Sewing Frame Actuator Synchronization via Coupling Bars
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Solution Overview
Problem
Existing embroidery sewing machines face challenges in accurately positioning the sewing frame due to distortion caused by uneven actuation of the X and Y actuator mechanisms, leading to inaccuracies in fabric stretching and positioning.
Innovation Solution
A sewing frame actuator system that includes multiple movable members and actuation blocks synchronized by a control circuit to evenly actuate the sewing frame in both the front-back and right-left directions, using ball screws and timing belts to maintain precise positioning and prevent distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only one side of the sewing frame is equipped with X and Y actuator mechanisms, then the device complexity is reduced, but the sewing frame becomes distorted and positioning accuracy deteriorates
Solution Approach 1:
The actuator system is segmented into multiple independent units distributed along both long sides of the sewing frame. Each side has its own X actuator mechanism and Y actuator mechanism, dividing the single actuation function into multiple parallel actuation units that work independently to maintain frame rigidity and positioning accuracy.
Solution Approach 2:
The patent combines multiple actuator mechanisms (X actuators and Y actuators) on both sides of the sewing frame into a coordinated system. The coupling bars connect corresponding actuators on opposite sides, merging their functions to provide balanced actuation that prevents frame distortion while maintaining positioning precision.
2Device complexity
If coupling bars are used to connect actuators on opposite sides, then the device complexity is reduced, but the coupling bars become distorted by tensile force and sewing frame distortion occurs
Solution Approach 1:
The patent applies different structural qualities to different parts of the coupling system. The coupling bars are designed with specific rigidity characteristics suitable for their local function of transmitting actuation forces, while the actuator mounting structures provide localized support and alignment. This local optimization prevents distortion propagation throughout the entire frame.
Solution Approach 2:
The coupling system uses composite construction combining rigid coupling bar elements with flexible mounting interfaces. The coupling bars themselves may be constructed from composite materials or composite structures that provide both the necessary rigidity for force transmission and the ability to accommodate minor misalignments without distorting the sewing frame.
3Device complexity
If transmission shafts are made longer to reach along the long sides of the sewing frame, then the device complexity is reduced, but the transmission shafts become twisted and actuation synchronization deteriorates
Solution Approach 1:
Instead of using long transmission shafts that extend along the length of the sewing frame (one-dimensional approach), the patent uses coupling bars that connect actuators across the width of the frame (two-dimensional approach). This dimensional change allows for shorter, stiffer connection elements that do not twist under load while still achieving synchronized actuation of opposite-side mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system minimizes distortion and ensures high-accuracy positioning of the sewing frame, maintaining fabric tension and preventing deflection even under tensile forces during sewing operations.
Implementation Method 1
Each of the X actuator mechanism and the Y actuator mechanism is configured so as to include one motor and a plurality of ball screws
Implementation Method 2
a timing belt mechanism that is actuated by the third actuation block
Data Source
AI summary
Each of front-back direction actuation blocks for actuating a sewing frame in a front-back direction has ball screws, motors, and movable members. An engagement roller of each of the movable members engages with a long side of the sewing frame, and an engagement roller of each of the movable members engages with a long side. The movable members of respective front-back direction actuation blocks are connected to short sides of the sewing frame. In each of the front-back direction actuation blocks, the ball screw and the ball screw are joined together by means of a joint member. Movable members of respective right-left direction actuation blocks support the respective front-back direction actuation blocks.