Sewing Machine Sensor System for Material Thickness Adaptation
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Solution Overview
Problem
Sewing machines struggle to automatically and finely adjust to changes in sewing material thickness, leading to suboptimal sewing parameters such as thread tension, stroke adjustment, and stitch length, which can result in inefficient operation and potential fabric damage.
Innovation Solution
Incorporating a combination of thickness and position sensors to detect both compressed and uncompressed material thickness, allowing for real-time adjustments of sewing parameters like thread tension, stroke adjustment, and stitch length, eliminating the need for manual settings and reducing setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only a single thickness sensor is used to measure material thickness, then the device complexity is reduced, but the manufacturing precision and adaptability of sewing parameters to material compressibility deteriorates
Solution Approach 1:
The measurement function is segmented into two independent sensors: a first thickness sensor for measuring uncompressed material thickness and a second thickness sensor for measuring compressed material thickness. This segmentation allows each sensor to specialize in a specific measurement state, providing comprehensive information about material compressibility while maintaining relatively simple individual sensor designs.
Solution Approach 2:
The measurement approach transitions from a single-dimensional thickness measurement to a two-dimensional measurement space by adding the compressed state measurement. The control device processes both uncompressed and compressed thickness values to calculate material compressibility, adding a new dimension of information that enables precise sewing parameter adaptation.
2Adaptability or versatility
If manual adjustment of sewing parameters is performed, then the adaptability to material thickness is improved, but the loss of time for setup and operation increases
Solution Approach 1:
The control device continuously receives feedback from both thickness sensors about the material thickness in uncompressed and compressed states. This feedback loop enables the control device to automatically calculate material compressibility and adjust sewing parameters in real-time without manual intervention, eliminating setup time while maintaining high adaptability.
Solution Approach 2:
The sewing machine performs self-adjustment of sewing parameters based on automatic material compressibility detection. The control device independently processes sensor data, determines appropriate parameter values, and modifies sewing settings without requiring operator intervention, making the system self-sufficient and time-efficient.
3Reliability
If the hold-down foot applies sufficient pressure to ensure reliable fabric transport, then the reliability of fabric handling is improved, but the object-affected harmful factors (fabric damage) increases
Solution Approach 1:
The hold-down foot pressure is made dynamic rather than static. The control device continuously adjusts the pressure applied by the hold-down foot based on real-time material compressibility measurements. This dynamic adjustment ensures sufficient pressure for reliable fabric transport while preventing excessive pressure that could damage the fabric, adapting the force to the actual material properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables precise adaptation to varying material thickness, ensuring reliable fabric transport, minimizing pressure on the fabric, and maintaining maximum sewing speed, thereby reducing overall sewing time and preventing fabric damage.
Implementation Method 1
An ultrasonic sensor according to claim 4 for uncompressed material thickness measurement is known from EP 1 479 809 A1.
Implementation Method 2
A piezo element in particular can be elegantly integrated into the housing.
Implementation Method 3
An optical sensor can be used either as a distance sensor or as a sensor determining the absolute position of a component in space
Data Source
AI summary
Sewing machine comprises a sensor (17) for determining the position of the presser foot (22) relative to the base plate (4) in the foot's lowered position, a sensor (34) for determining the thickness of the material to be sewn, and a control unit (20) for controlling the sewing machine in response to signals from the position sensor and thickness sensor.