External Sewing Unit With Needle-Synced Fabric Feed for Seam Quality
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Solution Overview
Problem
Existing sewing machines face challenges in improving the quality of seams, particularly when sewing buttonholes, due to the lack of precise control over the interaction between the sewing needle and the fabric during the sewing process.
Innovation Solution
A sewing machine external unit equipped with a holder, driver, position detector, and controller that allows for precise control over the movement of the sewing needle and fabric, using optical sensors to detect needle position and adjust the holder's movement accordingly, preventing interference and enhancing seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a frame with ratchet mechanism is used to move fabric in buttonhole patterns, then the sewing machine can form buttonhole shapes, but the seam quality deteriorates due to lack of precise control over needle-fabric interaction
Solution Approach 1:
The patent employs a position detector to continuously monitor the vertical position of the sewing needle and feeds this information back to the controller. The controller adjusts the holder's horizontal movement based on this feedback, ensuring precise coordination between needle penetration and fabric transport to maintain high seam quality while forming buttonhole patterns.
Solution Approach 2:
The patent makes the holder's movement dynamic by adjusting its horizontal position in real-time based on the needle's vertical position. The controller dynamically coordinates the holder's movement with the needle's penetration and withdrawal cycles, enabling precise control over fabric manipulation during pattern formation.
2Device complexity
If the holder moves independently without needle position coordination, then the device structure is simple, but interference between needle and fabric occurs reducing seam quality
Solution Approach 1:
The position detector provides real-time feedback on needle vertical position to the controller, which then adjusts the holder's horizontal movement accordingly. This feedback mechanism prevents needle-fabric interference by coordinating the timing and position of holder movement with needle penetration, achieving high seam quality without excessive structural complexity.
Solution Approach 2:
The patent replaces complex mechanical coordination mechanisms with an electronic control system. Instead of using mechanical linkages to synchronize holder movement with needle motion, the system uses a controller that receives positional data from the position detector and electronically coordinates the holder's movement, simplifying the overall device structure while improving precision.
3Manufacturing precision
If optical sensors are added to detect needle position, then seam quality improves through precise coordination, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical positioning and synchronization mechanisms with optical sensors and electronic control. The position detector uses optical fields to measure needle position, and the controller uses electronic signals to coordinate holder movement, simplifying the overall system compared to mechanical linkages while achieving precise needle-fabric coordination.
Solution Approach 2:
The optical position detector acts as an intermediary between the needle mechanism and the controller. Instead of direct mechanical coupling, the position detector measures needle position and converts it into positional data that the controller uses to adjust holder movement, enabling precise coordination with simpler overall system architecture.
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
The solution enables improved seam quality by accurately coordinating the vertical movement of the sewing needle with the horizontal movement of the fabric, reducing interference and allowing for the formation of various seam shapes.
Implementation Method 1
a position detector configured to detect a position of a sewing needle of the sewing machine in an up-down direction
Data Source
AI summary
The disclosure improves the quality of seams in sewing using a sewing machine, and includes: a holder holding fabric; a driver being detachable from a bed of a sewing machine and driving the holder along an upper surface of the bed; a position detector detecting a position of a sewing needle of the sewing machine in an up-down direction; and a controller controlling driving of the holder, which is performed by the driver, based on a detection result of the position detector.