Sewing Control Data Generation for Automatic Parameter Switching
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Solution Overview
Problem
Existing sewing machine technologies lack flexibility in adjusting sewing parameters across different seam sections, making it difficult to achieve optimal sewing results with varying clothing sizes and seam complexities without manual intervention.
Innovation Solution
A method for generating sewing control data that allows for independent assignment of sewing parameter values based on assigned seam positions, enabling automatic switching between different seam sections with optimized parameter combinations, including thread tension, shirring, and arc radius values, regardless of the seam's subdivision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sewing parameters are manually adjusted for different seam sections, then sewing precision can be optimized, but operation complexity and time consumption increase significantly
Solution Approach 1:
The seam is automatically divided into multiple seam sections based on geometric features and curvature changes. The control unit identifies transition points where sewing parameters should change and creates discrete sections, each with optimized parameter sets. This automatic segmentation eliminates manual intervention while maintaining precision.
Solution Approach 2:
Sewing parameter values are pre-calculated and stored for each seam section before actual sewing begins. The control unit determines optimal parameters (feed rate, needle position, tension) in advance based on the programmed seam geometry, then automatically applies them during sewing without real-time manual adjustment.
2Manufacturing precision
If multiple seam sections with different parameters are used, then sewing quality improves, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it divides the seam into sections, calculates optimal parameters for each section, stores parameter sets, and automatically switches between them during sewing. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated control unit.
Solution Approach 2:
The system automatically modifies sewing parameters (feed rate, needle position, tension values) based on the current seam section being processed. The control unit adjusts these parameters dynamically according to pre-calculated values associated with each section, enabling quality variation without manual intervention.
3Measurement precision
If seam division is performed manually, then parameter assignment accuracy improves, but productivity decreases
Solution Approach 1:
The manual mechanical process of measuring and marking seam sections is replaced by an automated computational system. The control unit uses programmed algorithms to identify transition points and calculate section boundaries based on seam geometry data, eliminating the need for manual measurement while maintaining or improving accuracy.
Solution Approach 2:
The seam geometry is digitally represented and stored in the control unit's memory. The system creates a virtual model of the seam with marked transition points and assigns parameter sets to each section in the digital domain, then transfers this information to control the physical sewing process, ensuring consistent and accurate parameter assignment.
Data Source
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AI summary
In a method for generating sewing control data for executing a sewing program during which a seam is sewn, the seam is first divided into a plurality of parameter seam sections (a1, bl, cl, dl). At least one assignment seam position (P1, P2, P3) is assigned to the seam. At least one assignment sewing parameter value is assigned to this assignment seam position (P1, P2, P3). An assignment sewing parameter value is assigned to the seam sections on which at least one assignment seam position (P1, P2, P3) is located. In an operating procedure for a sewing machine to generate the seam, the sewing control data is first generated. The seam is then sewn, starting from a sewing start point (17). The assigned sewing parameter is automatically changed when switching between two consecutive seam sections (a1/b1, bl/cl, cl/dl).A sewing machine used to perform this process has a control unit, a memory module for the positions and lengths of the seam sections (a1 to dl) and for the associated sewing parameters, a detection module for recording the current sewing position of the seam, and a conversion module for automatically changing the sewing parameter when switching between two consecutive seam sections (a1 to dl). This results in an operating procedure that enables flexible and, at the same time, as simple a sewing process as possible, where different sewing parameters can be used in different seam sections.