Sewing Machine Marker-Based Pattern Alignment Correction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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, condition acquisition device, data acquisition device, computation device, correction device, and sewing control device, which uses markers to capture images, compute positioning conditions, and correct pattern data to ensure accurate alignment and positioning of partial patterns across multiple machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple sewing machines are used to sew a single embroidery pattern, then the sewing time is shortened and productivity is improved, but the relative positions of partial patterns may be unintentionally altered due to frame attachment variations

Engineering Contradiction:

Improvesewing timeVSAvoidposition accuracy of partial patterns

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary actions by capturing images of markers on the embroidery frame and workcloth before sewing begins, computes the actual positions and angles of the embroidery frame relative to the carriage, and pre-corrects the pattern data. This allows the system to anticipate and compensate for attachment variations before they affect the sewing process, ensuring accurate positioning of partial patterns across multiple sewing machines.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses markers that create visual copies or representations of position and orientation information. By capturing images of these markers and computing their positions, the system creates a digital model of the actual embroidery frame setup, which is then used to correct the pattern data. This copying approach allows the system to transfer accurate positioning information from the physical marker setup to the digital pattern data without requiring perfect physical alignment.

Inventive Principle:

Principle #26Copying

2Ease of operation

If the embroidery frame is attached to the carriage, then the sewing machine can perform sewing operations, but attachment errors cause discrepancies in the position and angle of the embroidery pattern

Engineering Contradiction:

Improveframe attachmentVSAvoidposition and angle accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system replaces mechanical alignment methods with an optical and computational approach. Instead of relying on precise mechanical attachment of the embroidery frame to the carriage, the system uses image capture devices to photograph markers, then computes the actual position and angle through image processing. This substitution of mechanical precision with optical measurement and computational correction allows for easier attachment operations while maintaining high measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If markers are positioned on the embroidery frame and workcloth, then positioning information can be captured, but the system complexity increases due to additional components

Engineering Contradiction:

Improveposition detection accuracyVSAvoidsystem components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system introduces markers as intermediary elements that facilitate communication between the physical embroidery frame setup and the digital pattern data. These simple visual markers serve as mediators that can be captured by the image capture device, converted into position and angle information through image processing, and then used to correct the pattern data. The markers act as a bridge that translates physical attachment variations into computable correction parameters without requiring complex sensors or measurement devices.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8539892B2Sewing machine and computer-readable medium storing sewing machine control program

Publication Date: 2013.09.24 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 condition acquisition device, a data acquisition device, a computation device, a correction device, and a sewing control device. The data acquisition device acquires pattern data based on a pattern condition acquired by the condition acquisition device. The computation device computes, as a positioning condition, at least one of a reference position and a reference angle of at least one marker in relation to the carriage based on image data generated by the image capture device. The correction device sets a position and an angle of the partial pattern in relation to the carriage and corrects the pattern data. The sewing control device performs sewing of the partial pattern by controlling the transfer device and the sewing device in accordance with the corrected pattern data.