CN108978062B - Sewing machine and skip stitch detection device and detection method thereof - Google Patents

Sewing machine and skip stitch detection device and detection method thereof Download PDF

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CN108978062B
CN108978062B CN201710403616.7A CN201710403616A CN108978062B CN 108978062 B CN108978062 B CN 108978062B CN 201710403616 A CN201710403616 A CN 201710403616A CN 108978062 B CN108978062 B CN 108978062B
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tension
value
threshold range
tension value
preset
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CN108978062A (en
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卢明安
万义明
黄明学
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Jack Technology Co Ltd
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Jack Sewing Machine Co Ltd
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    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05BSEWING
    • D05B69/00Driving-gear; Control devices
    • D05B69/36Devices for stopping drive when abnormal conditions occur, e.g. thread breakage
    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05DINDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
    • D05D2205/00Interface between the operator and the machine
    • D05D2205/12Machine to the operator; Alarms

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Sewing Machines And Sewing (AREA)

Abstract

The invention discloses a skip stitch detection method for a sewing machine, which comprises the following steps: acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process; judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not; if at least one of the two is not, the next step is carried out; the operator is prompted for a sewing abnormality. The invention also discloses a skip stitch detection device for the sewing machine. The invention also discloses a sewing machine comprising the skip stitch detection device. The skip stitch detection method can timely know whether the skip stitch phenomenon occurs in the sewing process.

