Sewing Machine Hoop Dynamics for Accurate Embroidery Projection
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Solution Overview
Problem
Existing sewing machines struggle to properly project embroidery patterns when the sewing area is larger than the projector's projection area, leading to incomplete or distorted image representation.
Innovation Solution
A sewing machine equipped with a moving mechanism, a projector, and a controller that determines the sewing area and embroidery pattern position, adjusts the embroidery hoop's position to align the target area with the projector's projection area, and generates projection image data to ensure accurate projection of the pattern within the sewing area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sewing area is made larger to accommodate more embroidery patterns, then the productivity and versatility of the sewing machine is improved, but the projector cannot properly display the entire pattern when the sewing area exceeds the projection area
Solution Approach 1:
The embroidery hoop is made movable relative to the needle bar through a moving mechanism. The controller dynamically adjusts the position of the embroidery hoop so that different portions of the embroidery pattern can be projected onto the workpiece. This allows the system to adapt to various pattern sizes and positions, ensuring complete projection even when the sewing area is larger than the projection area.
Solution Approach 2:
The controller receives information about the embroidery pattern position and size, and automatically adjusts the embroidery hoop position and projection image parameters accordingly. This feedback mechanism ensures that the projection image is always correctly positioned and scaled to match the sewing area, maintaining reliable projection regardless of pattern dimensions.
2Area of stationary object
If the projection area is increased to display larger embroidery patterns, then the image representation is improved, but the device complexity increases due to larger projector requirements
Solution Approach 1:
Instead of increasing the projection area, the system dynamically repositions the embroidery hoop to display different portions of the pattern. The controller adjusts the hoop position and projection parameters to accommodate various pattern sizes, allowing a fixed projector to handle variable sewing areas effectively.
Solution Approach 2:
The embroidery pattern is divided into multiple portions that can be projected sequentially or in different positions. The controller manages the projection of different pattern segments by adjusting the embroidery hoop position, allowing the projector to display complete patterns through coordinated movement rather than requiring a larger projection area.
3Manufacturing precision
If the embroidery hoop position is adjusted to align with the projection area, then the projection accuracy is improved, but the operation time increases due to positioning adjustments
Solution Approach 1:
The controller pre-calculates and automatically positions the embroidery hoop before projection begins. The system determines the optimal hoop position based on the embroidery pattern characteristics and executes the positioning adjustment automatically, eliminating manual alignment time and ensuring precise projection alignment without significant time loss.
Data Source
AI summary
The sewing machine includes a projector and a controller. The controller determines a sewing area inside an embroidery hoop such that the sewing area is greater than a projection area where the projector projects a projection image. The controller determines an embroidery pattern and a position of the embroidery pattern located relative to the sewing area. The controller determines, in the sewing area, a target area corresponding to the projection area. The controller generates projection image data representing a part or a whole, which falls in the target area, of the embroidery patter relative to the sewing area, and controls the projector to project a projection image based on the projection image data after moving the embroidery hoop.