Sewing Sequence Determining Apparatus Minimizing Thread Replacements
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Solution Overview
Problem
In multi-needle sewing machines, determining optimal sewing sequences for multiple sewing targets is labor-intensive and increases thread replacement counts and sewing time, leading to inconvenience due to the need for operators to manually manage thread information and sequences.
Innovation Solution
A sewing sequence determining apparatus and program that calculates and determines optimal sewing sequences by comparing thread information with needle bar information, minimizing thread replacement counts through automated sequence determination and storage of sewing data, allowing for efficient thread management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual determination of sewing sequences is performed by operators, then flexibility in handling different sewing targets is maintained, but operator labor increases and determination efficiency decreases
Solution Approach 1:
The system enables self-service by automatically determining sewing sequences without operator intervention. The determination unit autonomously calculates optimal sewing sequences by comparing thread information across multiple sewing targets, eliminating the need for operators to manually manage thread information and sequence determination while maintaining flexibility for different sewing scenarios
Solution Approach 2:
The patent replaces the manual mechanical process of operator-based sequence determination with an automated information processing system. The determination unit uses computer-based algorithms to compare thread information, calculate replacement counts, and generate optimal sequences, substituting human cognitive and manual operations with automated computational processes
2Loss of time
If optimal sewing sequences are automatically determined, then thread replacement count and sewing time are reduced, but system complexity increases
Solution Approach 1:
The system segments the complex task of sequence determination into distinct functional units: a thread information storage unit that manages thread data, a determination unit that performs sequence calculation, and a control unit that executes sewing operations. This modular segmentation reduces overall system complexity by organizing functions into independent, manageable components
Solution Approach 2:
The system performs preliminary action by pre-storing thread information for multiple sewing targets and pre-calculating optimal sequences before actual sewing begins. This advance preparation reduces sewing time during production by eliminating real-time decision-making and thread replacement planning, as all sequences are determined in advance
3Productivity
If thread replacement is minimized through sequence optimization, then productivity increases, but the complexity of thread management increases
Solution Approach 1:
The system implements feedback by continuously comparing thread information across sewing targets and calculating the impact of different sequence arrangements on thread replacement counts. The determination unit uses this feedback to iteratively optimize sequences, selecting arrangements that minimize replacements while the control unit monitors and adjusts operations based on actual thread usage patterns
Solution Approach 2:
The thread information storage unit serves multiple functions: it stores thread data for individual sewing targets, compares thread information across multiple targets, identifies compatible threads for sequence optimization, and provides data for calculating replacement counts. This multi-functionality reduces the need for separate specialized systems, managing complexity through versatile components
Data Source
AI summary
Sewing data of multiple sewing targets stored in RAM of a sewing sequence determining apparatus is acquired. Permutations or combinations of the sewing targets are created as sewing sequence candidates. A number of needle bars N provided at a multi-needle sewing machine is acquired. An optimal thread replacement count is initialized. A thread replacement count is calculated for each of sewing sequence candidates, in the case where sewing operations are carried out by the multi-needle sewing machine equipped with N needle bars on the sewing targets in accordance with the sewing sequence candidates. A sewing sequence candidate of the fewest thread replacement count is determined to be an optimal sewing sequence candidate. The optimal sewing sequence candidate is displayed on a liquid crystal display and announced. Determination of sewing sequences at the time of carrying out sewing operations with respect to multiple sewing targets is easily achieved.