Description

Sewing machine and skip stitch detection device and detection method thereof
Technical Field
The invention relates to the technical field of sewing machines, in particular to a skip stitch detection method for a sewing machine. The invention also relates to a skip stitch detection device for the sewing machine; in addition, the invention also relates to a sewing machine with the skip stitch detection device.
Background
As is well known, in a sewing machine, a phenomenon that a needle passes through a sewing material but a lower thread and an upper thread do not continuously form a stitch, which is called a skip stitch, sometimes occurs. In the sewing process, empty stitches can be left once the needles jump, the attractiveness of the stitches is affected, and particularly in the high-end sewing process of automobile products, leather and the like, the products must be treated as defective products once the needles jump.
In fact, most of airbag manufacturers in asia and the usa select polyamide thread sewing when producing airbags, due to the safety reasons of the airbags, the sewing process must be strictly controlled, the principle of zero defect is adhered to, any broken thread occurs, the product with empty needles is directly scrapped, and according to statistics, the phenomena of needle skipping and broken thread occur most in the sewing process. In order to take safety into consideration, the sewing machine must be capable of giving an alarm in time for the defects of needle skipping and thread breakage, so as to ensure zero defects of the safety airbag leaving a factory.
Disclosure of Invention
The invention aims to provide a skip stitch detection method for a sewing machine, which can know whether a skip stitch phenomenon occurs in the sewing process in time. Another object of the present invention is to provide a skip stitch detecting device for a sewing machine. Still another object of the present invention is to provide a sewing machine having the skip stitch detecting device.
In order to achieve the above object, the present invention provides a skip stitch detecting method for a sewing machine, comprising:
acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not; if at least one of the two is not, the next step is carried out;
the operator is prompted for a sewing abnormality.
Preferably, the judging step is to judge whether the first tension value is within a preset first tension threshold range, and judge whether the second tension value is within a preset second tension threshold range; if at least one of the data is negative, the next step is carried out and further comprises the following steps:
judging whether the second tension value is within the second tension threshold range; if so, carrying out jumper prompt on the operator; if not, the disconnection prompt is given to the operator.
Preferably, before the step of determining whether the first tension value is within a preset first tension threshold range and the step of determining whether the second tension value is within a preset second tension threshold range, the method further includes:
acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
and determining the first tension threshold range and the second tension threshold range according to the first reference tension value and the second reference tension value respectively.
Preferably, the first tension value is an average value of the tension borne by the upper thread or a maximum value of the tension borne by the upper thread in the thread hooking process of the rotating shuttle; the second tension value is specifically the average value of the tension borne by the upper thread or the maximum value of the tension borne by the upper thread in the stitch locking process.
The present invention also provides a skip stitch detecting device for a sewing machine, comprising:
a tension sensor: the device is used for acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
a controller: the tension control device is used for judging whether the first tension value is within a preset first tension threshold range or not and judging whether the second tension value is within a preset second tension threshold range or not;
an alarm device: and the controller is used for prompting the sewing abnormity to an operator when the first tension value is not in a preset first tension threshold range or the second tension value is not in a preset second tension threshold range.
Preferably, the alarm is a wire breakage alarm for prompting a wire breakage to an operator when the second tension value is not within the second tension threshold range, and a wire jumping alarm for prompting a wire jumping to the operator when the first tension value is not within the first tension threshold range and the second tension value is within the second tension threshold range.
Preferably, the method further comprises the following steps:
a memory: the device is used for acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
a threshold determination unit: the tension threshold value range is determined according to the first reference tension value and the second reference tension value.
Preferably, the tension sensor is arranged between the take-up lever and the needle hole.
The invention also provides a sewing machine comprising the skip stitch detection device.
Compared with the background art, the skip stitch detection method for the sewing machine provided by the invention has the advantages that in the sewing process, the first tension value of the upper thread in the thread hooking process of the rotating shuttle and the second tension value of the upper thread in the stitch locking process are constantly obtained; judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not; and if the first tension value is not in the preset first tension threshold range or the second tension value is not in the preset second tension threshold range, prompting the operator of abnormal sewing. That is, by acquiring the tension values of the upper thread in the thread hooking process of the rotating shuttle and the stitch locking process and comparing the acquired first tension value and the acquired second tension value with the first tension threshold range and the second tension threshold range respectively, when the first tension value is not in the preset first tension threshold range or the second tension value is not in the preset second tension threshold range, the phenomenon of needle skipping or thread breakage is indicated, the sewing abnormity is timely prompted to an operator, and appropriate subsequent operation is adopted.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a waveform diagram of the tension of the upper thread in the normal operation of the sewing machine;
FIG. 2 is a waveform diagram of the tension of the upper thread when the needle skip phenomenon occurs;
FIG. 3 is a waveform diagram of the tension of the upper thread when the thread breakage phenomenon occurs;
FIG. 4 illustrates a stitch skipping detection method for a sewing machine according to an embodiment of the present invention;
FIG. 5 is a flowchart of a skip stitch detection method for a sewing machine according to an embodiment of the present invention;
FIG. 6 is a block diagram of a stitch skipping detecting device for a sewing machine according to an embodiment of the present invention;
fig. 7 is an external structural view of a sewing machine according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order that those skilled in the art will better understand the disclosure, the invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Referring to fig. 1 to 7, fig. 1 is a waveform diagram of the tension of the upper thread in the normal operation of the sewing machine; FIG. 2 is a waveform diagram of the tension of the upper thread when the needle skip phenomenon occurs; FIG. 3 is a waveform diagram of the tension of the upper thread when the thread breakage phenomenon occurs; FIG. 4 illustrates a stitch skipping detection method for a sewing machine according to an embodiment of the present invention; FIG. 5 is a flowchart of a skip stitch detection method for a sewing machine according to an embodiment of the present invention; FIG. 6 is a block diagram of a stitch skipping detecting device for a sewing machine according to an embodiment of the present invention; fig. 7 is an external structural view of a sewing machine according to an embodiment of the present invention.
