Sewing Machine Cutting Needle Orientation Control
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Solution Overview
Problem
Existing sewing machines require cumbersome data generation for cutting arbitrary configurations on workpiece cloths, as they are limited to forming predetermined cut patterns, necessitating the development of a system that can easily create custom cut patterns.
Innovation Solution
A sewing machine equipped with a detection unit to determine the moving direction and amount of the workpiece cloth, a cutting needle with a blade edge, an up-down drive mechanism for reciprocating the needle, and a rotational drive mechanism to adjust the needle's orientation based on detected movement, allowing for precise cutting in arbitrary configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sewing machine uses predetermined cut patterns with boring data, then the cutting function is simple to implement, but the user cannot easily create arbitrary cut configurations
Solution Approach 1:
The system allows users to directly input desired cut positions and orientations through a simple UI without requiring external data generation tools. The sewing machine itself performs the complex calculations and data processing needed to convert user inputs into executable cutting paths, making the system self-sufficient and eliminating the need for separate data generation software.
Solution Approach 2:
The patent replaces the traditional mechanical approach of using pre-generated boring data with an intelligent control system that uses imaging devices, coordinate transformation algorithms, and automated path generation. This substitution of mechanical data preparation with automated computational methods enables arbitrary cut configurations while maintaining ease of operation.
2Manufacturing precision
If the cutting needle rotates to match the moving direction of the workpiece cloth, then the cut orientation precision is improved, but the control system complexity increases
Solution Approach 1:
The system uses an imaging device to detect the moving direction of the workpiece cloth in real-time, feeds this information back to the control unit, which then calculates the appropriate rotation angle and commands the rotational drive mechanism to adjust the cutting needle's orientation. This closed-loop feedback system ensures precise cut orientation while automating the complex control calculations.
Solution Approach 2:
The control unit performs multiple functions including image processing, coordinate transformation, rotation angle calculation, and motion control coordination. By consolidating these diverse functions into a single multi-functional control unit, the system achieves precise cut orientation without proportionally increasing overall system complexity.
3Ease of operation
If the system detects workpiece cloth movement and adjusts cutting parameters in real-time, then the ease of operation for arbitrary cuts is improved, but the processing time increases
Solution Approach 1:
The control unit pre-calculates rotation angles and cutting paths based on detected workpiece movement trends, and prepares command sequences in advance. By performing preliminary calculations and command preparation before the actual cutting operation, the system reduces real-time processing delays while maintaining ease of operation for arbitrary cut configurations.
Data Source
AI summary
A sewing machine includes a detection unit configured to detect a moving direction of an object when the object placed on a sewing machine bed is moved in any direction, a cutting needle having a distal end formed with a blade edge and configured to form a cut in the object, an up-down drive mechanism configured to reciprocate the needle in an up-down direction, a rotational drive mechanism configured to rotate the needle about a rotation axis line of the needle, and a control device configured to control the up-down drive mechanism and the rotational drive mechanism based on a result of detection by the detection unit so that an orientation of the blade edge is changed according to the moving direction of the object and the needle is reciprocated to form the cut in the object with the blade edge being in the changed orientation.