3D Embroidery Frame Rotation for Full-Surface Stitching
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Solution Overview
Problem
Existing embroidery machines are limited to embroidering only a rectangular section of a cylinder surface, such as a cap, requiring multiple setups for full-surface embroidery, which is inefficient and labor-intensive.
Innovation Solution
An embroidery machine with an embroidery frame that allows positioning of a workpiece through three independent angles (Θ, µ, ω) relative to the embroidery head, enabling full-surface embroidery by continuous adjustment and synchronization with the needle's movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the workpiece is positioned using only X and Y directions of a partially existing embroidery frame, then the embroidery machine can embroider a rectangular section of a cylinder surface, but the movement equipment is inexpensive and simple, however full-surface embroidery of curved three-dimensional structures is not possible
Solution Approach 1:
The embroidery frame is transformed from a static structure with limited X-Y movement to a dynamic system that can rotate and position the workpiece along multiple axes (X, Y, Z) and angles. The frame includes rotation mechanisms that allow the workpiece to be oriented in different positions, enabling the embroidery needle to access and embroider any section of the curved three-dimensional surface without requiring complex external movement equipment.
Solution Approach 2:
The system transitions from two-dimensional positioning (X-Y directions only) to three-dimensional positioning by adding rotational capabilities and Z-axis movement. The embroidery frame can rotate the workpiece around multiple axes and adjust angles, adding spatial dimensions to the positioning capability. This allows the flat embroidery needle to access curved three-dimensional surfaces by positioning the workpiece in different orientations rather than moving the needle in complex paths.
2Productivity
If only a partial area of the cap surface is embroidered using a cylindrical section approach, then the embroidery process is simple and efficient, but multiple laborious re-clamping operations are required to embroider several parts
Solution Approach 1:
The embroidery frame incorporates dynamic rotation mechanisms that allow the workpiece to be repositioned along multiple axes during the embroidery process. Instead of stopping to re-clamp the workpiece, the frame can rotate and tilt the workpiece to present different sections to the embroidery needle, enabling continuous embroidery across multiple parts without interrupting the process.
Solution Approach 2:
The system enables continuous embroidery action by eliminating the need to stop and re-clamp the workpiece. The embroidery frame maintains the workpiece in a clamped state while providing continuous positioning adjustments through rotation and angle changes. This allows the embroidery needle to continuously stitch across different sections of the workpiece without interruption, maintaining productive action throughout the entire embroidery process.
3Area of stationary object
If the workpiece is re-clamped multiple times to embroider several parts, then complete surface coverage is achieved, but the process becomes laborious and time-consuming
Solution Approach 1:
The embroidery frame provides dynamic positioning capabilities with rotation mechanisms around multiple axes (X, Y, Z) and angle adjustments. Once the workpiece is initially clamped, the frame can dynamically reposition it to any required orientation, eliminating the need for repeated clamping operations. This dynamic adjustment capability allows the system to access and embroider the entire surface area of the workpiece from a single setup position.
Solution Approach 2:
The embroidery frame serves multiple functions: it not only holds and positions the workpiece in the initial position but also provides continuous rotation and angle adjustment capabilities. This multi-functional design allows the same frame structure to present different sections of the workpiece to the embroidery needle throughout the entire embroidery process, achieving complete surface coverage without requiring additional clamping operations or specialized equipment for each section.
Data Source
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AI summary
The present invention relates to a method for embroidering three-dimensional workpieces (2) using an embroidery machine (100) comprising at least one embroidery head (101) and at least one embroidery frame (1) for positioning the workpiece (2). The method according to the invention is characterized in that the workpiece (2) is positioned by means of the embroidery frame (1) at at least two angles (Θ, µ, ω) with respect to at least two axes (X, Y, Z) which are related to the axis of movement of the embroidery head (101), in order to introduce at least one stitch of an embroidery into the workpiece (2).