JP2019216984A - Sewing machine and sewing method - Google Patents

Abstract

To suppress manufacturing of a defective sewing object and occurrence of an abnormal operation of a sewing machine.SOLUTION: A sewing machine 1 includes: a holding member holding a sewing object S in a predetermined plane including a sewing position right under a sewing needle 3; actuators 16, 17 for moving the holding member; an imaging apparatus 30 capable of imaging the sewing object; a sewing data acquisition part for acquiring first sewing data which are referred to in first sewing processing and second sewing data which are referred to in second sewing processing that is executed next to the first sewing processing; an initial position data acquisition part for acquiring data of an initial position of a feature pattern; a current position data acquisition part for acquiring current position data of the feature pattern on the basis of image data of the sewing object; an abnormality detection part for detecting abnormality of the sewing object on the basis of the initial position data and the current position data; and a control part for outputting a detection result when abnormality has been detected, and for outputting a control signal for controlling the actuators on the basis of the first sewing data and the second sewing data when abnormality is not detected.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a sewing machine and a sewing method.

  Stitches may be formed on the sewing object in order to enhance the design of the sewing object. Patent Literature 1 and Patent Literature 2 disclose techniques for forming stitches on a skin material used for a vehicle seat.

JP 2013-162957 A JP-A-2006-141297

  A skin material used for a vehicle seat has a thickness and elasticity. When a stitch is formed on a thick and elastic sewing object, the sewing object may shrink and the surface of the sewing object may be displaced. For example, when forming the second stitch after forming the first stitch based on the sewing data, when the surface of the sewing object is displaced by the formation of the first stitch, the second stitch is moved to the target position of the sewing object. May be difficult to form. Despite a situation where it is difficult to form a stitch at the target position of the sewing object, if the sewing process is continued, a defective sewing object may be manufactured or the sewing machine may operate abnormally. There is.

  An object of the present invention is to suppress the production of a defective sewing object and the occurrence of abnormal operation of the sewing machine.

  According to the first aspect of the present invention, a holding member capable of holding and moving a sewing object in a predetermined plane including a sewing position immediately below a sewing needle, an actuator for moving the holding member, and a sewing object An imaging device capable of photographing an object, and sewing data for acquiring first sewing data referred to in a first sewing process and second sewing data referred to in a second sewing process performed after the first sewing process An acquisition unit, an initial position data acquisition unit that acquires initial position data indicating an initial position of a characteristic pattern arranged on the sewing target, and based on image data of the sewing target captured by the imaging device. A current position data acquisition unit for acquiring current position data indicating a current position of the characteristic pattern; and the sewing object based on the initial position data and the current position data. An abnormality detection unit that detects an abnormality, and when an abnormality is detected, outputs a detection result of the abnormality detection unit. When no abnormality is detected, the actuator detects the abnormality based on the first sewing data and the second sewing data. A control unit that outputs a control signal to be controlled.

  According to the second aspect of the present invention, the first sewing data referred to in the first sewing process and the second sewing data referred to in the second sewing process performed after the first sewing process are acquired. Acquiring the initial position data indicating the initial position of the characteristic pattern arranged on the sewing object, and acquiring the current position data indicating the current position of the characteristic pattern based on the image data of the sewing object And detecting an abnormality of the sewing target object based on the initial position data and the current position data.If an abnormality is detected, a detection result is output, and if no abnormality is detected, the second Forming a stitch on the sewing object by relatively moving the sewing needle and the sewing object in a predetermined plane based on the first sewing data and the second sewing data. A method is provided.

  ADVANTAGE OF THE INVENTION According to the aspect of this invention, manufacture of a defective sewing object and generation | occurrence | production of the abnormal operation | movement of a sewing machine can be suppressed.

FIG. 1 is a perspective view illustrating an example of the sewing machine according to the present embodiment. FIG. 2 is a perspective view showing a part of the sewing machine according to the embodiment. FIG. 3 is a perspective view showing a part of the sewing machine according to the present embodiment. FIG. 4 is a cross-sectional view illustrating an example of the sewing target object according to the present embodiment. FIG. 5 is a plan view illustrating an example of the sewing target object according to the present embodiment. FIG. 6 is a cross-sectional view illustrating an example of the sewing target object according to the present embodiment. FIG. 7 is a functional block diagram illustrating an example of the control device according to the present embodiment. FIG. 8 is a diagram illustrating an example of a characteristic pattern of the sewing target according to the present embodiment. FIG. 9 is a diagram for explaining a method of calculating the amount of displacement according to the present embodiment. FIG. 10 is a diagram for explaining a method of calculating the amount of displacement according to the present embodiment. FIG. 11 is a diagram for explaining a method of calculating the amount of displacement according to the present embodiment. FIG. 12 is a flowchart illustrating an example of the sewing method according to the present embodiment. FIG. 13 is a flowchart illustrating an example of the sewing method according to the present embodiment. FIG. 14 is a schematic diagram for explaining an example of the sewing method according to the present embodiment. FIG. 15 is a schematic diagram for explaining an example of the sewing method according to the present embodiment. FIG. 16 is a schematic diagram for explaining an example of the sewing method according to the present embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto. The components of the embodiments described below can be appropriately combined. In some cases, some components are not used.

  In the present embodiment, a local coordinate system (hereinafter, referred to as “sewing machine coordinate system”) is defined for the sewing machine 1. The sewing machine coordinate system is defined by an XYZ orthogonal coordinate system. In the present embodiment, a description will be given of the positional relationship between the components based on the sewing machine coordinate system. A direction parallel to the X axis in a predetermined plane is defined as an X axis direction. A direction parallel to the Y axis in a predetermined plane orthogonal to the X axis is defined as a Y axis direction. A direction parallel to the Z axis orthogonal to the predetermined plane is defined as a Z axis direction. In the present embodiment, a plane including the X axis and the Y axis is referred to as an XY plane. A plane including the X axis and the Z axis is referred to as an XZ plane. A plane including the Y axis and the Z axis is referred to as a YZ plane. The XY plane is parallel to the predetermined plane. The XY plane, the XZ plane, and the YZ plane are orthogonal to each other. In the present embodiment, the XY plane and the horizontal plane are parallel. The Z-axis direction is a vertical direction. The + Z direction is upward and the -Z direction is downward. Note that the XY plane may be inclined with respect to the horizontal plane.

  The sewing machine 1 will be described with reference to FIGS. FIG. 1 is a perspective view illustrating an example of a sewing machine 1 according to the present embodiment. FIG. 2 is a perspective view showing a part of the sewing machine 1 according to the present embodiment. In the present embodiment, the sewing machine 1 is an electronic cycle sewing machine. The sewing machine 1 includes a sewing machine main body 10, an operation device 20 operated by an operator, an imaging device 30 capable of photographing the sewing object S, and a control device 40 for controlling the sewing machine 1.

  The sewing machine main body 10 is mounted on the upper surface of the table 2. The sewing machine main body 10 includes a sewing machine frame 11, a needle bar 12 supported by the sewing machine frame 11, a needle plate 13 supported by the sewing machine frame 11, and a holding member 15 supported by the sewing machine frame 11 via a support member 14. An actuator 16 for generating power for moving the needle bar 12, an actuator 17 for generating power for moving the holding member 15, and an actuator 18 for generating power for moving at least a part of the holding member 15.

  The sewing machine frame 11 includes a horizontal arm 11A extending in the Y-axis direction, a bed 11B arranged below the horizontal arm 11A, a vertical arm 11C connecting the + Y side end of the horizontal arm 11A and the bed 11B. And a head 11D disposed on the −Y side of the horizontal arm 11A.

  The needle bar 12 holds the sewing needle 3. The needle bar 12 holds the sewing machine needle 3 so that the sewing machine needle 3 and the Z axis are parallel. The needle bar 12 is supported by the head 11D so as to be movable in the Z-axis direction.

  The needle plate 13 supports the sewing object S. The needle plate 13 supports the holding member 15. The needle plate 13 is supported by the bed 11B. The needle plate 13 is disposed below the holding member 15.

  The holding member 15 holds the sewing object S. The holding member 15 is capable of holding and moving the sewing object S in the XY plane including the sewing position Ps immediately below the sewing needle 3. The holding member 15 is capable of holding and moving the sewing object S in the XY plane including the shooting position Pf of the imaging device 30. The stitch GP is formed on the sewing object S by moving the holding member 15 in the XY plane including the sewing position Ps based on sewing data described later while holding the sewing object S. The holding member 15 is supported by the horizontal arm 11A via the support member 14.

  The holding member 15 has a pressing member 15A and a lower plate 15B that are arranged to face each other. The holding member 15A is a frame-shaped member and is movable in the Z-axis direction. The inside of the holding member 15A is referred to as a sewing area PA. Data including at least the shape and size of the sewing area PA is stored in the storage device 60 as mask data. The lower plate 15B is arranged below the holding member 15A. The holding member 15 holds the sewing object S by sandwiching the sewing object S between the holding member 15A and the lower plate 15B.

  When the holding member 15A moves in the + Z direction, the holding member 15A and the lower plate 15B separate from each other. Thereby, the operator can arrange the sewing target object S between the holding member 15A and the lower plate 15B. When the holding member 15A moves in the −Z direction in a state where the sewing object S is disposed between the holding member 15A and the lower plate 15B, the sewing object S is sandwiched between the holding member 15A and the lower plate 15B. Thereby, the sewing object S is held by the holding member 15. The holding of the sewing object S by the holding member 15 is released by the movement of the holding member 15A in the + Z direction. Thereby, the worker can take out the sewing target object S from between the holding member 15A and the lower plate 15B.

