Sewing Machine Ultrasonic Feed Correction
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Solution Overview
Problem
Sewing machines struggle to accurately cease operation at a set position due to discrepancies between the cloth feed pitch set by the feed adjustment device and the actual movement of the work cloth, caused by factors like puckering and slippage, leading to potential inaccuracies in sewing completion.
Innovation Solution
A sewing machine equipped with a feed portion, detection portion, and processor that uses ultrasonic waves to identify positions on the work cloth, calculate distances, and adjust the feed efficiency to ensure accurate feeding and completion of sewing up to a set position, employing a method that involves identifying a first position, calculating distances, and correcting feed distances based on actual efficiency to align with the intended sewing pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the feed adjustment device sets the cloth feed pitch based on angle of inclination, then the sewing machine can control feed amount, but the actual cloth movement does not match the set pitch due to puckering and slippage
Solution Approach 1:
The patent replaces the mechanical feed pitch detection system with an optical measurement system. A camera captures images of the work cloth, and image processing calculates the actual feed distance by detecting markers or features on the cloth. This optical system directly measures actual cloth movement, eliminating the discrepancy between mechanical feed pitch settings and actual cloth displacement caused by puckering and slippage.
Solution Approach 2:
The patent implements a feedback mechanism where the actual feed distance is continuously measured using image processing, and this information is fed back to correct the sewing completion position calculation. The system compares the measured actual feed distance with the target feed distance and adjusts the sewing completion position accordingly, ensuring accurate sewing completion despite variations in actual cloth movement.
2Productivity
If the sewing machine calculates sewing length by adding up cloth feed pitch data, then operation can cease at set length, but inaccuracies occur due to feed efficiency variations
Solution Approach 1:
The patent replaces the mechanical accumulation of feed pitch data with an optical measurement system using cameras and image processing. The system captures images at different positions, detects markers or features on the work cloth, and calculates actual distances through image processing algorithms. This provides direct visual measurement of the actual sewing length, replacing the indirect mechanical calculation method.
Solution Approach 2:
The system uses feedback by continuously monitoring actual cloth position through image processing and comparing it with the target sewing length. The measured actual feed distance is fed back to correct the sewing completion position, ensuring that the sewing operation ceases at the accurate set position rather than relying on accumulated mechanical feed data.
3Productivity
If the feed portion feeds work cloth based on set data, then sewing can proceed efficiently, but the actual feed distance differs from the set distance due to slippage and puckering
Solution Approach 1:
The patent introduces an optical measurement system using cameras and image processing to directly measure the actual feed distance of the work cloth. This system independently verifies the actual cloth movement regardless of mechanical feed variations, providing accurate measurement of feed distance that reflects the true state of cloth movement including slippage and puckering effects.
Solution Approach 2:
The system implements feedback by measuring the actual feed distance through image processing and using this information to correct subsequent feed operations. The measured actual feed distance is compared with the target feed distance, and corrections are applied to ensure accurate cumulative feed distance, maintaining manufacturing precision while preserving feed efficiency.
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 enables the sewing machine to accurately stop at the predetermined position, correcting for feed inefficiencies and ensuring precise sewing completion despite factors like puckering and slippage, thereby maintaining the integrity of the stitch pattern.
Implementation Method 1
The detection portion is configured to detect ultrasonic waves
Implementation Method 2
identifying a position of an ultrasonic wave transmission source as a first position, based on ultrasonic waves that have been transmitted from the ultrasonic wave transmission source and detected by the detection portion
Data Source
AI summary
A sewing machine includes a feed portion, a detection portion configured to detect ultrasonic waves, a processor and a memory configured to store computer-readable instructions. The computer-readable instructions cause the processor to perform processes that includes identifying a first position based on the ultrasonic waves, calculating a first distance based on the first position, causing the feed portion to feed the work cloth in accordance with first data, identifying a second position based on the ultrasonic waves after the feed portion has fed the work cloth in accordance with the first data, calculating as third distance based on the first distance and the second position, calculating a feed efficiency of the feed portion, correcting a fourth distance to a fifth distance based on the feed efficiency, and causing the feed portion to feed the work cloth in accordance with second data for feeding the work cloth over the fifth distance.