Automated Segmental Sewing of Oversized Patterns
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Solution Overview
Problem
Automated quilting systems face limitations in sewing oversized patterns due to restricted y dimension movement of the sewing machine carriage, leading to fabric stretch, mismatched pattern segments, and preservation of pattern integrity.
Innovation Solution
The method involves segmenting the sewing pattern into segments with lengths equal to or less than the maximum y dimension needle bar travel, using an actuator to optimize segment borders, and adjusting pattern lines to match start points with cut points, ensuring continuous and aligned stitching across segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sewing machine carriage is limited to fixed y dimension movement due to throat length constraints, then the sewing machine structure remains simple and compact, but the ability to sew oversized patterns is lost
Solution Approach 1:
The patent divides the oversized sewing pattern into multiple smaller segments that can be sewn sequentially within the throat length constraints. Each segment is processed individually, allowing the sewing machine to maintain its compact structure while achieving the ability to handle oversized patterns through systematic division and sequential processing.
2Adaptability or versatility
If fabric is scrolled to expand effective y dimension movement, then oversized patterns can be sewn, but fabric stretch and varying diameters of fabric roll occur
Solution Approach 1:
The patent performs preliminary actions by pre-positioning fabric markers and pre-calculating segment boundaries before sewing begins. This allows the system to account for fabric tension variations and scroll effects in advance, maintaining manufacturing precision while enabling expanded y dimension movement through controlled fabric handling procedures.
3Productivity
If pattern segments are sewn sequentially, then oversized patterns can be processed, but pattern lines do not match between segments
Solution Approach 1:
The patent implements feedback mechanisms by using detected marker positions and measured fabric scroll amounts to adjust and realign pattern lines between segments. The system continuously monitors and corrects positioning errors, ensuring that pattern lines match accurately across sequentially sewn segments while maintaining productivity in processing oversized patterns.
4Adaptability or versatility
If the throat length is increased to accommodate full pattern length, then all patterns can be sewn in one pass, but the sewing machine becomes impractically large and expensive
Solution Approach 1:
The patent applies segmentation to divide long patterns into manageable segments that fit within the existing throat length constraints. This allows the sewing machine to maintain its practical size and cost-effectiveness while achieving versatility in handling patterns of various lengths through systematic segmentation and sequential processing.
Data Source
AI summary
A method and apparatus for automated assisted sewing of an oversized, digitized sewing pattern, using a fabric retention mechanism and an automated sewing machine positioning mechanism. The sewing machine positioning mechanism is controlled by an actuator and provides for two dimensional positioning of a sewing machine with respect to the fabric retention mechanism. The oversized sewing pattern is segmented into pattern segments and the pattern segments are sewed sequentially in accordance with a selected order, with the fabric being repositioned after each segment is sewed. Cut points for pattern lines on the border of each pattern segment are matched by start points on the adjacent border of a subsequently sewed, adjacent pattern segment. A pattern program adjusts the pattern lines of each subsequently sewed segment to provide for continuity and alignment of the pattern lines which cross the borders between pattern segments.