  The frame member 15C arranged on the holding member 15 will be described with reference to FIG. FIG. 3 is a perspective view showing a part of the sewing machine according to the present embodiment. The frame member 15C is arranged inside the holding member 15A. The frame member 15C is a frame-shaped member that exposes an area where the stitch GP is formed on the sewing object S in the sewing area PA and covers another area. The area where the sewing area PA is exposed in the frame member 15C, in other words, the grooved area is referred to as the in-frame sewing area PA1. Data including at least the shape and size of the in-frame sewing area PA1 is stored in the storage device 60 as mask data.

  The actuator 16 generates power for moving the needle bar 12 in the Z-axis direction. The actuator 16 includes a pulse motor. The actuator 16 is arranged on the horizontal arm 11A.

  A horizontal arm shaft extending in the Y-axis direction is arranged inside the horizontal arm 11A. The actuator 16 is connected to the end on the + Y side of the horizontal arm shaft. The −Y side end of the horizontal arm shaft is connected to the needle bar 12 via a power transmission mechanism arranged inside the head 11D. The operation of the actuator 16 causes the horizontal arm shaft to rotate. The power generated by the actuator 16 is transmitted to the needle bar 12 via a horizontal arm shaft and a power transmission mechanism. Thereby, the sewing machine needle 3 held by the needle bar 12 reciprocates in the Z-axis direction.

  A timing belt extending in the Z-axis direction is disposed inside the vertical arm 11C. In addition, a bed shaft extending in the Y-axis direction is arranged inside the bed 11B. Pulleys are arranged on each of the horizontal arm shaft and the bed shaft. The timing belt is wound around each of a pulley arranged on the horizontal arm shaft and a pulley arranged on the bed shaft. The horizontal arm shaft and the bed shaft are connected via a power transmission mechanism including a timing belt.

  A shuttle is arranged inside the bed 11B. The bobbin accommodates a bobbin housed in a bobbin case. By the operation of the actuator 16, each of the horizontal arm shaft and the bed shaft rotates. The power generated by the actuator 16 is transmitted to the shuttle via the horizontal arm shaft, the timing belt, and the bed shaft. Thus, the shuttle rotates in synchronization with the reciprocating movement of the needle bar 12 in the Z-axis direction.

  The actuator 17 generates power for moving the holding member 15 in the XY plane. Actuator 17 includes a pulse motor. The actuator 17 includes an X-axis motor 17X that generates power for moving the holding member 15 in the X-axis direction, and a Y-axis motor 17Y that generates power for moving the holding member 15 in the Y-axis direction. The actuator 17 is arranged inside the bed 11B.

  The power generated by the actuator 17 is transmitted to the holding member 15 via the support member 14. Thus, the holding member 15 is movable between the sewing needle 3 and the needle plate 13 in the X-axis direction and the Y-axis direction. By the operation of the actuator 17, the holding member 15 can move while holding the sewing object S in the XY plane including the sewing position Ps immediately below the sewing needle 3.

  The actuator 18 generates power for moving the holding member 15A of the holding member 15 in the Z-axis direction. The actuator 18 includes a pulse motor. When the holding member 15A moves in the + Z direction, the holding member 15A and the lower plate 15B are separated from each other. By moving the holding member 15A in the −Z direction, the sewing target S is sandwiched between the holding member 15A and the lower plate 15B.

  As shown in FIG. 2, the sewing machine main body 10 has a middle pressing member 19 disposed around the sewing needle 3. The intermediate presser member 19 presses the sewing object S around the sewing needle 3. The intermediate pressing member 19 is supported by the head 11D so as to be movable in the Z-axis direction. Inside the head 11D, a middle presser motor that generates power for moving the middle presser member 19 in the Z-axis direction is arranged. By the operation of the intermediate presser motor, the intermediate presser member 19 moves in the Z-axis direction in synchronization with the needle bar 12. The lifting of the sewing object S due to the movement of the sewing needle 3 is suppressed by the middle presser member 19.

  The operation device 20 is operated by an operator. When the operation device 20 is operated, the sewing machine 1 operates. In the present embodiment, the operation device 20 includes an operation panel 21 and an operation pedal 22.

  The operation panel 21 generates input data by being operated by a worker and a display device including a flat panel display such as a liquid crystal display (LCD: Liquid Crystal Display) or an organic EL display (OELD: Organic Electroluminescence Display). An input device. In the present embodiment, the input device includes a touch sensor arranged on the display screen of the display device. That is, in the present embodiment, the operation panel 21 includes a touch panel having the function of an input device. The operation panel 21 is mounted on the upper surface of the table 2. The operation pedal 22 is arranged below the table 2. The operator operates the operation pedal 22 with the foot. When at least one of the operation panel 21 and the operation pedal 22 is operated by the operator, the sewing machine 1 operates.

  The imaging device 30 captures an image of the sewing target S held by the holding member 15. The imaging device 30 includes an optical system and an image sensor that receives light incident through the optical system. The image sensor includes a CCD (Couple Charged Device) image sensor or a CMOS (Complementary Metal Oxide Semiconductor) image sensor.

  The imaging device 30 is arranged above the needle plate 13 and the holding member 15. The photographing position Pf includes the position of the optical axis AX of the optical system of the imaging device 30. An imaging area FA is defined in the imaging device 30. The photographing area FA includes a visual field area of the optical system of the imaging device 30. The photographing area FA includes a photographing position Pf. The imaging device 30 acquires image data of at least a part of the sewing target object S arranged in the shooting area FA. The imaging device 30 captures an image of at least a part of the sewing target S arranged inside the holding member 15A from above.

  The position of the imaging device 30 is fixed. The relative position between the imaging device 30 and the sewing machine frame 11 is fixed. The relative position between the optical axis AX of the optical system of the imaging device 30 and the sewing machine needle 3 in the XY plane is fixed. The relative position data indicating the relative position between the optical axis AX of the optical system of the imaging device 30 and the sewing machine needle 3 in the XY plane is known data that can be derived from the design data of the sewing machine 1.

  When a difference occurs between the actual position of the imaging device 30 and the position in the design data due to the mounting error of the imaging device 30, after the mounting of the imaging device 30, the position of the sewing machine needle 3 in the XY plane is changed. The measured position of the sewing needle 3 is moved toward the imaging device 30 by the amount of known data, and the difference between the actual position of the imaging device 30 in the XY plane and the moved position of the sewing needle 3 is measured. By doing so, it is possible to calculate an accurate relative position between the optical axis AX of the optical system of the imaging device 30 and the sewing machine needle 3 based on the measurement result of the difference.

  Further, the sewing machine 1 has a drive amount sensor 31 for detecting the drive amount of the actuator 16 and a drive amount sensor 32 for detecting the drive amount of the actuator 17.

  The drive amount sensor 31 includes an encoder that detects the amount of rotation of the pulse motor serving as the actuator 16. The detection data of the drive amount sensor 31 is output to the control device 40.

  The drive amount sensor 32 includes an X-axis sensor 32X that detects a rotation amount of the X-axis motor 17X, and a Y-axis sensor 32Y that detects a rotation amount of the Y-axis motor 17Y. The X-axis sensor 32X includes an encoder that detects a rotation amount of the X-axis motor 17X. Y-axis sensor 32Y includes an encoder that detects the amount of rotation of Y-axis motor 17Y. The detection data of the drive amount sensor 32 is output to the control device 40.

  The drive amount sensor 32 functions as a position sensor that detects the position of the holding member 15 in the XY plane. The driving amount of the actuator 17 and the moving amount of the holding member 15 correspond one to one.

  The X-axis sensor 32X can detect the amount of movement of the holding member 15 in the X-axis direction from the origin in the sewing machine coordinate system by detecting the amount of rotation of the X-axis motor 17X. The Y-axis sensor 32Y can detect the amount of rotation of the holding member 15 from the origin in the sewing machine coordinate system in the Y-axis direction by detecting the amount of rotation of the Y-axis motor 17Y.

  The sewing object S will be described with reference to FIGS. 4 and 5. FIG. 4 is a cross-sectional view illustrating an example of the sewing target object S according to the present embodiment. FIG. 5 is a plan view illustrating an example of the sewing target object S according to the present embodiment. 4 and 5 show the sewing target S before the sewing process is performed. In the present embodiment, the sewing object S is a skin material used for a vehicle seat.

  As shown in FIG. 4, the sewing target S has a surface material 4, a pad material 5, and a backing material 6. A hole 7 is formed in the surface material 4.

  The surface of the front material 4 is a seating surface that comes into contact with the occupant when the occupant sits on the vehicle seat. The surface material 4 includes at least one of a woven fabric, a nonwoven fabric, and leather. The pad material 5 has elasticity. The pad material 5 contains, for example, urethane resin. The backing 6 includes at least one of a woven fabric, a nonwoven fabric, and leather.

  As shown in FIG. 5, a plurality of holes 7 are arranged in the surface material 4. The holes 7 are arranged in a prescribed pattern DP. In the present embodiment, the specified pattern DP includes a plurality of reference patterns DPh. One reference pattern DPh is formed by a plurality of holes 7. In the present embodiment, the reference pattern DPh is formed by the plurality of holes 7. In the present embodiment, one reference pattern DPh is formed by 17 holes 7.

