Sewing Data Generation via 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 an embroidery frame and sewing target to generate outline data, allowing for automatic generation of sewing data without pre-prepared patterns, enabling accurate and flexible applique sewing.

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 are limited to pre-defined patterns

Engineering Contradiction:

Improvesewing precisionVSAvoidpattern adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system allows the applique cloth itself to define the sewing pattern through image recognition. The camera captures the cloth's shape and color, and the control unit automatically generates sewing data based on these visual characteristics, eliminating the need for pre-prepared patterns and enabling users to sew any custom shape they place on the base cloth.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes the sewing parameters by detecting the applique cloth's color, shape, and position through image processing. The control unit adjusts sewing data in real-time based on the detected parameters, allowing the system to adapt to any custom shape while maintaining accurate sewing through automated parameter optimization.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If users manually perform zig-zag or over-edge stitching for custom applique shapes, then design freedom is improved, but operation complexity and time consumption worsen

Engineering Contradiction:

Improvedesign freedomVSAvoidstitching operation ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system replaces manual mechanical stitching operations with an automated image recognition and control system. The camera captures the applique cloth's outline, the control unit processes this visual information to generate sewing paths, and the sewing machine automatically executes the stitching, eliminating the need for users to manually guide the fabric through complex zig-zag or over-edge patterns.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control unit acts as an intermediary between the user's design intent and the sewing machine's execution. It receives visual input from the camera, processes the applique cloth's shape and position, generates appropriate sewing data, and transmits it to the sewing machine, thereby automating the complex coordination required for manual stitching techniques.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If users manually hold and adjust the cloth during stitching, then design flexibility is improved, but positioning precision deteriorates due to manual handling errors

Engineering Contradiction:

Improvedesign flexibilityVSAvoidpositioning precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system uses real-time visual feedback from the camera to monitor the applique cloth's position and orientation on the base cloth. The control unit continuously compares the detected position with the intended sewing path and automatically adjusts the sewing data to compensate for any misalignment, ensuring precise positioning without requiring manual adjustment by the user.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS10017888B2Sewing data generating apparatus, sewing data generating method, recording medium for storing program, and sewing system

Publication Date: 2018.07.10 JANOME CORP

AI summary

A sewing data generating apparatus acquires information with respect to an embroidery frame. The sewing data generating apparatus acquires an image including a base cloth mounting a sewing target and mounted on the embroidery frame, and analyzes a correspondence between acquired information with respect to the embroidery frame and the image of the embroidery frame thus acquired. The sewing data generating apparatus generates outline data for the sewing target based on the analysis result, and generates sewing data based on the outline data thus generated. The sewing data generating apparatus transmits the sewing data thus generated to a sewing machine. The sewing machine receives the sewing data from the sewing data generating apparatus. The sewing machine executes sewing for the outline of the sewing target according to the sewing data thus received. This allows an applique to be sewn at an accurate position without a need to prepare dedicated data.