Sewing Machine Projector Calibration for Embroidery Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The position of the maximum area onto which a projector can project an image varies among sewing machines due to assembling errors and individual differences, making it challenging to ensure a consistent 'guarantee area' for image projection, which is essential for accurate embroidery patterns.
Innovation Solution
A sewing machine is configured to determine a target area containing a guarantee area by calibrating the projector, using a controller to project an image onto the maximum area, capture images with a camera, and calculate world coordinates to define a rectangular target area that includes the guarantee area, ensuring the projector can project onto this area consistently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the projector is assembled without calibration, then the manufacturing process is simple and fast, but the projection position varies due to assembling errors and individual differences
Solution Approach 1:
The patent applies preliminary action by performing projector calibration before actual embroidery operations. The calibration process projects a reference image, detects its position using a camera, calculates world coordinates, and determines the target area containing the guarantee area in advance. This preliminary setup ensures that subsequent embroidery operations can proceed with high precision without repeated adjustments, thus resolving the contradiction between assembly speed and projection accuracy.
2Reliability
If a guarantee area is specified for image projection, then consistent embroidery quality is ensured, but the usable projection area is reduced
Solution Approach 1:
The patent applies dynamics by making the projection target area adaptable rather than fixed. The system dynamically determines the target area based on the actual maximum projection area detected during calibration. The target area is calculated to contain the guarantee area while maximizing the usable space. This dynamic adjustment allows the system to maintain reliable embroidery quality within the guarantee area while also utilizing additional space when conditions permit, thus resolving the contradiction between reliability and area utilization.
3Measurement precision
If the projector is calibrated to determine the maximum area, then the projection precision is improved, but the calibration process becomes more complex
Solution Approach 1:
The patent applies self-service by implementing an automated calibration process. The system uses a camera to automatically capture the projected reference image, automatically calculates the world coordinates and maximum projection area, and automatically determines the target area containing the guarantee area. This self-calibration eliminates the need for manual measurement and complex manual setup procedures, thus achieving high measurement precision while keeping the calibration process relatively simple and quick.
Data Source
AI summary
A sewing machine includes a bed, a projector configured to project an image toward the bed onto at least a guarantee area, a storage medium, and a controller. The controller controls the projector to project the image toward the bed onto a maximum area. The controller determines, based on a position of the image projected onto the maximum area, first world coordinates representing, in a real space coordinate system, a rectangular area contained in the maximum area. The controller determines, based on the first world coordinates, second world coordinates representing, in the real space coordinate system, a target area containing at least the guarantee area. The controller stores the second world coordinates in the storage medium.