  As shown in FIG. 5, the reference patterns DPh are arranged on the front material 4 at intervals. The reference patterns DPh are arranged at regular intervals in each of the X-axis direction and the Y-axis direction. Reference patterns DPh having different positions in the Y-axis direction are arranged between the reference patterns DPh adjacent in the X-axis direction. No hole 7 is formed between adjacent reference patterns DPh. In the following description, a region on the surface of the surface material 4 where the holes 7 are not formed between the reference patterns DPh is referred to as a stitch forming region MA. In the stitch formation area MA, a target pattern RP of a stitch GP formed on the sewing object S is defined.

  A displacement generated on the surface of the sewing object S when the stitch GP is formed on the sewing object S having a thickness and elasticity will be described with reference to FIG. FIG. 6 is a cross-sectional view illustrating an example of the sewing target object S according to the present embodiment. FIG. 6 shows the sewing target S after the sewing process has been performed. The sewing object S has a thickness and elasticity. By forming the stitch GP on the thick and elastic sewing object S, there is a high possibility that the sewing object S shrinks as shown in FIG. When the sewing target S contracts, the surface of the sewing target S may be displaced. When the surface of the sewing target S is displaced in the XY plane, there is a high possibility that the target position of the stitch GP defined on the surface of the sewing target S is displaced in the XY plane. When the target position of the stitch GP is displaced in the XY plane, if the holding member 15 is moved according to the target pattern RP, it becomes difficult to form the stitch GP at the target position. In this embodiment, even if the sewing object S shrinks due to the formation of the stitch GP and the surface of the sewing object S is displaced, the stitch GP is held in accordance with the displacement amount so that the next stitch GP is formed at the target position. The member 15 is moved.

  When the amount of displacement of the surface of the sewing target object S exceeds the allowable range, the holding member 15 moves largely in the XY plane according to the amount of displacement. As a result, for example, at least a part of the holding member 15 may be arranged at the sewing position Ps immediately below the sewing needle 3. When the holding member 15 is disposed at the sewing position Ps, there is a possibility that the sewing needle 3 contacts the holding member 15. That is, when the amount of displacement of the surface of the sewing object S exceeds the allowable range, the sewing machine 1 may operate abnormally. The abnormal operation of the sewing machine 1 includes driving the actuator 17 so that at least a part of the holding member 15 is arranged at the sewing position Ps.

  In the present embodiment, when the amount of displacement of the surface of the sewing object S exceeds the allowable range, the control device 40 determines that the sewing is abnormal, outputs an abnormal result, and prevents the sewing process of the next stitch GP from continuing. To control. Thereby, the occurrence of the abnormal operation of the sewing machine 1 is suppressed. Further, when the displacement of the surface of the sewing object S is within the allowable range, the control device 40 sets the next stitch even if the sewing object S shrinks due to the formation of the stitch GP and the surface of the sewing object S is displaced. Control is performed so that GP is formed at the target position.

  The control device 40 will be described with reference to FIG. FIG. 7 is a functional block diagram illustrating an example of the control device 40 according to the present embodiment. The control device 40 outputs a control signal for controlling the sewing machine 1. Control device 40 includes a computer system. The control device 40 includes an input / output interface device 50, a storage device 60 including a nonvolatile memory such as a ROM (Read Only Memory) or a storage and a volatile memory such as a RAM (Random Access Memory), and a CPU (Central Processing). And an arithmetic processing unit 70 including a processor such as a unit.

  As shown in FIG. 7, the controller 40 includes an actuator 16 for moving the sewing machine needle 3 in the Z-axis direction, an actuator 17 for moving the holding member 15 in the XY plane, and a pressing member 15A for the holding member 15 in the Z direction. The actuator 18 that moves in the axial direction, the operation device 20, the imaging device 30, and the notification device 80 are connected via the input / output interface device 50.

  In the present embodiment, the control device 40 is connected with a drive amount sensor 31 that detects the drive amount of the actuator 16 and a drive amount sensor 32 that detects the drive amount of the actuator 17.

  The control device 40 controls the actuator 16 based on the detection data of the drive amount sensor 31. The control device 40 determines, for example, the operation timing of the actuator 16 based on the detection data of the drive amount sensor 31.

  The control device 40 controls the actuator 17 based on the detection data of the drive amount sensor 32. The control device 40 performs feedback control of the actuator 17 based on the detection data of the drive amount sensor 32 so that the holding member 15 moves to the target position.

  The control device 40 calculates the position of the holding member 15 in the XY plane based on the detection data of the drive amount sensor 32. The amount of movement of the holding member 15 from the origin in the XY plane is detected based on the detection data of the drive amount sensor 32. The control device 40 calculates the position of the holding member 15 in the XY plane based on the detected movement amount of the holding member 15.

  The storage device 60 includes a sewing data storage unit 61 and a program storage unit 62.

  The sewing data storage unit 61 stores sewing data.

  The sewing data will be described with reference to FIG. As described above, the sewing data includes the target pattern RP of the stitch GP formed on the sewing target S and the moving condition of the holding member 15.

  The target pattern RP includes a target shape or a target pattern of the stitch GP formed on the sewing target S. The target pattern RP is defined in the sewing machine coordinate system.

  The movement condition of the holding member 15 includes a movement locus of the holding member 15 defined in the sewing machine coordinate system. The movement path of the holding member 15 includes the movement path of the holding member 15 in the XY plane. The moving condition of the holding member 15 is determined based on the target pattern RP.

  The sewing data includes a target position of the stitch GP defined on the surface of the sewing object S. In the following description, the target position of the stitch GP defined on the surface of the sewing object S is referred to as a stitch formation target position. The stitch formation target position is defined in the sewing machine coordinate system.

  The stitch formation target position is defined in the stitch formation area MA. The sewing machine 1 performs a sewing process based on the sewing data so that the stitch GP is formed at the stitch formation target position.

  The sewing data includes a plurality of pieces of sewing data for forming each of the plurality of stitches GP. In the present embodiment, the sewing data includes first sewing data for forming the first stitch GP1, second sewing data for forming the second stitch GP2, and similarly the third stitch GP3 to the tenth stitch GP10. Is included from the third sewing data to the tenth sewing data.

  As shown in FIG. 5, the target pattern RP includes a first target pattern RP1, a second target pattern RP2, and similarly, a third target pattern RP3 to a tenth target pattern RP10. In the present embodiment, a plurality of target patterns RP (RP1, RP2, RP3, RP4, RP5, RP6, RP7, RP8, RP9, RP10) are defined in the Y-axis direction. In the sewing machine coordinate system, each of the plurality of target patterns RP is separated. One target pattern RP is defined in a line shape. In the present embodiment, one target pattern RP extends in the X-axis direction and is defined in a zigzag shape in the Y-axis direction. The stitch formation target position is defined in the stitch formation area MA in the X-axis direction and in a zigzag manner in the Y-axis direction, corresponding to the target pattern RP.

  The first sewing data includes the first target pattern RP1 of the first stitch GP1 formed on the sewing target S in the first sewing process. Further, the first sewing data includes a moving condition of the holding member 15 in the XY plane in the first sewing process.

  The second sewing data includes the second target pattern RP2 of the second stitch GP2 formed on the sewing target S in the second sewing process. The second sewing data includes a condition for moving the holding member 15 in the XY plane in the second sewing process.

  Similarly, each of the third sewing data to the tenth sewing data is the third target of the third stitch GP3 to the tenth stitch GP10 formed on the sewing object S in each of the third sewing processing to the tenth sewing processing. Each of the pattern RP3 to the tenth target pattern RP10 is included. Further, each of the third sewing data to the tenth sewing data includes the moving condition of the holding member 15 in the XY plane in each of the third sewing processing to the tenth sewing processing.

  The first sewing data is referred to in the first sewing processing. The second sewing data is referred to in the second sewing processing. Similarly, each of the third sewing data to the tenth sewing data is referred to in each of the third sewing processing to the tenth sewing processing.

  The first sewing process includes a process of forming the first stitch GP1 on the sewing target S based on the first target pattern RP1. The first sewing process is a process of first forming a stitch GP on the sewing object S after the sewing object S is held by the holding member 15.

  The second sewing process includes a process of forming the second stitch GP2 on the sewing target S based on the second target pattern RP2. The second sewing process is performed after the first sewing process.

  Similarly, in each of the third sewing process to the tenth sewing process, each of the third stitch GP3 to the tenth stitch GP10 is formed on the sewing target S based on each of the third target pattern RP3 to the tenth target pattern RP10. Including processing. The third to tenth sewing processes are sequentially performed.

  The program storage unit 62 stores a computer program for controlling the sewing machine 1. The sewing data stored in the sewing data storage unit 61 is input to a computer program stored in the program storage unit 62. The computer program is read into the arithmetic processing unit 70. The arithmetic processing unit 70 controls the sewing machine 1 according to a computer program stored in the program storage unit 62.

  The arithmetic processing unit 70 includes a sewing data acquisition unit 71, an initial position data acquisition unit 72, a current position data acquisition unit 73, a displacement amount calculation unit 74, a correction data generation unit 75, an abnormality detection unit 76, And a portion 77.