The invention provides a skip stitch detection method for a sewing machine, as shown in the attached figure 4 of the specification, which mainly comprises the following steps:
s1, acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
s2, judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not; if at least one of the two is not, the next step is carried out;
s3, the operator is prompted about sewing abnormality.
Before describing the skip stitch detection method of the present invention, the tension of the upper thread, the tension when the skip stitch occurs, and the tension waveform when the thread breakage occurs in the normal operation process of the sewing machine can be studied, as shown in the accompanying drawings 1 to 3 of the specification.
In the attached figure 1 of the specification, a horizontal axis is a rotation angle of a main shaft of the sewing machine, wherein 0 degree is an upper needle stop position of the sewing machine, a point 1 is a tension state of a stitch locking time of a previous needle space of the sewing machine, a point 2 is a time when a rotating shuttle hooks an upper thread to the vicinity of a lowest point, and a point 3 is a tension state of a stitch locking time of a current needle space. As can be seen from the waveform diagram, point 1 and point 3 are the time points when the tension on the sewing thread is maximum during sewing, and point 2 is a maximum value of the tension waveform. The tension of the point 1 and the point 3 is the maximum, one part is caused by the fact that the stitch is locked, the upper thread and the bottom thread are mutually tensioned, and the other part is caused by the fact that the take-up lever quickly takes up the thread.
In the working process of the sewing machine, the needle skipping is that the thread loop cannot be locked because the rotating shuttle tip does not hook the upper thread, so that an empty needle track is formed. When the skipping stitch occurs, in the period of the main shaft, no stitch locking exists, and the process of hooking the thread by the rotating shuttle does not exist, if the skipping stitch occurs in the current stitch length, namely the tip of the rotating shuttle does not have an upper thread at the moment of the point 2, the tension wave peak of the point 2 is greatly reduced, and the peak value of the point 3 is mainly caused by the quick take-up of the thread take-up lever, so that the change is not large, the maximum values of the waveforms in the two angle ranges are detected by selecting the two angle ranges, the maximum values are compared with the recorded average value of the maximum values of the normal sewing period, and the maximum values can also be compared with the limit value set by a user, so that the skipping stitch is effectively judged. On the other hand, when the thread breakage occurs, the sewing thread is instantaneously loosened, the tension of the sewing thread is sharply reduced, and whether the thread breakage occurs or not can be effectively judged by detecting the range of the tension value, as shown in fig. 2 and fig. 3 of the specification.
Based on the above analysis, a tension sensor may be utilized to obtain a tension value; in the working process of the sewing machine, the tension sensor detects the tension of the sewing thread in real time and transmits data to the related data processing module. The tension sensor detects a signal of line tension, the signal is transmitted to the detection module CPU after passing through the amplifier, a synchronous signal is collected by the encoder and transmitted to the main electronic control unit of the sewing machine, and the main electronic control unit shares the signal to the detection module CPU. The circuit is provided with a data storage module which can store data for comparison.
In step S1, a first tension value of the upper thread in the hook process of the rotating hook and a second tension value of the upper thread in the stitch locking process are acquired; the first tension value and the second tension value are used as actual detected tension values and should be acquired in real time in the sewing process so as to timely know whether a jumping phenomenon occurs.
In step S2, the first tension threshold range and the second tension threshold range may be the average value of the maximum values of the normal sewing cycle or preset limit values; judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not; if at least one of the two is not, the next step is carried out;
in step S3, the operator is presented with a sewing abnormality.
Further, if the first tension value is not within the preset first tension threshold range, or the second tension value is not within the preset second tension threshold range, the following determination may be further made:
when the first tension value is not within a preset first tension threshold range and the second tension value is not within a preset second tension threshold range, namely the first tension value and the second tension value are not within the corresponding tension threshold ranges, a wire breakage prompt is given to an operator;
when the first tension value is within a preset first tension threshold range and the second tension value is not within a preset second tension threshold range, the operator is also prompted to break the wire;
when the first tension value is not within a preset first tension threshold range and the second tension value is within a preset second tension threshold range, performing jumper prompt on an operator;
and only when the first tension value is within a preset first tension threshold range and the second tension value is within a preset second tension threshold range, namely the first tension value and the second tension value are within the corresponding tension threshold ranges, the sewing process is normal.
Before the step S2, that is, before the step of determining whether the first tension value is within a preset first tension threshold range, and determining whether the second tension value is within a preset second tension threshold range, the method further includes:
acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
and determining the first tension threshold range and the second tension threshold range according to the first reference tension value and the second reference tension value respectively.
The method comprises the steps of determining a first tension threshold range and a second tension threshold range, obtaining a first reference tension value of an upper thread in the thread hooking process of a rotating shuttle and a second reference tension value of the upper thread in the stitch locking process when normal sewing is carried out, namely, thread breakage and thread jumping do not occur, determining the first tension threshold range and the second tension threshold range according to the first reference tension value and the second reference tension value and by combining actual conditions, and then detecting the actual sewing process in real time to timely know the occurrence of thread jumping and thread breakage.
It should be noted that the first tension threshold range and the second tension threshold range may be defined in a smaller range according to actual needs, and when the range is infinite, the range approaches a certain value; that is, the first tension threshold range and the second tension threshold range may be regarded as certain values, and it is determined whether the first tension value reaches the first tension threshold range (certain value) and the second tension value reaches the second tension threshold range (other value) in the actual sewing process, thereby determining whether a sewing abnormality occurs.
Aiming at the step S1, acquiring a first tension value of the upper thread in the hook process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process; the first tension value and the second tension value are specific numerical values, and a plurality of numerical values exist in the hook process of the rotating shuttle and the stitch locking process, so that the first tension value can be set as the average value of the tension borne by the upper thread or the maximum value of the tension borne by the upper thread in the hook process of the rotating shuttle; the second tension value is set as the average value of the tension borne by the upper thread or the maximum value of the tension borne by the upper thread in the stitch locking process.
