Sewing Data Generation Using Image Analysis for Applique Positioning

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Solution Overview

Problem

Existing sewing technologies require dedicated data for applique patterns, limiting flexibility and requiring manual zig-zag or over-edge stitching for custom shapes, which is cumbersome and inaccurate.

Innovation Solution

A sewing data generating apparatus that acquires and analyzes images of embroidery frames and sewing targets to automatically generate sewing data, allowing for accurate positioning and stitching without pre-prepared data, using a combination of image acquisition, analysis, and data transmission to a sewing machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If dedicated embroidery data is prepared beforehand for applique patterns, then sewing precision is improved, but adaptability deteriorates as users cannot easily create custom shapes

Engineering Contradiction:

Improvesewing precisionVSAvoidadaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system enables users to create their own applique patterns by freely cutting cloth shapes and using image processing to automatically generate sewing data. The image processing unit extracts outline information from captured images of the user-cut cloth pieces, converting them into digital sewing patterns without requiring pre-prepared data or manual coordinate input.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual zig-zag stitching or over-edge stitching operations with automated image processing and data generation. Instead of mechanically guiding the cloth along complex paths, the system uses image capture and processing to automatically determine sewing paths, substituting manual mechanical operations with automated digital processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual zig-zag stitching or over-edge stitching is used for custom applique shapes, then adaptability is improved, but ease of operation deteriorates due to the cumbersome process of holding and adjusting the cloth by hand

Engineering Contradiction:

ImproveadaptabilityVSAvoidease of operation

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system performs automatic image capture and processing to generate sewing data without requiring manual manipulation. The image processing unit automatically extracts outline information from captured images, eliminating the need for users to manually hold, position, and adjust the cloth during the data generation process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of holding and guiding cloth with automated image capture and digital processing. The sewing data generating apparatus automatically captures images, processes them to extract outline information, and generates sewing paths without requiring manual intervention in the positioning and adjustment of the cloth.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If multiple dedicated data files are prepared for cutting marks, alignment, and sewing, then manufacturing precision is improved, but device complexity deteriorates due to the need to manage multiple data sets

Engineering Contradiction:

Improvemanufacturing precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system merges multiple data generation functions into a single integrated process. The image processing unit simultaneously extracts cutting outline information, alignment mark positions, and sewing path data from a single captured image, eliminating the need to separately prepare and manage multiple dedicated data files for different purposes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sewing data generating apparatus performs multiple functions through a single image processing operation. It can extract various types of information (cutting outlines, alignment marks, sewing paths) from the same image data, making the system universal and eliminating the need for separate specialized data preparation processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9957651B2Sewing data generating apparatus, sewing data generating method, recording medium for storing program, and sewing system

Publication Date: 2018.05.01 JANOME CORP

AI summary

A sewing data generating unit acquires embroidery frame information and a mark alignment region displayed on a display unit for guiding multiple marks that define an embroidery region of the embroidery frame. When the marks are all positioned within the mark alignment region displayed on the display unit, the sewing data generating apparatus acquires an image of the embroidery frame and a sewing target mounted on a base cloth mounted on the embroidery frame. The sewing data generating apparatus performs image analysis based on a correspondence between the acquired information with respect to the embroidery frame and the marks in the acquired image, so as to determine the embroidery region of the embroidery frame. The sewing data generating apparatus generates outline data for the sewing target based on the determined embroidery region. This allows an applique to be sewn at an accurate position without a need to prepare dedicated data.