  The sewing data acquisition unit 71 acquires sewing data from the sewing data storage unit 61. In the present embodiment, the sewing data acquisition unit 71 converts the first sewing data referred to in the first sewing process and the second sewing data referred to in the second sewing process performed after the first sewing process into the sewing data. Obtained from the storage unit 61. Similarly, the sewing data acquisition unit 71 acquires from the sewing data storage unit 61 each of the third sewing data to the tenth sewing data referred to in each of the third sewing processing to the tenth sewing processing.

  The initial position data obtaining unit 72 obtains initial position data indicating the initial position of the characteristic pattern UP arranged on the sewing target S. The initial position data of the characteristic pattern UP indicates an initial position of the characteristic pattern UP in the sewing machine coordinate system.

  The initial position data of the characteristic pattern UP is known data such as CAD (Computer Aided Design) data which can be derived from design data of the sewing target S. The initial position data of the characteristic pattern UP is stored in the sewing data storage unit 61. The initial position data acquisition unit 72 acquires the initial position data of the characteristic pattern UP from the sewing data storage unit 61.

  The initial position of the characteristic pattern UP includes the position of the characteristic pattern UP before the sewing process is performed. The initial position data acquisition unit 72 determines the initial position of the characteristic pattern UP based on the image data of the characteristic pattern UP of the sewing object S before the sewing process is started, without being based on the design data of the sewing object S. Can be obtained.

  The current position data acquisition unit 73 acquires current position data indicating the current position of the characteristic pattern UP arranged on the sewing target S based on the image data of the sewing target S captured by the imaging device 30. The current position data of the characteristic pattern UP indicates the current position of the characteristic pattern UP in the sewing machine coordinate system.

  In the present embodiment, the characteristic pattern UP of the sewing target S is a part of the specified pattern DP. In the present embodiment, the feature pattern UP is a part of the reference pattern DPh. In the present embodiment, as shown in FIG. 8, the feature pattern UP is a pattern including both the obtuse corners K3 and K4 of the reference pattern DPh. The feature pattern UP is a pattern that can be specified by a pattern matching method, which is a type of image processing method. The current position data acquisition unit 73 performs image processing on the image data captured by the imaging device 30 by the pattern matching method, and calculates the current position data of the characteristic pattern UP in the sewing machine coordinate system.

  A method of acquiring current position data indicating the current position of the characteristic pattern UP arranged on the sewing target S will be described. First, the control device 40 controls the actuator 17 to move the characteristic pattern UP of the sewing object S held by the holding member 15 to the shooting area FA of the imaging device 30. In the present embodiment, the center position C of the feature pattern UP is moved to a shooting position Pf which is the center position of the shooting area FA of the imaging device 30. The imaging device 30 captures the characteristic pattern UP arranged in the capturing area FA. The current position data acquisition unit 73 acquires image data of the characteristic pattern UP. The current position data acquisition unit 73 performs image processing on the image data of the characteristic pattern UP by a pattern matching method, and specifies the specific pattern UP. The drive amount sensor 32 detects the position of the holding member 15 in the sewing machine coordinate system when the characteristic pattern UP is arranged in the photographing area FA of the imaging device 30. As described above, the drive amount sensor 32 functions as a position sensor that detects the position of the holding member 15 in the XY plane. The current position data acquisition unit 73 acquires the detection data of the drive amount sensor 32. In this manner, the current position data acquisition unit 73 determines whether the characteristic pattern UP located in the imaging area FA is based on the detection data of the drive amount sensor 32 when the characteristic pattern UP is located in the imaging area FA. Current position data indicating the current position in the XY plane can be obtained.

  Even after the sewing process is performed, the current position data indicating the current position of the characteristic pattern UP can be obtained in the same manner. First, the imaging device 30 captures the characteristic pattern UP of the sewing target S after at least the sewing process is performed. The current position data acquisition unit 73 can acquire the current position data of the characteristic pattern UP based on the image data of the sewing target object S captured by the imaging device 30 after the sewing process is performed.

  The displacement amount calculation unit 74 calculates the characteristic pattern based on the initial position data of the characteristic pattern UP acquired by the initial position data acquisition unit 72 and the current position data of the characteristic pattern UP acquired by the current position data acquisition unit 73. The displacement of the UP is calculated.

  The initial position of the characteristic pattern UP includes the position of the characteristic pattern UP in the sewing machine coordinate system before the sewing process is performed. The current position of the characteristic pattern UP includes the position of the characteristic pattern UP in the sewing machine coordinate system after the sewing process is performed. The displacement amount calculation unit 74 calculates the displacement amount of the feature pattern UP displaced by performing the sewing process.

  As described above, when the sewing process is performed, the sewing target S may shrink and the surface of the sewing target S may be displaced. When the surface of the sewing object S is displaced, the position of the feature pattern UP in the XY plane is also displaced. The displacement calculating unit 74 calculates the displacement of the feature pattern UP based on the initial position data of the feature pattern UP before the sewing process is performed and the current position data of the feature pattern UP after the sewing process is performed. Is calculated.

  A method of calculating the displacement after the first sewing process is performed will be described with reference to FIGS. 9, 10, and 11. FIG. Hereinafter, a method of calculating the amount of displacement in each of two feature patterns UPa (UPa0, UPa1) and feature pattern UPb (UPb0, UPb1) arranged in the X-axis direction will be described.

  In FIG. 9, the characteristic patterns UPa0 and UPb0 before the first sewing process is performed are indicated by broken lines, and the characteristic patterns UPa1 and UPb1 after the first sewing process are executed are indicated by solid lines. Each image data of the characteristic pattern UPa0, the characteristic pattern UPb0, the characteristic pattern UPa1, and the characteristic pattern UPb1 is captured by the imaging device 30.

  The center position Ca0 is the center position of the feature pattern UPa0, and the center position Cb0 is the center position of the feature pattern UPb0.

  Before the first sewing process is performed, the characteristic pattern UPa0 and the characteristic pattern UPb0 are not displaced. That is, before the first sewing process is performed, the initial position of the feature pattern UPa0 stored in the sewing data storage unit 61 matches the current position of the feature pattern UPa0. The initial position of the characteristic pattern UPb0 stored in the sewing data storage unit 61 matches the current position of the characteristic pattern UPb0.

  As shown in FIG. 9, the first sewing process is performed based on the first sewing data and the first stitch GP1 is formed, so that at least a part of the sewing target S is contracted. As a result, the feature pattern UPa0 is displaced to the feature pattern UPa1 in the XY plane. The center position Ca0 is displaced to the center position Ca1 in the XY plane. The feature pattern UPb0 is displaced to the feature pattern UPb1 in the XY plane. The center position Cb0 is displaced to the center position Cb1 in the XY plane.

  FIG. 10 and FIG. 11 are diagrams schematically illustrating an example of a method of calculating the amount of displacement of the feature pattern UP according to the present embodiment. The displacement of the feature pattern UP includes a shift, a scale, and a rotation.

  In the present embodiment, after the displacement of the feature pattern UPa is calculated, the displacement of the feature pattern UPb is calculated. FIG. 10 is a diagram schematically illustrating an example of a method of calculating the amount of displacement of the feature pattern UPa. FIG. 11 is a diagram schematically illustrating an example of a method of calculating the amount of displacement of the feature pattern UPb.

  As shown in FIG. 10, when calculating the amount of displacement of the feature pattern UPa, a fixed point P0 is set on the sewing object S. The fixed point P0 is set to a point whose position in the sewing machine coordinate system is known. The fixed point P0 is set to, for example, a point at which no displacement occurs even when the first sewing process is performed or a point at which displacement is sufficiently suppressed. In the present embodiment, the fixed point P0 is set as a part of the first stitch GP1.

  By performing the first sewing process, the center position Ca0 of the feature pattern UPa0 is displaced to the center position Ca1. The displacement amount calculation unit 74 calculates a shift at the center position Ca based on a vector from the center position Ca0 to the center position Ca1. Further, the displacement amount calculation unit 74 calculates a first vector from the fixed point P0 to the center position Ca0 and a second vector from the fixed point P0 to the center position Ca1. The displacement amount calculation unit 74 calculates the scale at the center position Ca based on the ratio between the length of the first vector and the length of the second vector. Further, the displacement amount calculation unit 74 calculates the rotation at the center position Ca based on the angle between the first vector and the second vector with respect to the fixed point P0.

  The calculation method of the shift, scale, and rotation at the center position Ca in the feature pattern UPa has been described above. The displacement amount calculation unit 74 performs the same processing for each of the plurality of positions Pn of the feature pattern UPa. FIG. 10 schematically shows a state in which a shift, a scale, and a rotation at a position Pi among a plurality of positions Pn are calculated. Thereby, a shift, a scale, and a rotation are calculated for each of the plurality of positions of the feature pattern UPa. As described above, the displacement amount calculation unit 74 can calculate the displacement amount and the displacement direction of the feature pattern UPa in the sewing machine coordinate system after the first sewing process has been performed.

  As shown in FIG. 11, when calculating the amount of displacement of the characteristic pattern UPb, a fixed point P0 is set on the sewing object S. As described above, the fixed point P0 is set to a point whose position in the sewing machine coordinate system is known. In the present embodiment, the position Pn whose position has been calculated by the processing described with reference to FIG. 10 is set as the fixed point P0.