Of course, the first tension value and the second tension value may also be average values in the hook process of the rotating shuttle and the stitch locking process, respectively, and the definitions of the hook process of the rotating shuttle and the stitch locking process in terms of time may be determined according to actual needs, and are not described herein again.
Fig. 5 is a flowchart of a skip stitch detection method, in which after step S10 is started, skip stitches and a thread break flag are set to OFF, that is, step S20; in step S30, a synchronization signal and a piezoelectric sensor signal are obtained, where the synchronization signal is a spindle rotation signal and the piezoelectric sensor signal is a tension sensor signal; certainly, the present disclosure is not limited to only using the piezoelectric sensor to obtain the piezoelectric sensor signal, but also uses the hall sensor, that is, using the hall sensor to detect, and by arranging the spring additionally, the hall sensor can detect the distance change generated by the deformation of the spring, and can also obtain the above-mentioned signal; in step S40, it is determined whether the upper shaft angle, that is, the rotation angle of the main shaft, is within the test range; step S40 is to determine whether the rotation of the spindle is normal; if not, returning to the step S30 again; if the rotation of the spindle is normal, in step S50, a waveform peak value of the monitoring interval is obtained, that is, the graphs shown in fig. 1 to fig. 3 are obtained; in the acquiring process, firstly, whether the first tension value is abnormal is judged, as in step S60; that is, whether the first tension value is within the first tension threshold range is determined, and if the first tension value is normal (the first tension value is within the first tension threshold range), step S70 is performed to continuously determine whether the second tension value is within the second tension threshold range, that is, whether the second tension value is abnormal; if the second tension value is normal (the second tension value is within the second tension threshold), step S80 is performed, the current first tension value and the current second tension value are used as normal values, that is, defined as a normal period and stored with data, and the next determination process is performed with the data as a reference, that is, step S30 is repeated.
If the first tension value is abnormal (the first tension value is not within the first tension threshold range), step S61 is performed to continuously determine whether the second tension value is within the second tension threshold range, that is, whether the second tension value is abnormal; if the second tension value is not within the second tension threshold range, that is, if the second tension value is abnormal, performing step S62, setting the wire break flag to ON, and then outputting a wire break alarm signal and ending, as in steps S62 to S64; when the second tension value is within the second tension threshold range, that is, the second tension value is normal, step S610 is performed, and a skipping alarm signal is output and ended, in step S611 and step S612.
When the first tension value is normal (the first tension value is within the first tension threshold range), and the second tension value is judged to be abnormal, namely the second tension value is not within the second tension threshold range, the steps S71 to S73 are carried out, the wire breakage sign is set to be ON, and then a wire breakage alarm signal is output and the process is ended.
In the process, by monitoring the tension waveform of the suture (namely the facial suture) in the important interval, if the waveform peak value of the monitoring interval where the point 2 is located disappears (the waveform tends to be horizontal), and the waveform peak value of the monitoring interval where the point 3 is located is still normal, the occurrence of the skipping stitch is judged, and a skipping stitch alarm signal is output. And when the waveform tension of the point 3 is abnormal, judging that the wire is broken and outputting a wire breaking alarm signal.
So set up, through the tension change detection jump needle and the broken string of facial suture, it is high to detect the precision, external tension sensor 101, and the automatically controlled part can be integrated to the automatically controlled of sewing machine, and overall structure is compact. Meanwhile, digital detection of needle skipping and thread breakage of the sewing machine can be realized, and the reliability of detection is greatly improved. The monitoring of the two intervals (the hook process and the stitch locking process) has the advantages that one of the two intervals is as follows: in the two intervals, the waveforms are relatively regular, and the main tension peak value formation corresponds to the formation of the stitch; the second step is as follows: aiming at the actual tension abnormity, possible reasons are not only jump pins, but also over-thin and over-thick, and two intervals are set, which means that two conditions exist for triggering alarm, and the generation of false alarm can be greatly reduced. The method improves the sewing performance of the sewing machine, can specifically show the real-time detection of the conditions of needle skipping, thread breakage and the like, can help operators to find problems at the first time, and is favorable for the attractive appearance of stitches of the sewing product.
The invention also provides a skip stitch detection device for a sewing machine, as shown in the attached figure 6 of the specification, mainly comprising:
the tension sensor 101: the device is used for acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
the controller 102: the tension control device is used for judging whether the first tension value is within a preset first tension threshold range or not and judging whether the second tension value is within a preset second tension threshold range or not;
the alarm 103: and the controller is used for prompting the sewing abnormity to an operator when the first tension value is not in a preset first tension threshold range or the second tension value is not in a preset second tension threshold range.
Preferably, the alarm is a wire breakage alarm for prompting a wire breakage to an operator when the second tension value is not within the second tension threshold range, and a wire jumping alarm for prompting a wire jumping to the operator when the first tension value is not within the first tension threshold range and the second tension value is within the second tension threshold range.
Preferably, the method further comprises the following steps:
a memory: the device is used for acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
a threshold determination unit: the tension threshold value range is determined according to the first reference tension value and the second reference tension value.
In addition, the tension sensor 101 may be provided between the thread take-up lever and the needle hole. The tension sensor 101 is not fixed in the installation position, the tension level of the thread is highest after passing through the take-up lever, and the tension sensor is preferentially installed at the section from the take-up lever to the needle hole. The installation position of the tension sensor 101 is shown in fig. 7 in the specification.
The invention provides a sewing machine with a skip stitch detection device, which comprises the skip stitch detection device described in the specific embodiment; other parts of the sewing machine can be referred to the prior art and are not expanded herein.
It is noted that, in this specification, relational terms such as first and second, and the like are used solely to distinguish one entity from another entity without necessarily requiring or implying any actual such relationship or order between such entities.
The sewing machine and the skip stitch detection device and the detection method thereof provided by the invention are described in detail above. The principles and embodiments of the present invention are explained herein using specific examples, which are presented only to assist in understanding the method and its core concepts. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.

