Sewing Machine Marker Data Alignment for Multi-Head Embroidery

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Solution Overview

Problem

In existing sewing systems, inconsistencies in the attachment of embroidery frames across multiple sewing machines can lead to unintended alterations in the relative positions of partial patterns, resulting in a compromised appearance of the embroidery pattern.

Innovation Solution

A sewing machine system equipped with a transfer device, image capture device, communication device, and correction device that computes and adjusts marker data to align partial patterns accurately across multiple machines, ensuring consistent positioning and angle settings for seamless pattern integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple sewing machines are used to sew a single embroidery pattern, then productivity is improved by reducing thread spool replacement times and shortening sewing time, but manufacturing precision deteriorates due to unintended alterations in relative positions of partial patterns caused by attachment errors

Engineering Contradiction:

Improvesewing timeVSAvoidpositioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by capturing images of markers on the embroidery frame and work cloth before sewing begins, computing reference positions and angles, and determining correction conditions in advance. This preliminary positioning data is then used to correct pattern data for all sewing machines before sewing starts, preventing positioning errors rather than correcting them during sewing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical alignment methods with an optical and computational system. Instead of relying on physical attachment precision alone, the system uses image capture devices to photograph markers, computes positional relationships through image processing, and applies computational corrections to pattern data, substituting mechanical alignment with optical-mechanical-computational integration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If manual attachment of embroidery frames is used, then ease of operation is improved by allowing flexible setup, but manufacturing precision deteriorates due to attaching errors that cause position deviations

Engineering Contradiction:

Improvesetup flexibilityVSAvoidattachment accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system enables self-service by allowing the embroidery frame to be manually attached with flexible positioning, then automatically detecting the actual attachment position through marker images captured by the image capture device. The system computes correction conditions based on the detected position and automatically applies corrections to pattern data, eliminating the need for precise manual attachment while maintaining high positioning accuracy.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If position correction based on marker images is implemented, then manufacturing precision is improved by accurately aligning partial patterns, but device complexity increases due to additional image capture and computation components

Engineering Contradiction:

Improvepattern alignmentVSAvoidsystem configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The image capture device serves multiple functions: it captures marker images for position detection, captures work cloth images for pattern verification, and provides data for computing both reference positions and correction conditions. The control device also performs multiple roles including image processing, computation of reference positions, determination of correction conditions, and correction of pattern data. This multi-functionality reduces the need for separate dedicated components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8286568B2Sewing machine and computer-readable medium storing sewing machine control program

Publication Date: 2012.10.16 BROTHER KOGYO KK

AI summary

A sewing machine that is included in a sewing system includes a transfer device, a sewing device, an image capture device, a communication device, a data computation device, a first control device, a marker data acquisition device, a sewing condition acquisition device, a condition computation device, a correction device, and a sewing control device. The data computation device computes first marker data, and the first control device transmits the first marker data, through the communication device, to another sewing machine. The marker data acquisition device acquires, as second marker data, the first marker data. The sewing condition acquisition device acquires a sewing condition, and the pattern data acquisition device acquires pattern data. The condition computation device computes a correction condition. The correction device corrects the pattern data. The sewing control device performs the sewing in accordance with the corrected pattern data.