  By performing the first sewing process, the center position Cb0 of the feature pattern UPb0 is displaced to the center position Cb1. The displacement amount calculation unit 74 calculates a shift at the center position Cb based on a vector from the center position Cb0 to the center position Cb1. Further, the displacement amount calculation unit 74 calculates a third vector from the fixed point P0 to the center position Cb0 and a fourth vector from the fixed point P0 to the center position Cb1. The displacement amount calculation unit 74 calculates the scale at the center position Cb based on the ratio between the length of the third vector and the length of the fourth vector. Further, the displacement amount calculation unit 74 calculates the rotation at the center position Cb based on the angle between the third vector and the fourth vector with respect to the fixed point P0.

  The method of calculating the shift, scale, and rotation at the center position Cb of the feature pattern UPb has been described above. The displacement amount calculation unit 74 performs the same processing for each of the plurality of positions Qn of the feature pattern UPb. FIG. 11 schematically illustrates a state in which a shift, a scale, and a rotation at a position Qi among a plurality of positions Qn are calculated. Thereby, a shift, a scale, and a rotation are calculated for each of the plurality of positions of the feature pattern UPb. As described above, the displacement amount calculation unit 74 can calculate the displacement amount and the displacement direction of the feature pattern UPb in the sewing machine coordinate system after the first sewing process has been performed.

  Here, the method of calculating the amount of displacement in each of the two feature patterns UPa and UPb arranged in the X-axis direction has been described. When three or more feature patterns UP are arranged in the X-axis direction, as described with reference to FIG. 10, the fixed point P0 is set, and the displacement of the first feature pattern UP is set based on the fixed point P0. The amount is calculated. When calculating the displacement amount of the second feature pattern UP adjacent to the first feature pattern UP, as described with reference to FIG. 11, the position of the first feature pattern UP in the sewing machine coordinate system is known. The arbitrary position is set as the fixed point P0, and the displacement amount of the second feature pattern UP is calculated based on the fixed point P0. When calculating the displacement amount of the third feature pattern UP adjacent to the second feature pattern UP, an arbitrary position in the second feature pattern UP whose position in the sewing machine coordinate system is known is set as the fixed point P0. The displacement of the third feature pattern UP is calculated based on the fixed point P0. Hereinafter, in the same procedure, the displacement amount is calculated for each of the plurality of feature patterns UP arranged in the X-axis direction.

  The correction data generation unit 75 corrects the sewing data based on the displacement amount of the characteristic pattern UP calculated by the displacement amount calculation unit 74 to generate correction data. The target pattern RP of the sewing data is generated on the assumption that the sewing target S is not contracted, and is stored in the sewing data storage unit 61. When the sewing object S shrinks due to the execution of the sewing process and the surface of the sewing object S is displaced, the stitch formation target position defined on the surface of the sewing object S is displaced in the XY plane. When the stitch formation target position is displaced in the XY plane, if the holding member 15 is moved based on the sewing data, it becomes difficult to form the stitch GP at the stitch formation target position. When the feature pattern UP is displaced, the correction data generation unit 75 corrects the sewing data based on the displacement amount of the feature pattern UP so that the stitch GP is formed at the stitch formation target position.

  The correction data generation unit 75 determines a relative position in the sewing machine coordinate system between the target pattern RP of the stitch GP and the characteristic pattern UP before the sewing object S contracts, and a stitch GP actually formed on the sewing object S by the sewing process. The correction data is generated such that the relative position in the sewing machine coordinate system between the sewing object S and the characteristic pattern UP after the contraction of the sewing object S is matched. By performing the sewing process based on the correction data, the stitch GP is formed at the stitch formation target position even if the surface of the sewing object S is displaced.

  The correction data generation unit 75 corrects the first sewing data based on the image data captured by the imaging device 30 before the first sewing process is performed, and generates first correction data. The correction data generation unit 75 corrects the second sewing data based on the displacement calculated by the displacement calculation unit 74 to generate second correction data.

  The abnormality detection unit 76 is configured to sew an object to be sewn based on the initial position data of the characteristic pattern UP acquired by the initial position data acquisition unit 72 and the current position data of the characteristic pattern UP acquired by the current position data acquisition unit 73 S abnormality is detected. The abnormality of the sewing target S includes an abnormality in the position of the sewing target S in the XY plane. In addition, the abnormality of the sewing target object S includes an abnormality of the displacement calculated by the displacement calculator 74. Further, the abnormality of the sewing target object S includes an abnormality of the degree of coincidence between the feature pattern UP and the template when the feature pattern UP is subjected to the image processing by the pattern matching method. The abnormality detection unit 76 outputs a detection result to the control unit 77.

  The abnormality of the sewing target object S is an abnormality that may cause an abnormal operation of the sewing machine 1. The abnormal operation of the sewing machine 1 includes an operation in which a defective sewing object S may be manufactured, and a possibility that at least a part of the holding member 15 is disposed at the sewing position Ps and the sewing needle 3 contacts the holding member 15. Including certain actions.

  The abnormality detection unit 76 determines that the position of the sewing object S is abnormal when it is determined that the continuation of the formation of the stitch GP may cause an abnormal operation of the sewing machine 1. More specifically, the abnormality of the position of the sewing object S is detected as follows.

  The current position data acquisition unit 73 performs image processing on the characteristic pattern UP by a pattern matching method using a template to acquire current position data of the characteristic pattern UP. When the degree of coincidence between the feature pattern UP and the template is equal to or smaller than the threshold, the abnormality detection unit 76 determines that the detection result is abnormal. For example, the degree of coincidence is set to a value of 0 or more and 1 or less, where "1" is set when all of the feature pattern UP and the template match, and "0" is set when they do not all match. When the degree of coincidence is equal to or smaller than the threshold, the abnormality detection unit 76 outputs a detection result indicating that the abnormality is present.

  Further, the abnormality detecting unit 76 compares the displacement calculated by the displacement calculating unit 74 with a predetermined threshold to determine whether the displacement of the surface of the sewing target S is abnormal. Is also good. When the displacement calculated by the displacement calculator 74 is larger than the threshold, the abnormality detector 76 may output a detection result indicating that the abnormality is abnormal. As described above, a threshold may be set for each of the shift, scale, and rotation defined as the displacement, and when at least one of the thresholds is larger than the threshold, a detection result indicating an abnormality may be output. The threshold value of the amount of displacement may be derived experimentally, for example. For example, the maximum displacement when the sewing object S is contracted by the sewing process is measured, and the threshold value may be set to a value larger than the maximum displacement.

  The displacement amount threshold may include a first threshold and a second threshold smaller than the first threshold. The first threshold value is used for determining the abnormality of the displacement amount of the sewing target S after the execution of the first sewing process and before the execution of the second sewing process. The second threshold value is used for determining an abnormality in the displacement amount of the sewing object S after the execution of the second sewing process. If the displacement amount is equal to or larger than the first threshold after the execution of the first sewing process and before the execution of the second sewing process, the abnormality detection unit 76 determines that the displacement amount is abnormal. If the amount of displacement is equal to or greater than the second threshold after the execution of the second sewing process, the abnormality detection unit 76 determines that the amount of displacement is abnormal.

  The displacement amount when the first stitch GP1 is first formed by the first sewing process is likely to be larger than the displacement amount when the subsequent stitch GP is formed. Therefore, the first threshold is used to determine the displacement amount after the execution of the first sewing process, and the second threshold value smaller than the first threshold value is used to determine the displacement amount after the execution of the second sewing process. Is used.

  Further, the abnormality detection unit 76 detects an abnormality in the position of the sewing target S based on the correction data generated by the correction data generation unit 75. In the present embodiment, based on the correction data generated by the correction data generation unit 75 and the mask data of the sewing area PA, the abnormality detection unit 76 sets the stitch GP formed based on the correction data outside the sewing area PA. If it is determined to be formed, a detection result indicating an abnormality is output. More specifically, when the stitch GP formed by the correction data deviates from the movement trajectory of the sewing area PA of the holding member 15, the abnormality detection unit 76 outputs a detection result indicating an abnormality. That is, when the correction data that may cause the sewing needle 3 to come into contact with the holding member 15 is generated, the abnormality detection unit 76 outputs a detection result indicating that the abnormality is abnormal.

  Further, when the frame member 15C is mounted on the holding member 15, the abnormality detection unit 76 forms the correction data based on the correction data generated by the correction data generation unit 75 and the mask data of the in-frame sewing area PA1. When it is determined that the stitch GP to be performed is formed outside the in-frame sewing area PA1 of the frame member 15C, in other words, the sewing needle 3 for forming the stitch GP based on the correction data comes into contact with the frame member 15C. If there is a possibility, a detection result indicating an abnormality is output. More specifically, when the stitch GP formed by the correction data deviates from the movement locus of the in-frame sewing area PA1 of the frame member 15C, the abnormality detection unit 76 outputs a detection result indicating that the abnormality is abnormal.

  Further, the abnormality detection unit 76 detects an abnormality in the displacement amount based on the first correction data generated by the correction data generation unit 75. Further, the abnormality detection unit 76 detects an abnormality in the displacement amount based on the second correction data generated by the correction data generation unit 75.

  When an abnormality is detected, the control unit 77 outputs a detection result of the abnormality detection unit 76, and when no abnormality is detected, controls the actuator 17 based on sewing data including at least the first sewing data and the second sewing data. Output a control signal.

  When no abnormality is detected, the controller 77 outputs a control signal for controlling the actuator 17 based on the displacement calculated by the displacement calculator 74. When no abnormality is detected, the control unit 77 outputs a control signal in the second sewing processing based on the second sewing data and the displacement amount.

