Sewing Machine Optical Feedback Seam Pitch Control
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Solution Overview
Problem
Conventional sewing machines cannot correct errors in the sewing pitch of formed seams, leading to potential continuation of sewing with uncorrected errors.
Innovation Solution
A sewing machine equipped with imaging parts around the needle bar and a control unit that images the seam, measures the length of the most recent seam, and adjusts the sewing machine motor's rotations to match the set sewing pitch, ensuring accurate seam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sewing machine uses a conventional optical element to image the workpiece and control the needle drop based on workpiece movement amount, then the sewing pitch can be maintained at a set value, but errors in the actually formed seam cannot be corrected
Solution Approach 1:
The patent implements feedback control by imaging the actually formed seam with an optical element, measuring its length, and using this measurement to correct the sewing pitch. The control unit adjusts the needle drop timing based on the measured seam length, creating a closed-loop system that continuously corrects errors in real-time sewing operations.
Solution Approach 2:
The patent replaces conventional mechanical pitch control mechanisms with an optical measurement and electronic control system. Instead of relying solely on mechanical feed dog movement to determine sewing pitch, the system uses optical imaging to measure the actual seam length and electronically adjusts the needle drop timing, substituting mechanical control with optical-electronic control for higher precision.
2Productivity
If the sewing machine controls the needle drop based on predetermined movement amount, then the sewing process can continue efficiently, but errors accumulate without correction
Solution Approach 1:
The system maintains high productivity by implementing real-time feedback control during sewing operations. The control unit continuously monitors seam length through optical imaging and immediately adjusts needle drop timing, allowing the sewing process to proceed at normal speed while automatically correcting errors to maintain consistent quality throughout production.
Solution Approach 2:
The sewing machine performs self-correction of sewing pitch errors through automated optical measurement and control. The system independently detects seam length deviations and adjusts its own operation without external intervention, maintaining both productivity and quality consistency through autonomous error correction during the sewing process.
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 allows for real-time correction of seam errors, enhancing the accuracy and quality of the sewing process by adjusting the sewing pitch to match the set value.
Implementation Method 1
an imaging part for imaging a seam formed in a workpiece at a needle drop position
Data Source
AI summary
A sewing machine includes a sewing machine motor serving as a drive source for driving the vertical movement of a needle bar, a control part for controlling the sewing machine motor such that a sewing pitch coincides with a set value, and imaging part for imaging a seam formed in a workpiece at a needle drop position. The control part obtains the length of the most recent seam from an image of the most recent seam imaged by the imaging part and also compares the length of the most recent seam with the set value of the sewing pitch to thereby correct the number of rotations of the sewing machine motor.