Sewing Machine Trajectory Control for Needle Bar Adjustment
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Solution Overview
Problem
Users of sewing machines face difficulties in accurately adjusting the relationship between the vertical position of the needle bar and the horizontal position of the feed base due to varying movement trajectories, making maintenance and adjustments challenging.
Innovation Solution
A sewing machine with a control method that allows switching between normal and adjustment modes, where the trajectory of the feed base can be set to a standard or special trajectory, enabling users to easily recognize and adjust the timing of movements, and preventing erroneous operations during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sewing machine uses multiple movement trajectories (standard and special) adapted to different sewing object thicknesses and materials, then the adaptability to different sewing conditions is improved, but the complexity of adjusting and determining the appropriate trajectory increases
Solution Approach 1:
The patent implements dynamic switching between standard and special movement trajectories based on real-time detection of sewing object properties. The control unit automatically selects the appropriate trajectory by detecting cloth thickness and material characteristics, making the system adaptable without requiring manual intervention for trajectory selection. This resolves the contradiction by enabling the system to dynamically adjust to different sewing conditions while maintaining simple operation for the user.
2Ease of operation
If the user manually rotates the upper shaft to adjust the horizontal position of the feed base while checking the positional relationship with the needle bar, then the ease of operation is improved, but the measurement precision of the positional relationship deteriorates due to varying trajectories
Solution Approach 1:
The patent replaces the manual mechanical adjustment method with an automated control system that uses detection units to measure cloth properties and a control unit to calculate and execute the appropriate movement trajectory. This substitution eliminates the imprecision caused by manual adjustment while maintaining ease of operation, as the system automatically determines and implements the correct trajectory without requiring the user to manually rotate shafts or visually check positional relationships.
Solution Approach 2:
The system incorporates detection units that continuously monitor sewing object properties and provide feedback to the control unit. Based on this feedback, the control unit automatically adjusts the movement trajectory to ensure precise positioning of the feed base relative to the needle bar. This feedback mechanism eliminates measurement precision issues by using sensor-based detection rather than manual visual inspection, while the automated nature maintains operational simplicity.
3Manufacturing precision
If the sewing machine stores and uses different trajectory data for different sewing conditions, then the manufacturing precision of the sewing process is improved, but the loss of information regarding which trajectory to select increases
Solution Approach 1:
The patent implements a self-service system where the detection unit automatically detects sewing object properties and the control unit autonomously selects the appropriate movement trajectory without requiring user input or decision-making. The system serves itself by using sensor data to determine the correct trajectory, thereby eliminating information loss related to trajectory selection while maintaining high manufacturing precision through accurate, condition-appropriate trajectory execution.
Data Source
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AI summary
When a power source switch of a sewing machine (1) is turned on, a CPU (41) of the sewing machine displays a home screen on a display (11). When the CPU receives an operation of a setting key (10A), the CPU shifts to an adjustment mode. The CPU saves a movement trajectory and a feed pitch set by a user in a temporary storage area of a RAM (43). The CPU sets the movement trajectory to a standard trajectory, and sets the feed pitch to a standard pitch. When the user manually rotates a pulley, a feed base (33) moves at the standard pitch along the standard trajectory. In the adjustment mode, the CPU disables an operation of a pedal (22) and does not drive a main motor. When the CPU receives an operation of a return key or a home key, the CPU shifts to a normal mode.