Quilted Pattern Input Digitizing Frame With Transparent Encoder
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Solution Overview
Problem
Current computer-controlled quilting systems face inefficiencies in aligning preexisting patterns on fabrics and inputting these patterns into the system, leading to labor-intensive and error-prone processes, especially when dealing with intricate stitching and varying quilt blocks.
Innovation Solution
An X-Y encoder with a transparent sensing zone is integrated into the quilting machine, allowing for precise alignment and input of patterns by converting motion or presence into electronic signals, which are then used to control the sewing head, enabling accurate and efficient stitching of complex designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an operator manually moves the sewing head to multiple locations to create reference points, then the computer controlled system can provide accurate and reproducible stitching, but the process becomes time consuming and labor intensive
Solution Approach 1:
The patent replaces the mechanical manual movement of the sewing head with an optical/electronic X-Y encoder system that automatically detects and digitizes the pattern. The encoder uses optical sensing to convert physical pattern coordinates into electronic signals, eliminating the need for manual reference point creation while maintaining stitching accuracy.
Solution Approach 2:
The patent creates a digital copy of the physical pattern by using the X-Y encoder to trace and digitize the pattern's shape and position. This digital representation is then used by the computer controlled system to guide the sewing head, replacing the need for manual point-by-point reference creation.
2Adaptability or versatility
If an operator manually inputs pattern locations, then the pattern can be transferred to the computer controlled system, but the process is labor intensive and error prone
Solution Approach 1:
The patent replaces manual data input operations with an automated optical sensing system. The X-Y encoder automatically detects pattern coordinates and converts them into electronic signals that are directly transferred to the computer controlled system, eliminating manual input errors and reducing operational complexity.
Solution Approach 2:
The system performs self-digitization by using the X-Y encoder to automatically trace and record the pattern's geometric features. The encoder system serves itself by autonomously capturing pattern information without requiring external manual intervention, thereby improving ease of operation.
3Measurement precision
If a transparent sensing zone is used for the X-Y encoder, then the sensing zone allows visibility of the workpiece for accurate pattern tracing, but the encoder must be precisely positioned and maintained
Solution Approach 1:
The transparent sensing zone serves multiple functions: it allows optical sensing of the X-Y encoder while simultaneously providing visibility of the workpiece for accurate pattern tracing. This multi-functionality reduces the need for separate positioning aids and simplifies the overall system complexity despite the precision requirements.
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
This solution streamlines the pattern alignment and input process, reducing errors and increasing efficiency by allowing operators to accurately trace and digitize existing patterns, enabling precise and reproducible stitching of intricate designs on quilts.
Implementation Method 1
The X-Y encoder can include a transparent or translucent sensing zone, in which motion or the presence of an indicator is converted into an electronic signal
Data Source
AI summary
A digitizer is operably coupled to a quilting machine controller, wherein an operator can input free hand or traced patterns for regulating operation of a sewing head. The digitizer can be an X-Y encoder wherein the encoder includes a transparent or translucent sensing zone which provides for the operator to input a pattern while simultaneously viewing a portion of a textile, which can itself include a pattern.