JP2021053241A - Sewing data processing device and sewing machine - Google Patents

Abstract

To provide a sewing data processing device capable of reducing possibility of a fabric holding frame and a sewing needle interfering with each other, and to provide a sewing machine.SOLUTION: A sewing machine forms a fabric holding frame for holding an object to be sewn. A CPU images a groove into which a sewing needle of the sewing machine can be inserted by an imaging part, and acquires a whole image which is an imaged image including the entire groove (S105-S111). The CPU detects a positional relation between the position of the groove of the whole image and a needle location of coordinate data based on the acquired whole image and the coordinate data which shows the needle location of the sewing needle contained in sewing data (S115, S121). The CPU analyzes the detected positional relation by a statistic method (S113-S129); thereby, the CPU calculates a correction amount of the sewing data (S129). The CPU corrects the sewing data by applying the calculated correction amount (S133).SELECTED DRAWING: Figure 10

Description

The present invention relates to a sewing data processing device and a sewing machine.

The sewing device described in Patent Document 1 includes a cloth holding frame, a camera, a shape recognition unit, and a sewing machine control unit. The cloth holding frame includes a plurality of contact portions and a plurality of edge detection openings. The plurality of contact portions abut on the end faces of the sewn object. The plurality of edge detection openings expose the edge positions of the sewn material. The camera takes an image of the sewn object in a state where the plurality of contact portions are in contact with each other and the end positions are exposed by the plurality of edge detection openings. The shape recognition unit recognizes the end position of the sewn object based on the image data of the sewn object captured by the camera. The sewing machine control unit creates sewing pattern data based on the end position recognized by the shape recognition unit.

Japanese Unexamined Patent Publication No. 2014-91008

The sewing device may have poor dimensional accuracy of the cloth holding frame. In this case as well, the sewing device detects the end position of the sewn object from the captured image and performs sewing based on the sewing pattern data created based on the recognized end position of the sewn object. Therefore, in the sewing device, the cloth holding frame and the sewing needle may interfere with each other.

An object of the present invention is to provide a sewing data processing device and a sewing machine capable of reducing the possibility of interference between the cloth holding frame and the sewing needle.

The sewing data processing device according to claim 1 of the present invention is a sewing data processing device that processes sewing data for sewing a sewn object, and is formed on a cloth holding frame for holding the sewn object and is a sewing machine. The imaging control unit that photographs the groove through which the sewing needle can be inserted and acquires the entire image that is the captured image including the entire groove, the overall image acquired by the imaging control unit, and the sewing data. Based on the coordinate data indicating the needle drop position of the sewing needle included in the above, the detection unit that detects the positional relationship between the groove position of the entire image and the needle drop position of the coordinate data, and the detection unit detects it. By analyzing the positional relationship obtained by a statistical method, the sewing data is corrected by applying the first calculation unit that calculates the correction amount of the sewing data and the correction amount calculated by the first calculation unit. It is characterized in that it is provided with a first correction unit.

The sewing data processing device of the first aspect detects the positional relationship between the position of the groove in the entire image and the needle drop position of the coordinate data. The sewing data processing device calculates the correction amount of the sewing data by analyzing the positional relationship by a statistical method. The sewing data processing device applies the calculated correction amount to correct the sewing data. Therefore, the sewing data processing device can reduce the possibility of interference between the cloth holding frame and the sewing needle.

