Sewing Machine Tapering Pattern Positioning via Image Feedback
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Solution Overview
Problem
Sewing machines face difficulties in forming tapering patterns, especially at curved portions or when the sewing workpiece expands or contracts, making it challenging to accurately position and size the pattern as intended by the user.
Innovation Solution
A sewing machine equipped with a bed, needle bar, feed dog, actuator, image sensor, and controller that captures images and generates display images to guide the user in positioning and sizing the tapering pattern, allowing for real-time preview and adjustment during the sewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the sewing machine forms a tapering pattern based on predetermined sewing data, then the sewing automation is improved, but the positioning accuracy deteriorates when the workpiece expands or contracts or has curved portions
Solution Approach 1:
The system performs preliminary actions by capturing an image of the workpiece before sewing, detecting curved portions and expansion/contraction characteristics in advance, and using this information to adjust the tapering pattern formation. The controller pre-calculates the modified tapering pattern based on the detected workpiece characteristics, ensuring accurate positioning even when the workpiece geometry varies from the predetermined data.
2Ease of operation
If the sewing machine uses a fixed tapering pattern from sewing data, then the sewing process is simplified, but the adaptability to workpiece variations deteriorates
Solution Approach 1:
The system transforms the static, fixed tapering pattern into a dynamic, adaptive pattern. The controller detects the actual workpiece geometry including curved portions and expansion/contraction characteristics, then dynamically modifies the tapering pattern formation parameters in real-time. This allows the sewing process to automatically adapt to different workpiece variations while maintaining operational simplicity for the user.
Solution Approach 2:
The system implements feedback by using the image sensor to detect the actual workpiece geometry and feeding this information back to the controller. The controller then adjusts the tapering pattern formation based on this feedback, creating a closed-loop control system that adapts to workpiece variations. The feedback mechanism enables the system to compensate for curved portions and expansion/contraction without requiring manual intervention.
3Device complexity
If the sewing machine does not provide visual guidance during sewing, then the device complexity is reduced, but the user control and positioning accuracy deteriorate
Solution Approach 1:
The system creates a visual copy or representation of the tapering pattern on the display device, showing the user where the pattern will be formed on the workpiece. This visual copy includes information about the detected curved portions and expansion/contraction characteristics, allowing the user to verify the positioning accuracy before sewing begins. The display serves as a virtual model that confirms the pattern will be formed at the intended location despite workpiece variations.
Data Source
AI summary
A controller of a sewing machine acquires sewing data for forming a utility pattern continuously in a first direction, acquires a condition for sewing a tapering pattern including a tapering portion, acquires a captured image captured by an image sensor, generates a display image in which the tapering pattern is arranged on the captured image based on the sewing data, the condition, and the captured image, controls a needle bar, a feed dog, and an actuator in accordance with the sewing data to sew the utility pattern, after starting sewing of the utility pattern, controls a display to display the display image, and performs a tapering pattern sewing operation of, after starting display of the display image, controlling the needle bar, the feed dog, and the actuator in accordance with the sewing data and the condition to sew the tapering pattern that is continuous with the utility pattern.