Torque Sensor Assisted Sewing Head Movement Control
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Solution Overview
Problem
Operators face difficulties in moving or operating sewing heads of quilting machines due to physical limitations, machine size, or weight, making it challenging to initiate stitching, change direction, or adjust speed during free motion quilting.
Innovation Solution
A method and apparatus that utilize a torque sensor and motor system to assist the movement of the sewing head by sensing user-applied torque and adjusting the direction and speed of the sewing head's movement, allowing for easier operation and reduced operator fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a longarm sewing machine is used to quilt, then productivity is improved, but operator fatigue increases due to the weight and size of the sewing head
Solution Approach 1:
The patent replaces the purely mechanical manual movement system with an automated motorized system. The motor automatically moves the sewing head along the quilt, eliminating the need for operators to manually lift and reposition the heavy sewing head, thus reducing fatigue while maintaining high productivity
Solution Approach 2:
The motorized system enables the sewing machine to move itself automatically without continuous manual intervention. The motor drives the sewing head along predetermined paths, allowing the machine to service itself during the quilting process and reducing operator physical burden
2Ease of operation
If manual control of sewing head movement is used, then ease of operation is maintained, but manufacturing precision decreases for complex patterns
Solution Approach 1:
The patent incorporates sensors that detect the position and movement of the sewing head, providing feedback to the control system. This feedback mechanism ensures precise following of predetermined patterns and allows for real-time corrections, maintaining high manufacturing precision while keeping the system easy to operate
Solution Approach 2:
The motorized system with programmable control can execute various complex patterns automatically while maintaining ease of operation through a user-friendly interface. The system universalizes the quilting process by combining automated precision movement with simple operator control for different design requirements
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
Enables more efficient and effortless free motion quilting by assisting the sewing head's movement, reducing operator fatigue and improving the ability to create complex patterns with greater precision and control.
Implementation Method 1
a torque sensor operably coupled to the motor, the torque sensor able to sense a torque on the motor from the sewing head
Data Source
AI summary
Presented is a method, apparatus, and computer-readable medium for moving. A method includes sensing a change in a torque on a motor operably connected to a sewing head for at least partially assisting movement of the sewing head relative to a workpiece. The method further includes adjusting an output of the motor to change at least one of a direction and a speed of movement of the sewing head in response to the sensed change in the torque.