In the sewing data processing device according to claim 2, the photographing control unit acquires a plurality of divided images generated by the photographing unit taking a plurality of images of the groove one by one, and the detection unit acquires a plurality of divided images as the whole image. With respect to the position of the groove in each of the plurality of divided images, the first detection unit that moves the relative position of the needle drop position of the coordinate data according to the movement amount indicated by the predetermined orthogonal coordinate system and the polar coordinate system. The ratio of the divided image in which the relative position of the needle drop position is included in the groove position among the plurality of divided images in a state where the relative position is moved by the moving amount by the first detection unit. The movement of the relative position of the needle drop position according to the movement amount by the first detection unit and the detection of the ratio by the second detection unit are performed by the second detection unit. The first calculation unit includes a third detection unit that repeats for each quantity, and the first calculation unit has the correction amount according to the movement amount of the ratio that is the maximum among the plurality of the ratios detected by the third detection unit. Is calculated. The sewing data processing device detects the ratio of the divided images in which the relative position of the needle drop position is included in the groove position among the plurality of divided images. The sewing data processing device repeats the movement of the relative position of the needle drop position according to the movement amount and the detection of the ratio for each of the plurality of movement amounts. The sewing data processing device calculates the correction amount according to the movement amount of the maximum ratio among the plurality of detected ratios. Therefore, the sewing data processing device can reduce the possibility of interference between the cloth holding frame and the sewing needle.

In the sewing data processing apparatus of claim 3, the first calculation unit includes a specific unit that specifies whether or not there is a plurality of the maximum ratios among the plurality of ratios detected by the third detection unit. When the first calculation unit determines that there are a plurality of the ratios that maximize the specific unit, the first calculation unit determines the correction amount according to the plurality of movement amounts corresponding to the plurality of maximum ratios. .. When the sewing data processing device determines that there are a plurality of maximum ratios, the sewing data processing device determines a correction amount according to a plurality of movement amounts corresponding to the plurality of maximum ratios. Therefore, the sewing data processing device can further reduce the possibility of interference between the cloth holding frame and the sewing needle.

In the sewing data processing device of claim 4, whether or not the needle drop position of the sewing data after correction by the first correction unit is included in the groove position in the overall image acquired by the imaging control unit. A determination unit for determining whether or not, and a notification unit for notifying the needle drop position not included in the groove position when the determination unit determines that the needle drop position is not included in the groove position. Be prepared. When the sewing data processing device determines that the needle drop position of the corrected sewing data is not included in the groove position of the entire image, the sewing data processing device notifies the needle drop position not included in the groove position. Therefore, the sewing data processing device can notify the user of the possibility that the cloth holding frame and the sewing needle interfere with each other in the corrected sewing data.

In the sewing data processing device of claim 5, whether or not the needle drop position of the coordinate data corrected by the first correction unit is included in the groove position in the overall image acquired by the imaging control unit. It is provided with a determination unit for determining whether or not, and a second correction unit for correcting the needle drop position determined by the determination unit not to be included in the groove position to a position included in the groove position. The sewing data processing device corrects the needle drop position determined not to be included in the groove position to the position included in the groove position. Therefore, the sewing data processing device can further reduce the possibility of interference between the cloth holding frame and the sewing needle.

In the sewing data processing device of claim 6, when the sewing machine drives the feed mechanism to move the cloth holding frame based on the sewing data, the photographing control unit photographs the groove of the cloth holding frame. The whole image is acquired. When the sewing machine drives the feed mechanism to move the cloth holding frame, the sewing data processing device photographs the groove of the cloth holding frame and acquires the entire image. Therefore, the sewing data processing device can efficiently photograph the entire groove of the cloth holding frame by driving the feed mechanism based on the sewing data by the sewing machine.

The sewing data processing device according to claim 7 sets a predetermined position in the photographing range of the photographing unit when the sewing machine drives the feed mechanism to move the cloth holding frame, and a virtual needle drop of the sewing data. A conversion unit that converts the sewing data as a position is provided. The sewing data processing device converts the sewing data by setting a predetermined position in the photographing range of the photographing unit as a virtual needle drop position of the sewing data. Therefore, the sewing data processing device can determine whether the virtual needle drop position and the cloth holding frame interfere with each other without directly photographing the needle drop position of the sewing needle.

The sewing machine according to claim 8 of the present invention sews the sewn object based on the sewing data processing device according to any one of claims 1 to 7 and the sewing data corrected by the sewing data processing device. It is characterized by having a sewing control unit.

The sewing machine of the second aspect can be sewn based on the sewing data corrected by the sewing data processing device according to any one of claims 1 to 7. Therefore, the sewing machine can obtain the same effect as the sewing data processing device according to any one of claims 1 to 7.

