Sewing Machine Applique Positioning via Image Recognition

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Solution Overview

Problem

Existing sewing machines face challenges in accurately positioning and angling applique pieces during the applique sewing process, leading to potential misalignment of stitches and requiring precise user intervention for accurate placement.

Innovation Solution

A sewing machine equipped with an imaging device, processor, and memory that captures images, identifies the position and angle of markers or feature points, and corrects sewing data to ensure accurate alignment and positioning of applique pieces on the base material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If guide position stitches are formed on the base material to indicate positioning, then the applique piece can be positioned relative to the base material, but the position and angle cannot be changed after the guide stitches are formed and the user must perform accurate positioning when setting the base material in the embroidery frame

Engineering Contradiction:

Improvepositioning accuracyVSAvoidoperational flexibility

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system performs preliminary image capture and marker detection to identify the position and angle of the applique piece before sewing begins. This allows the sewing machine to pre-calculate and adjust the sewing path based on the actual positioning, eliminating the need for rigid guide stitches and allowing flexible repositioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical guide stitch system with an optical/image recognition system. Instead of using physical guide stitches that constrain positioning, the system uses imaging devices to detect markers and automatically calculates positioning corrections, providing both precision and flexibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If the user manually positions the applique piece accurately in relation to guide position stitches, then the stitches for attaching the applique piece will be aligned with the contour, but the process becomes time-consuming and requires high skill

Engineering Contradiction:

Improvestitch alignment accuracyVSAvoidpositioning time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs self-positioning by automatically detecting the marker on the applique piece through image capture, calculating the actual position and angle relative to the base material, and automatically adjusting the sewing path. This eliminates the need for manual positioning by the user, reducing both time and skill requirements while maintaining high precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses image capture and marker detection to obtain feedback on the actual positioning of the applique piece. This feedback is used to automatically calculate and adjust the sewing path, ensuring accurate stitch alignment without requiring manual intervention or high user skill.

Inventive Principle:

Principle #23Feedback

3Loss of information

If guide position stitches are formed on the base material, then positioning information is provided, but once formed it is not possible to change the position and angle at which the applique piece will be arranged

Engineering Contradiction:

Improvepositioning information availabilityVSAvoidposition adjustment capability

Core Design Contradiction:

Loss of informationVSAdaptability or versatility

Solution Approach 1:

The system replaces static guide position stitches with a dynamic image-based detection system. The imaging device captures the actual position and angle of the applique piece, and the system dynamically adjusts the sewing path based on this information. This allows flexible repositioning and angle adjustment while maintaining positioning information availability.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If the sewing machine uses predetermined sewing data assuming accurate positioning, then the sewing process is simple, but misalignment occurs when the applique piece is not accurately positioned

Engineering Contradiction:

Improvesewing process complexityVSAvoidstitch position accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces the predetermined mechanical sewing path with a dynamically calculated path based on image recognition. The imaging device detects the actual position and angle of the applique piece, and the system automatically adjusts the sewing data to compensate for positioning deviations, maintaining simplicity while ensuring accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8948901B2Sewing machine

Publication Date: 2015.02.03 BROTHER KOGYO KK

AI summary

A sewing machine includes an imaging device, a processor, and a memory configured to store sewing data and computer-readable instructions. The sewing data includes at least first stitch data to form first stitches that indicate a contour of a pattern on a first work cloth, and second stitch data to form second stitches that attach the pattern cut out along the first stitches onto a second work cloth. The computer-readable instructions cause the processor to perform processes comprising causing the imaging device to capture a first image, identifying a position and an angle of a marker in relation to the contour, causing the imaging device to capture a second image, identifying a position and an angle of the contour in relation to the second work cloth, and correcting the second stitch data in accordance with the identified position and angle of the contour in relation to the second work cloth.