complexity through integration.
Solution Approach 2:
The system dynamically changes the needle speed parameter in real-time based on detected fabric movement. The processor adjusts speed parameters automatically to maintain consistent stitch length, transforming a static parameter into a dynamic controlled variable.
3Measurement precision
If single-frequency sensor is used, then the device complexity is reduced, but the measurement precision deteriorates due to interference from fabric color
Solution Approach 1:
The patent segments the sensing function by using multiple sensors operating at different frequencies (e.g., red and blue light sources). This segmentation allows each sensor to detect movement independently, and the processor combines their outputs to achieve accurate measurement while compensating for fabric color interference.
Solution Approach 2:
The system uses a composite sensing approach combining multiple frequency sensors. By integrating sensors with different frequency characteristics, the system achieves robust movement detection that is insensitive to fabric color variations, similar to how composite materials combine properties to achieve superior performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Automatically adjusts needle speed to compensate for non-uniform movements, resulting in consistently uniform stitch lengths across the fabric, reducing the need for manual adjustments and improving sewing precision.
Implementation Method 1
a first sensor configured to emit first electromagnetic radiation at a first frequency in order to sense relative movement of the fabric and the frame
Implementation Method 2
a second sensor configured to emit second electromagnetic radiation at a second frequency, that is different from the first frequency, in order to sense relative movement of the fabric and the frame
Data Source
AI summary
Multi-sensor sewing machine with automatic needle speed adjustment. In some embodiments, a sewing machine may include a frame, a needle bar, a motor, a first sensor configured to emit first electromagnetic radiation at a first frequency in order to sense relative movement of the fabric and the frame, a second sensor configured to emit second electromagnetic radiation at a second frequency, that is different from the first frequency, in order to sense relative movement of the fabric and the frame, and a processor. The processor may be configured to control a speed of the motor, determine a translational relative movement of the fabric and the frame based on the sensed relative movement of the first sensor and/or based on the sensed relative movement of the second sensor, and, in response to the determined translational relative movement, alter the speed of the motor.