Claims (7)

1. A skip stitch detection method for a sewing machine, characterized by comprising:
acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
judging whether the first tension value is within a preset first tension threshold range or not, and judging whether the second tension value is within a preset second tension threshold range or not;
when the first tension value is not within a preset first tension threshold range and the second tension value is not within a preset second tension threshold range, performing disconnection prompt on an operator;
when the first tension value is within a preset first tension threshold range and the second tension value is not within a preset second tension threshold range, performing disconnection prompt on an operator;
and when the first tension value is not within a preset first tension threshold range and the second tension value is within a preset second tension threshold range, performing jumper prompt on an operator.
2. The method of claim 1, wherein the step of determining whether the first tension value is within a preset first tension threshold range and the step of determining whether the second tension value is within a preset second tension threshold range further comprises:
acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
and determining the first tension threshold range and the second tension threshold range according to the first reference tension value and the second reference tension value respectively.
3. The skip stitch detection method according to claim 1 or 2, wherein the first tension value is a mean value of the tension of the upper thread or a maximum value of the tension of the upper thread in the hook process of the rotating shuttle; the second tension value is specifically the average value of the tension borne by the upper thread or the maximum value of the tension borne by the upper thread in the stitch locking process.
4. A skip stitch detection device for a sewing machine, comprising:
a tension sensor: the device is used for acquiring a first tension value of the upper thread in the thread hooking process of the rotating shuttle and a second tension value of the upper thread in the stitch locking process;
a controller: the tension control device is used for judging whether the first tension value is within a preset first tension threshold range or not and judging whether the second tension value is within a preset second tension threshold range or not;
an alarm device: the sewing machine is used for prompting sewing abnormity to an operator when the first tension value is not in a preset first tension threshold range or the second tension value is not in a preset second tension threshold range;
the alarm is specifically a wire breakage alarm for prompting wire breakage to an operator when the second tension value is not within the second tension threshold range, and a wire jumping alarm for prompting wire jumping to the operator when the first tension value is not within the first tension threshold range and the second tension value is within the second tension threshold range.
5. The pogo pin detection device of claim 4, further comprising:
a memory: the device is used for acquiring a first reference tension value of the upper thread in the thread hooking process of the rotating shuttle during normal sewing and a second reference tension value of the upper thread in the stitch locking process;
a threshold determination unit: the tension threshold value range is determined according to the first reference tension value and the second reference tension value.
6. The skipping-stitch detecting device according to claim 4 or 5, wherein the tension sensor is disposed between the thread take-up lever and the needle hole.
7. A sewing machine comprising the skip stitch detecting device according to any one of claims 4 to 6.
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