Sewing Machine Embroidery Alignment via Image Detection
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Solution Overview
Problem
Existing sewing machines face challenges in accurately aligning embroidery patterns before and after repositioning the work cloth, leading to potential misalignment during the sewing process due to the need for manual visual alignment of reference marks.
Innovation Solution
A sewing machine equipped with a transfer device, storage device for embroidery data, image capture device, detection devices for marker positions and angles, and a difference computation device that adjusts and converts coordinate data to ensure precise alignment of embroidery patterns across repositioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reference marks are sewn on work cloth for alignment, then alignment between sub-patterns is improved, but manual visual alignment process increases operation time and complexity
Solution Approach 1:
The patent replaces the manual visual alignment mechanism with an automated image processing system. The image capture device photographs the reference marks, and the control unit automatically calculates positions and angles to determine work cloth displacement, eliminating the need for manual visual alignment while maintaining high precision.
Solution Approach 2:
The system performs self-alignment by automatically detecting reference mark positions through image capture and computation. The control unit independently calculates the displacement amount and angle without requiring operator intervention, enabling the machine to correct its own positioning errors autonomously.
2Adaptability or versatility
If work cloth is repositioned manually for multi-batch embroidery, then flexibility to handle large patterns is improved, but alignment accuracy between batches deteriorates
Solution Approach 1:
The system captures images of reference marks after work cloth repositioning, computes the actual displacement and angle changes, and uses this feedback information to correct the coordinate data for subsequent sub-patterns. This closed-loop feedback mechanism ensures that even after manual repositioning, the alignment accuracy is maintained through automatic compensation.
Solution Approach 2:
The patent dynamically adjusts the coordinate parameters (position and angle) of subsequent embroidery patterns based on the detected displacement of reference marks. By changing the coordinate data parameters according to actual work cloth positioning, the system maintains alignment accuracy despite manual repositioning operations.
3Device complexity
If visual alignment method is used, then device complexity is reduced, but alignment precision and reliability deteriorate
Solution Approach 1:
The patent introduces an image capture device as an intermediary between the work cloth positioning and the embroidery pattern alignment. This intermediary automatically measures the position and angle of reference marks, providing precise measurement data to the control unit without requiring complex mechanical alignment mechanisms.
Data Source
AI summary
A sewing machine that is capable of sewing an embroidery pattern includes a transfer device that transfers the embroidery frame, a storage device that stores embroidery data, a first selection device that selects first embroidery data, a first control device that performs sewing of the first pattern, an image capture device that captures an image, a first detection device that detects at least one of a marker position and a marker angle based on information for a first image, a second detection device that detects at least one of the marker position and the marker angle based on information for a second image, a difference computation device that computes at least one of a position difference and an angle difference, a second selection device that selects second embroidery data, a conversion device that converts coordinate data, and a second control device that performs sewing of the second pattern.