  When no abnormality is detected, the control unit 77 controls the actuator 17 that moves the holding member 15 based on the second correction data generated based on the displacement amount in the correction data generation unit 75 in the second sewing process. Outputs control signal.

  When no abnormality is detected, the control unit 77 controls the actuator 17 that moves the holding member 15 based on the first correction data generated based on the displacement amount in the correction data generation unit 75 in the first sewing process. Outputs a control signal to control.

  When an abnormality is detected, the control unit 77 outputs a detection result of the abnormality detection unit 76 to the notification device 80. As the notification device 80, at least one of a display device, a printing device, and a light emitting device is exemplified. The notification device 80 operates to notify an abnormality. When the notification device 80 includes a display device, the display device displays the determination result and the data on which the determination is based to notify the abnormality. When the notification device 80 includes a printing device, the printing device outputs the determination result and the data on which the determination is based on a printed matter to notify the abnormality. When the notification device 80 includes a light-emitting device, the light-emitting device issues light to notify an abnormality.

  Next, a sewing method according to the present embodiment will be described with reference to FIGS. FIG. 12 is a flowchart illustrating an example of the sewing method according to the present embodiment. FIG. 13 is a flowchart illustrating an example of the sewing method according to the present embodiment.

  The sewing target S before the stitch GP is formed is set on the holding member 15. The holding member 15 holds the sewing object S (Step S10). The holding member 15 is arranged at the origin in the sewing machine coordinate system.

  The sewing data acquisition unit 71 acquires the first sewing data referred to in the first sewing process from the sewing data storage unit 61 (Step S20).

  The control device 40 acquires the image data of at least two characteristic patterns UP among the plurality of characteristic patterns UP arranged on the sewing target S by the imaging device 30 before the first sewing process is performed (Step S10). S30).

  FIG. 14 is a diagram schematically illustrating the sewing target object S held by the holding member 15 before the first sewing process is performed. As shown in FIG. 14, after the first sewing data including the first target pattern RP1 is obtained, the control device 40 operates the holding member so that the first feature pattern UP1 is arranged in the shooting area FA of the imaging device 30. 15 is moved. After the center position C1 of the first feature pattern UP1 is located at the shooting position Pf of the shooting area FA of the imaging device 30, the imaging device 30 acquires image data of the first feature pattern UP1. After the image data of the first feature pattern UP1 is obtained, the control device 40 moves the holding member 15 so that the second feature pattern UP2 is arranged in the shooting area FA of the imaging device 30. After the center position C2 of the second feature pattern UP2 is located at the shooting position Pf of the shooting area FA of the imaging device 30, the imaging device 30 acquires image data of the second feature pattern UP2.

  The first feature pattern UP1 and the second feature pattern UP2 are feature patterns related to the first sewing process. The feature pattern UP related to the first sewing process is a feature pattern UP closest to a stitch formation target position where the first stitch GP1 is formed by the first sewing process in the sewing machine coordinate system. In other words, the feature pattern UP related to the first sewing process is a feature pattern UP closest to the first target pattern RP1 in the sewing machine coordinate system.

  Each of the first feature pattern UP1 and the second feature pattern UP2 is arranged near a vertex of the first target pattern RP1 defined in a zigzag shape. In the present embodiment, the first characteristic pattern UP1 is arranged near the + X side end of the sewing target S. The second feature pattern UP2 is arranged near the end on the −X side of the sewing target S.

  The abnormality detection unit 76 performs image processing on the first sewing data and the characteristic pattern related to the first sewing processing by a pattern matching method, and determines whether the degree of coincidence is equal to or smaller than a threshold (step S40). For example, when the sewing target object S is arranged with a large shift with respect to the holding member 15, the center position C of each feature pattern UP is arranged with a position shifted with respect to the photographing position Pf. Becomes less than or equal to the threshold. If the degree of coincidence is equal to or greater than the threshold (step S40: Yes), the abnormality detection unit 76 proceeds to step S50. If the degree of coincidence is not equal to or greater than the threshold (step S40: No), the abnormality detection unit 76 proceeds to step S240.

  The correction data generation unit 75 corrects the first sewing data based on the image data of at least two characteristic patterns UP (UP1, UP2) captured by the imaging device 30 before the first sewing process is performed. First correction data is generated (step S50).

  The current position data acquisition unit 73 acquires image data of two characteristic patterns UP (UP1, UP2). The current position data acquisition unit 73 performs image processing on the image data of the first feature pattern UP1 by the pattern matching method, and the position of the holding member 15 when the first feature pattern UP1 is arranged in the imaging area FA of the imaging device 30. Based on the data, the current position data of the first feature pattern UP1 in the sewing machine coordinate system is obtained. Further, the current position data acquisition unit 73 performs image processing on the image data of the second feature pattern UP2 by the pattern matching method, and the holding member 15 when the second feature pattern UP2 is arranged in the shooting area FA of the imaging device 30. , The current position data of the second feature pattern UP2 in the sewing machine coordinate system is obtained. The correction data generation unit 75 corrects the first sewing data based on the current position data of the first characteristic pattern UP1 and the current position data of the second characteristic pattern UP2 acquired by the current position data acquisition unit 73, and performs the first sewing data correction. Generate correction data.

  The sewing object S before the first stitch GP1 is formed is held by the holding member 15 after being set on the needle plate 13 by the operator. Also, due to the cutting error of the sewing target S, there is a high possibility that the relative position between the edge of the sewing target S and the characteristic pattern UP differs for each sewing target S. In other words, even if the holding member 15 is arranged at the origin of the sewing machine coordinate system, the initial position of the characteristic pattern UP in the sewing machine coordinate system may be changed due to an installation error or a cutting error of the sewing object S by the operator. It is highly possible that each object S differs. On the other hand, the position of the first target pattern RP1 stored in the sewing data storage unit 61 in the sewing machine coordinate system is predetermined. Therefore, when the first sewing process is performed according to the first target pattern RP1 obtained by the sewing data obtaining unit 71, the stitch GP is formed at a position different from the stitch formation target position on the surface of the sewing object S. there is a possibility.

  In the present embodiment, before the first sewing process is performed, image data of at least two characteristic patterns UP (UP1, UP2) of the sewing target object S held by the holding member 15 is acquired, and the image data is obtained. , The current position data of the two feature patterns UP (UP1, UP2) in the XY plane is obtained. The stitch formation target position data indicating the relative position between the characteristic pattern UP of the sewing target S and the stitch formation target position is known data that can be derived from the design data of the sewing target S, and is stored in the sewing data storage unit 61. Have been. Therefore, the correction data generation unit 75 is based on the current position data of the two characteristic patterns UP (UP1, UP2) specified in the sewing machine coordinate system and the stitch formation target position data stored in the sewing data storage unit 61. Thus, the stitch formation target position in the sewing machine coordinate system can be specified.

  The correction data generation unit 75 corrects the first target pattern RP1 based on the stitch formation target position specified in the sewing machine coordinate system so that the first stitch GP1 is formed at the stitch formation target position, and performs the first correction. First correction data indicating the pattern HP1 is calculated.

  In other words, the correction data generation unit 75 is formed on the sewing object S by performing the first sewing process and the relative position between the first target pattern RP1 and the characteristic pattern UP before the first sewing process is performed. The first correction data is generated so that the relative position between the first stitch GP1 and the characteristic pattern UP after the first sewing process has been performed.

  The abnormality detection unit 76 determines whether the first correction data, which is the correction calculation result by the correction data generation unit 75, is within the sewing area PA (Step S60). When the first stitch GP1 formed by the first correction data is within the sewing area PA (Step S60: Yes), the abnormality detection unit 76 proceeds to Step S70. If the first stitch GP1 formed by the first correction data is not within the sewing area PA (Step S60: No), the abnormality detection unit 76 proceeds to Step S240.

  The abnormality detection unit 76 determines whether the first correction data, which is the correction calculation result by the correction data generation unit 75, does not collide with the frame member 15C (Step S70). If the first stitch GP1 formed by the first correction data does not collide with the frame member 15C (Step S70: Yes), the abnormality detection unit 76 proceeds to Step S80. When the first stitch GP1 formed by the first correction data collides with the frame member 15C (Step S70: No), the abnormality detection unit 76 proceeds to Step S240.

  In the present embodiment, the initial position data acquisition unit 72 initializes the characteristic pattern UP in the sewing machine coordinate system based on the image data of the sewing object S captured by the imaging device 30 before the first sewing process is performed. The position data is acquired (step S80).

  The relative position data indicating the relative positions of the plurality of specific patterns UP on the sewing target S is known data that can be derived from the design data of the sewing target S, and is stored in the sewing data storage unit 61. Therefore, when the positions of at least two feature patterns UP (UP1, UP2) are detected using the imaging device 30, the correction data generation unit 75 causes the correction feature generating unit 75 to specify the two feature patterns UP (UP1, UP1, UP1) specified in the sewing machine coordinate system. The initial position of each of the plurality of feature patterns UP of the sewing target object S in the sewing machine coordinate system based on the current position data of UP2) and the relative position data of the plurality of feature patterns UP stored in the sewing data storage unit 61. Data can be calculated. The initial position data of each of the plurality of characteristic patterns UP in the sewing machine coordinate system is stored in the sewing data storage unit 61.

