Sewing Machine Camera Vision System for Embroidery Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sewing machines lack a method to accurately and precisely position embroidery or seams on fabrics without pre-printed machine-readable symbols, and existing solutions are limited in displaying an undistorted view of the sewing area, making it difficult to align patterns with high precision.
Innovation Solution
A sewing machine equipped with a small, built-in camera and a vision system that scans the fabric within a hoop, tiles images to form a coordinated display of the sewing area, allowing for precise alignment of embroidery elements by controlling the hoop's movement based on stored stitch data and image processing to compensate for geometrical distortion and uneven light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is used to capture images of the sewing area, then positioning precision is improved, but geometrical distortion occurs in the captured images
Solution Approach 1:
The patent applies parameter changes by transforming the captured image coordinates through a mathematical transformation function that maps distorted camera coordinates to undistorted sewing area coordinates. This transformation compensates for the geometrical distortion introduced by the camera, allowing precise positioning while maintaining accurate geometric representation of the sewing area.
2Area of stationary object
If the camera captures the entire sewing area, then overview is improved, but image resolution decreases
Solution Approach 1:
The patent segments the large sewing area into multiple smaller image sections captured by the camera. Each section maintains high resolution while collectively covering the entire sewing area. These segmented images are then tiled and transformed to create a complete undistorted view, resolving the contradiction between coverage area and resolution.
3Adaptability or versatility
If the hoop is moved to position embroidery elements, then positioning flexibility is improved, but synchronization complexity increases
Solution Approach 1:
The patent implements feedback by continuously monitoring the actual position of the hoop through the camera system and comparing it with the desired position from the stitch data. The system uses this feedback to automatically adjust and synchronize the hoop movement with the needle position, simplifying the control process while maintaining positioning flexibility.
Solution Approach 2:
The patent replaces manual mechanical synchronization with an automated optical-mechanical system. The camera captures the sewing area position, and the processor automatically translates this visual information into coordinated hoop movement commands, substituting complex manual mechanical synchronization with an automated vision-based control system.
Data Source
AI summary
A sewing machine (1) has access to a memory (M) for stitch data and a processor (C) for reading said stitch data and for operating the sewing machine (1) to execute stitches according to stitch data, wherein the sewing machine (1) has a hoop (20) for framing a pattern of the sewing material (2), and for moving the framed pattern in a direction comprising a component of at least one of a first coordinate (x) and a second coordinate (y) and wherein further the processor (C) controls movements of the hoop (20) according to said direction in relation to the position of a needle (5) of the sewing machine and synchronously with the movement of the needle for executing stitches, wherein: —the stretched sewing material (2) is clamped to the hoop (20) for forming a framed pattern in the hoop, —the framed pattern of the sewing material (2) is scanned by means of a camera (10) mounted in the sewing machine (1) and directed towards the sewing material (2) for the purpose of taking pictures of part views of said framed pattern, —said part views are tiled together for forming on a display an image of the pattern framed in the hoop, whereby a coordinate of the image of a display (11) refers to a corresponding coordinate of the pattern framed in the hoop (20).