Sewing Data Generation Optimizing Embroidery Thread Sequencing
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Solution Overview
Problem
Existing embroidery sewing machines lack an efficient sewing order strategy when sewing multiple embroidery patterns with various colors, leading to suboptimal sewing processes.
Innovation Solution
A non-transitory computer-readable storage medium and sewing data generation device that acquire pattern data for each embroidery pattern, determine common thread data between patterns, and set a sewing order to optimize thread usage by positioning patterns with common thread data last or first in the sewing order accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If embroidery patterns are sewn one by one without optimized sequencing, then the sewing process is simple to execute, but thread changes occur frequently and sewing efficiency decreases
Solution Approach 1:
The system performs preliminary analysis of thread data across multiple embroidery patterns before sewing begins. It identifies common thread sequences and pre-determines the optimal sewing order of patterns, so that when sewing starts, the machine can follow the pre-optimized sequence without frequent thread changes, thereby improving productivity without adding operational complexity
Solution Approach 2:
The sewing order optimization system dynamically adjusts the sewing sequence based on the specific thread data and pattern characteristics being processed. Rather than using a fixed sequencing rule, the system adapts the pattern execution order to match the actual thread usage requirements, enabling efficient thread utilization while maintaining flexibility for different pattern sets
2Loss of time
If thread changes are made frequently during sewing, then all embroidery patterns can be completed, but the sewing time increases and productivity decreases
Solution Approach 1:
The optimization system ensures continuous useful action by sequencing embroidery patterns so that thread usage flows continuously from one pattern to the next. By identifying patterns that share common thread sequences and arranging them in an optimal order, the system minimizes interruptions and thread changes, maintaining continuous sewing operation and reducing total sewing time
Solution Approach 2:
The system skips unnecessary thread change operations by intelligently sequencing patterns to maximize thread reuse. When common thread data is identified between consecutive patterns, the system rushes through the transition by maintaining the same thread, effectively skipping the time-consuming thread change process and reducing overall sewing time
3Ease of operation
If the sewing order is not optimized, then the sewing process is straightforward, but thread utilization is inefficient and many thread changes are required
Solution Approach 1:
The sewing system performs self-service optimization by automatically analyzing its own thread data and determining the optimal sewing sequence without external intervention. The system extracts thread information from pattern data, identifies common sequences, and autonomously generates the optimized sewing order, improving productivity while maintaining ease of operation as no additional user input or complexity is required
Data Source
AI summary
A computer-readable medium stores instructions for a processor in a sewing data generation device. When the instructions are executed, the processor acquires pattern data of embroidery pattern including partial patterns using different thread. If first common data indicating the same thread is included in first data of a first embroidery pattern and second data of a second embroidery pattern, the processor sets a sewing order in the first data, while causing the partial pattern using the thread of the first common data to be the partial pattern that is last in the sewing order in the first embroidery pattern, and sets a sewing order in the second data, while causing the partial pattern using the thread of the first common data to be the partial pattern that is first in the sewing order in the second embroidery pattern that is the embroidery pattern subsequently to the first embroidery pattern.