  After the first correction data is generated, the control device 40 starts the first sewing process (Step S90). The controller 77 outputs a control signal for controlling the actuator 17 based on the first correction data in the first sewing process.

  FIG. 15 is a diagram schematically illustrating the sewing target object S on which the first sewing process has been performed. When performing the first sewing process, the control unit 77 moves the holding member 15 to the start position SP1 of the first sewing process. The start position SP1 is a position where the end on the −X side of the stitch formation area MA where the first stitch GP1 is formed is located at the sewing position Ps. In the present embodiment, each of the start position SP1 and the second feature pattern UP2 is located at the end of the sewing target S on the −X side. Therefore, the moving distance of the holding member 15 from the end of the acquisition of the image data of the second characteristic pattern UP2 to the position at the start position SP1 may be short.

  The control unit 77 controls the movement of the holding member 15 so that the first stitch GP1 is formed from the end of the stitch formation area MA on the −X side. When the holding member 15 moves to the end position EP1 of the first sewing process, the first sewing process ends. The end position EP1 is a position where the end on the + X side of the stitch forming area MA where the first stitch GP1 is formed is located at the sewing position Ps.

  As shown in FIG. 15, by performing the first sewing processing based on the first correction pattern HP1, the first stitch GP1 is formed along the stitch formation target position of the sewing target S.

  After the end of the first sewing process, the counter n is set to "2" (step S100).

  The sewing data acquisition unit 71 acquires the second sewing data referred to in the second sewing processing from the sewing data storage unit 61 (Step S110).

  The initial position data acquisition unit 72 stores, from the sewing data storage unit 61, the initial position data of the characteristic pattern UP of the sewing target S related to the second sewing process among the initial position data of the plurality of characteristic patterns UP acquired in step S80. It is acquired (Step S120).

  The characteristic pattern UP related to the second sewing process is a feature pattern UP closest to the stitch formation target position where the second stitch GP2 is formed by the second sewing process in the sewing machine coordinate system. In other words, the characteristic pattern UP related to the second sewing process is a characteristic pattern UP closest to the second target pattern RP2 in the sewing machine coordinate system.

  After acquiring the second sewing data including the second target pattern RP2 and the initial position data of the characteristic pattern UP related to the second sewing process, the control device 40 sets the photographing area FA of the imaging device 30 according to the second sewing process. The actuator 17 is controlled so that a plurality of feature patterns UP are sequentially arranged. That is, the control device 40 moves the holding member 15 stepwise in the X-axis direction, and sequentially acquires the image data of the plurality of characteristic patterns UP of the sewing target object S held by the holding member 15 (step S130).

  FIG. 16 is a diagram schematically illustrating the sewing target object S held by the holding member 15 before the second sewing process is performed. After the end of the first sewing process, the control unit 77 moves the holding member 15 from the end position of the first sewing process so that the characteristic pattern UP relating to the second sewing process is arranged in the photographing area FA of the imaging device 30. Move. As shown in FIG. 16, in the present embodiment, the feature patterns UP related to the second sewing process include a third feature pattern UP3, a fourth feature pattern UP4, a fifth feature pattern UP5, a sixth feature pattern UP6, and a seventh feature. It includes a pattern UP7, an eighth feature pattern UP8, and a ninth feature pattern UP9.

  A plurality of characteristic patterns UP (UP3, UP4, UP5, UP6, UP7, UP8, UP9) related to the second sewing process are arranged in the X-axis direction. Among the plurality of feature patterns UP (UP3, UP4, UP5, UP6, UP7, UP8, UP9) related to the second sewing process, the third feature pattern UP3 is arranged closest to the + X side, and the ninth feature pattern UP9 is most often -X. Placed on the side.

  After the third feature pattern UP3 is arranged in the shooting area FA of the imaging device 30, the imaging device 30 acquires the image data of the third feature pattern UP3. After the image data of the third feature pattern UP3 is obtained, the control device 40 controls the actuator 17 so that the fourth feature pattern UP4 is arranged in the shooting area FA of the imaging device 30. The actuator 17 moves the holding member 15 stepwise in the + X direction. After the fourth feature pattern UP4 is arranged in the shooting area FA of the imaging device 30, the imaging device 30 acquires image data of the fourth feature pattern UP4. Similarly, the control device 40 sequentially arranges the fifth feature pattern UP5, the sixth feature pattern UP6, the seventh feature pattern UP7, the eighth feature pattern UP8, and the ninth feature pattern UP9 in the shooting area FA of the imaging device 30. Thus, the actuator 17 is controlled to move the holding member 15 stepwise in the X-axis direction. The image pickup device 30 includes image data of the fifth characteristic pattern UP5, image data of the sixth characteristic pattern UP6, image data of the seventh characteristic pattern UP7, image data of the eighth characteristic pattern UP8, and image data of the ninth characteristic pattern UP9. Are sequentially obtained.

  The abnormality detection unit 76 performs image processing on the second sewing data and the characteristic pattern related to the second sewing processing by a pattern matching method, and determines whether the degree of coincidence is equal to or smaller than a threshold (step S140). If the degree of coincidence is equal to or greater than the threshold (step S140: Yes), the abnormality detection unit 76 proceeds to step S150. If the degree of coincidence is not equal to or greater than the threshold (step S140: No), the abnormality detection unit 76 proceeds to step S240.

  The current position data acquisition unit 73 stores the image data of each of the plurality of characteristic patterns UP (UP3, UP4, UP5, UP6, UP7, UP8, UP9) of the sewing object S photographed by the imaging device 30 after the first sewing process. , The current position data of each of the plurality of characteristic patterns UP is obtained (step S150).

  That is, the current position data acquiring unit 73 converts the current position data of the characteristic pattern UP based on the image data of the characteristic pattern UP captured during the period between the end of the first sewing process and the start of the second sewing process. get.

  The displacement amount calculation unit 74 calculates the displacement amount of the feature pattern UP based on the initial position data of the feature pattern UP acquired in step S120 and the current position data of the feature pattern UP acquired in step S150 (step S160). ). As described above, the displacement amount of the feature pattern UP includes the shift, the scale, and the rotation.

  The abnormality detection unit 76 determines whether the amount of displacement of the feature pattern UP is equal to or less than a threshold (Step S170). When the displacement amount of the characteristic pattern UP is equal to or smaller than the threshold value (Step S170: Yes), the abnormality detection unit 76 proceeds to Step S180. If the displacement amount of the characteristic pattern UP is not equal to or smaller than the threshold (step S170: No), the abnormality detection unit 76 proceeds to step S240.

  The correction data generation unit 75 corrects the second sewing data acquired in step S110 based on the displacement amount calculated in step S160, and generates second correction data HP2 (step S180).

  The sewing target S after the first stitch GP1 is formed is more likely to be shrunk than the sewing target S before the first stitch GP1 is formed. As a result, there is a high possibility that the stitch formation target position of the sewing target object S defined in the sewing machine coordinate system is displaced. On the other hand, the position of the second target pattern RP2 stored in the sewing data storage unit 61 in the sewing machine coordinate system is predetermined. Therefore, when the second sewing process is performed according to the second target pattern RP2 obtained by the sewing data obtaining unit 71, the second stitch GP2 is formed on the surface of the sewing target S at a position different from the stitch formation target position. May be

  In the present embodiment, before the second sewing process is performed, at least the current position of the feature pattern UP related to the second sewing process among the plurality of feature patterns UP of the sewing target object S held by the holding member 15. Is detected using the imaging device 30. The displacement amount calculation unit 74 calculates the displacement amount of the characteristic pattern UP from the initial position to the current position based on the initial position and the current position of the characteristic pattern UP according to the second sewing process. The correction data generation unit 75 corrects the second target pattern RP2 based on the displacement amount so that the second stitch GP2 is formed at the stitch formation target position in the sewing machine coordinate system, and displays the second correction pattern HP2. 2 Compute the correction data.

  In other words, the correction data generation unit 75 is formed on the sewing object S by performing the second sewing process and the relative position between the second target pattern RP2 and the characteristic pattern UP before the first sewing process is performed. The second correction data is generated such that the relative position between the second stitch GP2 and the characteristic pattern UP after the second sewing process has been performed matches.

  The abnormality detection unit 76 determines whether the second correction data, which is the correction calculation result by the correction data generation unit 75, is within the sewing area PA (step S190). When the second stitch GP2 formed by the second correction data is within the sewing area PA (Step S190: Yes), the abnormality detection unit 76 proceeds to Step S200. If the second stitch GP2 formed by the second correction data is not within the sewing area PA (Step S190: No), the abnormality detection unit 76 proceeds to Step S240.

  The abnormality detection unit 76 determines whether the second correction data, which is the result of the correction calculation by the correction data generation unit 75, does not collide with the frame member 15C (step S200). When the second correction data does not collide with the frame member 15C (Step S200: Yes), the abnormality detection unit 76 proceeds to Step 210. When the second correction data collides with the frame member 15C (Step S200: No), the abnormality detection unit 76 proceeds to Step S240.

  After the second correction data is generated, the control device 40 starts a second sewing process (Step S210). The control unit 77 outputs a control signal for controlling the actuator 17 based on the second correction data in the second sewing process. In the second sewing process, the holding member 15 holds and moves the sewing target object S in the XY plane including the sewing position Ps based on the second correction data. Thereby, the second stitch GP2 is formed on the sewing target S.

