Sewing Machine Controller for Automated Embroidery Pattern Layout

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Solution Overview

Problem

Existing sewing machines face complexity in generating pattern data for rectangular frame embroidery patterns with unit patterns of arbitrary sizes, making it difficult for users to lay out and repeat patterns accurately.

Innovation Solution

A sewing machine and computer-readable medium that include a controller to obtain the size of a rectangular frame embroidery pattern, determine the number of repeats for a second unit pattern, and generate pattern data for laying out first and second unit patterns in corner and side portions, simplifying the operation and automating the layout process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If users manually lay out unit patterns using markers on a display, then positioning accuracy is achieved, but operation complexity increases significantly

Engineering Contradiction:

Improvepositioning accuracyVSAvoidoperation complexity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system performs automatic pattern layout calculation and determination of repeat numbers without requiring user intervention. The controller automatically calculates the number of repeats based on the embroidery pattern size and unit pattern size, eliminating the need for users to manually position patterns using markers while maintaining high positioning accuracy.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical process of positioning patterns with markers and visual alignment with an automated computational system. The controller uses mathematical calculations to determine pattern positions and repeat numbers, substituting the mechanical marker-based positioning method with an automated digital calculation and control system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If users manually adjust relative positions of unit patterns with reference to markers, then pattern layout flexibility is achieved, but time consumption increases

Engineering Contradiction:

Improvepattern layout flexibilityVSAvoidtime consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system pre-calculates the number of repeats and positions of unit patterns before the embroidery process begins. The controller determines the optimal layout configuration in advance based on the embroidery pattern dimensions and unit pattern specifications, eliminating the need for time-consuming manual adjustments during operation while maintaining layout flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent automatically adjusts layout parameters such as the number of repeats and pattern positions based on input variables including embroidery pattern size and unit pattern size. The controller dynamically calculates and modifies these parameters to achieve optimal pattern arrangement, providing flexibility without requiring manual time-consuming adjustments.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the system supports arbitrary size unit patterns in rectangular frame embroidery, then design versatility improves, but calculation complexity increases

Engineering Contradiction:

Improvedesign versatilityVSAvoidcalculation complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the rectangular frame embroidery pattern into distinct segments including corner portions and side portions. The controller separately determines the number of repeats for unit patterns in different segments based on their respective dimensions, simplifying the overall calculation by breaking down the complex arbitrary size pattern into manageable segments with independent calculations.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11008685B2Sewing machine and non-transitory computer-readable medium storing computer-readable instructions

Publication Date: 2021.05.18 BROTHER KOGYO KK

AI summary

A controller of a sewing machine obtains a rectangular frame embroidery pattern and obtains a first unit pattern to be laid out in each of four corner portions of the embroidery pattern and a second unit pattern to be repeatedly laid out in each of side portions of the embroidery pattern. The controller determines, based on the size of the embroidery pattern, the number of repeats of the second unit pattern in a target side portion. The controller generates pattern data for the embroidery pattern including the first unit pattern being laid out in each corner portion and the second unit pattern being laid out in the target side portion as many as the determined number of repeats of the second unit pattern. The controller causes the sewing machine to form the embroidery pattern on a workpiece held by an embroidery hoop based on the generated pattern data.