Sewing Machine Fabric Feedback Control for Uniform Stitch Length
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Solution Overview
Problem
Irregularities in textile fabric properties and movements during sewing, embroidering, or quilting, such as weaving faults and uneven speed, lead to deteriorated results.
Innovation Solution
A sewing machine equipped with a detector module that senses fabric properties and states, adjusting its operating mode to compensate for these irregularities, including a needle bar, gripper system, and control unit to maintain uniform stitch length and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine operates at high speed to maintain productivity, then productivity is improved, but fabric irregularities such as uneven speed and deformation increase, deteriorating sewing quality
Solution Approach 1:
The patent implements a feedback mechanism where a sensor detects fabric properties and movement state in real-time, and the control unit adjusts operating parameters (needle position, stitch frequency, gripper timing) based on this feedback to maintain uniform stitch quality even at high speeds
Solution Approach 2:
The system dynamically adjusts operating parameters during the sewing process based on detected fabric conditions. The control unit modifies needle bar position, stitch frequency, and gripper system timing in real-time to adapt to varying fabric properties and maintain manufacturing precision
2Device complexity
If the machine operates without detection and adjustment systems, then device complexity is reduced, but fabric irregularities cannot be compensated, deteriorating sewing results
Solution Approach 1:
The patent replaces complex mechanical adjustment mechanisms with an automated control system that uses sensors and electronic control to detect fabric properties and adjust operating parameters, reducing mechanical complexity while improving precision
3Productivity
If the needle bar operates at high frequency to maintain productivity, then productivity is improved, but the needle may miss optimal fabric positions due to irregular fabric movement, worsening stitch quality
Solution Approach 1:
The system performs preliminary detection of fabric properties and movement state before the needle reaches the fabric, allowing the control unit to pre-adjust needle bar position and timing to ensure optimal needle positioning despite high operating frequencies
Solution Approach 2:
Real-time feedback from sensors about fabric position and movement allows dynamic adjustment of needle bar timing and position, ensuring the needle consistently reaches optimal fabric positions even at high stitch frequencies
Data Source
AI summary
A machine (M) for sewing, embroidering or quilting, in which a flat section (T1) of a textile structure (T) in a stretched state can be pressed against a textile structure support area (TA) adjacent to a stitch plate (SP) and/or against the stitch plate (SP) and moved in a plane parallel to the stitch plate (SP) at a speed (v) relative to the stitch plate (SP) so that the flat section (T1) lies flat against the stitch plate (SP). The machine (M) contains a detector module (DM) with which a property and/or a state of the moved flat section (T1) of the textile structure (T) can be detected, and a control unit (SE) with which an operating mode of the machine (M) can be adjusted depending on the detected property or the detected state of the moved flat section (T1) of the textile structure (T).