  After the end of the second sewing process, it is determined whether to end the sewing process (step S220). If the sewing process is not to be ended (Step S220: No), the counter n is set to “n + 1” (Step S230). Hereinafter, the processes of steps S110 to S240 are repeated until it is determined in step S220 that the sewing process is to be ended.

  When it is determined that the position of the sewing target object S is abnormal, more specifically, when the degree of coincidence between the first sewing data and the characteristic pattern related to the first sewing process is not equal to or larger than the threshold (step S40: No). When the first stitch GP1 formed by the first correction data is not within the sewing area PA (Step S60: No), when the first stitch GP1 formed by the first correction data collides with the frame member 15C (Step S70). : No), when the degree of coincidence between the second sewing data and the feature pattern related to the second sewing process is not equal to or larger than the threshold (Step S140: No), and when the displacement amount of the feature pattern UP is not equal to or smaller than the threshold (Step S170: No), when the second stitch GP2 formed by the second correction data is not within the sewing area PA (Step S190: No), or When the second correction data collides with the frame member 15C (Step S200: No), the control unit 77 informs abnormality to the notification device 80 (output) (step S240). As described above, at least one of the display device, the printing device, and the light emitting device is exemplified as the notification device 80. The notification (output) of the abnormality may be performed by displaying the determination result and the data on which the determination is based on a display device, outputting the data on a printing device, or turning on a light emitting device. When the abnormality is notified, the process ends without executing the sewing process for forming the subsequent stitch GP. The operator confirms the content of the reported abnormality and takes measures such as re-creating the sewing data, for example.

  As described above, according to the present embodiment, if the surface of the sewing object S is displaced and the subsequent formation of the stitches GP is continued, the quality of the sewing object S becomes poor or the sewing needle If there is a possibility that the sewing object 3 will come into contact with the holding member 15, it is determined that the position of the sewing object S is abnormal. According to the present embodiment, there is a possibility that an abnormal operation of the sewing machine 1 may be caused, and when it is not suitable for forming the subsequent stitch GP, it is determined that there is an abnormality in the position of the sewing target S, and thereafter, Of the stitch GP can be stopped. As described above, according to the present embodiment, it is possible to suppress the quality of the sewing target object S from becoming poor. Further, according to the present embodiment, it is possible to prevent the sewing needle 3 from contacting the holding member 15. In this manner, the present embodiment determines the case where the sewing machine 1 causes an abnormal operation due to the displacement of the surface of the sewing object S, and determines whether the sewing machine 1 is manufacturing the defective sewing object S and the abnormal operation of the sewing machine 1. Generation can be suppressed.

  In the present embodiment, based on the initial position data of the characteristic pattern UP and the current position data, image processing is performed by the pattern matching method, and if the degree of coincidence is equal to or smaller than a threshold, the detection result is determined to be abnormal. According to the present embodiment, when the sewing object S is arranged with a large deviation, it is determined that there is an abnormality in the position of the sewing object S, and the subsequent stitch GP is not formed as it is. it can.

  In the present embodiment, based on the displacement calculated by the displacement calculator 74, if the displacement is not smaller than or equal to the threshold, the detection result is determined to be abnormal. According to the present embodiment, when the displacement exceeds the range caused by contraction due to sewing, it is determined that there is an abnormality in the position of the sewing object S, and the subsequent stitch GP is not formed as it is. can do.

  In the present embodiment, based on the correction data generated by the correction data generation unit 75, if the stitch GP formed by the correction data is not within the sewing area PA, the detection result is determined to be abnormal. According to the present embodiment, when the correction data is such that the sewing machine needle 3 comes into contact with the holding member 15, the subsequent stitch GP can be prevented from being formed as it is.

  In the present embodiment, when the frame member 15C is mounted on the holding member 15, based on the correction data generated by the correction data generation unit 75, when the stitch GP formed by the correction data is not in the frame member 15C, In other words, when the stitch GP formed by the correction data may collide with the frame member 15C, the detection result is determined to be abnormal. According to the present embodiment, when the correction data is such that the sewing machine needle 3 comes into contact with the frame member 15C, the subsequent stitch GP can be prevented from being formed as it is.

  DESCRIPTION OF SYMBOLS 1 ... Sewing machine, 2 ... Table, 3 ... Sewing needle, 4 ... Surface material, 5 ... Pad material, 6 ... Backing material, 7 ... Hole, 10 ... Sewing machine main body, 11 ... Sewing machine frame, 11A ... Horizontal arm, 11B ... Bed , 11C: vertical arm, 11D: head, 12: needle bar, 13: needle plate, 14: support member, 15: holding member, 15A: holding member, 15B: lower plate, 16: actuator, 17: actuator, 17X ... X-axis motor, 17Y: Y-axis motor, 18: Actuator, 19: Middle pressing member, 20: Operating device, 21: Operation panel, 22: Operating pedal, 30: Imaging device, 31: Drive amount sensor, 32: Drive amount Sensor, 32X: X-axis sensor, 32Y: Y-axis sensor, 40: control device, 50: input / output interface device, 60: storage device, 61: sewing data storage unit, 62: program storage unit Reference numeral 70: arithmetic processing unit, 71: sewing data acquisition unit, 72: initial position data acquisition unit, 73: current position data acquisition unit, 74: displacement amount calculation unit, 75: correction data generation unit, 76: abnormality detection unit, 77 ... Control unit, AX ... optical axis, Ca ... center position, Cb ... center position, DP ... prescribed pattern, DPh ... reference pattern, FA ... photographing area, GP ... stitch, GP1 ... first stitch, GP2 ... second stitch GP3: third stitch, K3: corner, K4: corner, MA: stitch formation area, Pf: shooting position, Ps: sewing position, RP: target pattern, RP1: first target pattern, RP2: second target pattern , RP3: third target pattern, UP: feature pattern, UPa: feature pattern, UPb: feature pattern, UP1: first feature pattern, UP2: second feature pattern, UP3 ... Feature pattern, UP4: fourth feature pattern, UP5: fifth feature pattern, UP6: sixth feature pattern, UP7: seventh feature pattern, UP8: eighth feature pattern, UP9: ninth feature pattern, S: sewing target .

Claims (8)

A holding member that is capable of holding and moving a sewing object in a predetermined plane including a sewing position immediately below a sewing needle,
An actuator for moving the holding member,
An imaging device capable of photographing the sewing object;
A sewing data acquisition unit that acquires first sewing data referred to in the first sewing process and second sewing data referred to in a second sewing process performed after the first sewing process;
An initial position data obtaining unit that obtains initial position data indicating an initial position of a feature pattern arranged on the sewing object;
A current position data acquisition unit that acquires current position data indicating a current position of the feature pattern based on image data of the sewing target imaged by the imaging device;
An abnormality detection unit that detects an abnormality of the sewing target object based on the initial position data and the current position data,
A controller that outputs a detection result of the abnormality detector when an abnormality is detected, and outputs a control signal that controls the actuator based on the first sewing data and the second sewing data when an abnormality is not detected. When,
Sewing machine with A displacement calculation unit that calculates a displacement of the feature pattern based on the initial position data and the current position data,
The abnormality includes an abnormality of the displacement amount,
The sewing machine according to claim 1. When no abnormality is detected, the control unit outputs the control signal in the second sewing process based on the second sewing data and the displacement amount.
The sewing machine according to claim 2. The first sewing process is a process of first forming a stitch after the sewing target object is held by the holding member,
The abnormality detection unit determines whether or not the abnormality by comparing the displacement amount and a threshold,
The threshold includes a first threshold and a second threshold smaller than the first threshold,
After the execution of the first sewing process and before the execution of the second sewing process, if the displacement amount is equal to or more than a first threshold, it is determined that the displacement amount is abnormal,
If the displacement amount is equal to or greater than a second threshold after the execution of the second sewing process, it is determined that the displacement amount is abnormal.
The sewing machine according to claim 2 or 3. A correction data generation unit that corrects the second sewing data based on the displacement amount to generate second correction data;
The abnormality detection unit detects an abnormality in the displacement amount based on the second correction data,
When no abnormality is detected, the control unit outputs the control signal based on the second correction data in the second sewing process.
The sewing machine according to any one of claims 2 to 4. The correction data generation unit generates first correction data by correcting the first sewing data based on the image data captured by the imaging device before the first sewing process is performed,
The abnormality detection unit detects an abnormality in the displacement amount based on the first correction data,
The control unit outputs the control signal based on the first correction data in the first sewing process when no abnormality is detected.
The sewing machine according to claim 5. The current position data acquisition unit acquires the current position data by performing image processing on the feature pattern by a pattern matching method,
The abnormality includes an abnormality in the degree of coincidence between the feature pattern and the template.
The sewing machine according to any one of claims 1 to 6. Acquiring first sewing data referred to in the first sewing process and second sewing data referred to in a second sewing process performed subsequent to the first sewing process;
Acquiring initial position data indicating an initial position of a characteristic pattern arranged on the sewing object;
Acquiring current position data indicating a current position of the feature pattern based on image data of the sewing target;
Detecting an abnormality of the sewing target object based on the initial position data and the current position data,
When an abnormality is detected, a detection result is output. When no abnormality is detected, the sewing machine needle and the sewing target object are relatively moved within a predetermined plane based on the first sewing data and the second sewing data. Forming a stitch on the sewing object;
Sewing method including.

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