Perspective view of sewing machine 1. The right side view of the front end portion 7 of the sewing machine 1. The plan view of the cloth holding frame 80 and the holding part 70. The block diagram which shows the electrical structure of the sewing machine 1. The figure which shows the positional relationship between the virtual needle drop position P and the groove 87 in the divided image 25A. The figure which shows the whole image 68 in the case where the virtual needle drop position P of sewing data is not included in the groove 87 of the photographed divided image 25. The figure which shows the positional relationship between the virtual needle drop position P of sewing data to which the movement amount (X, Y, θ) is applied, and the groove 87 of the photographed divided image 25. The chart which shows the calculation result of the ratio when the movement amount (θ) is applied. Flow diagram of main processing. Flow chart of sewing data correction processing.

The sewing machine 1 of the first embodiment of the present invention will be described with reference to the drawings. The upper side, lower side, diagonally lower left side, diagonally upper right side, diagonally upper left side, and diagonally lower right side of FIG. 1 are the upper side, lower side, front side, rear side, left side, and right side of the sewing machine 1, respectively.

The overall structure of the sewing machine 1 will be described with reference to FIGS. 1 to 3. As shown in FIG. 1, the sewing machine 1 includes a bed portion 2, a pedestal portion 3, and an arm portion 4. The bed portion 2 is arranged on the table 95. The bed portion 2 extends in the front-rear direction and is provided with a vertical hook (vertical rotary hook / rocking hook) or the like inside. The sewing machine 1 is provided with a workbench 5 and a feed mechanism 6 above the bed portion 2. The workbench 5 includes a needle plate 29 (see FIG. 2). The needle plate 29 has a needle hole 28 through which the sewing needle 11 can be inserted at a position directly below the sewing needle 11 attached to the needle rod 10.

The feed mechanism 6 includes a holding portion 70, a frame support portion 65, an elevating portion 62, a holding frame 63, an air cylinder (not shown), an X-axis moving mechanism (not shown), and a Y-axis moving mechanism (not shown). The holding portion 70 extends in the left-right direction, and the cloth holding frame 80 can be attached and detached. The cloth holding frame 80 has a groove 87 through which the sewing needle 11 can be inserted, and can hold the sewn object. The frame support portion 65 is located behind the workbench 5. The frame support portion 65 includes an arm portion 64 extending forward, and a holding portion 70 is fixed below the arm portion 64. The arm portion 64 supports the elevating portion 62 at the front end. The air cylinder is provided on the arm portion 64 and is connected to the elevating portion 62. The feed mechanism 6 drives the air cylinder with the air supplied by the compressor. The air cylinder moves up and down the elevating part 62.

The presser frame 63 is connected to the lower end of the elevating portion 62. The holding frame 63 is a rectangular frame-shaped plate member. In order to prevent the sewing needle 11 and the cloth holding frame 80 from interfering with each other, the sewing area where the stitch can be formed is smaller than the area inside the cloth holding frame 80. When the elevating part 62 moves downward, the holding frame 63 lowers. At the time of sewing, the presser frame 63 presses the cloth holding frame 80 from above to prevent the cloth holding frame 80 from being lifted from the workbench 5. The feed mechanism 6 moves the holding frame 63 and the holding portion 70 supported by the frame supporting portion 65 in the X-axis direction (left-right direction) and the Y-axis direction (front-back direction).

The X-axis moving mechanism and the Y-axis moving mechanism are provided inside the bed portion 2. The X-axis movement mechanism uses the X-axis motor 114 (see FIG. 4) as a drive source, and moves the frame support portion 65 and the holding portion 70 in the X-axis direction. The Y-axis movement mechanism uses the Y-axis motor 116 (see FIG. 4) as a drive source, and moves the frame support portion 65 and the holding portion 70 in the Y-axis direction.

The pedestal portion 3 extends upward from the rear side of the bed portion 2. The pedestal portion 3 includes a sewing machine motor 112 (see FIG. 4) and the like inside. The arm portion 4 extends forward from the upper end of the pedestal portion 3 toward the upper surface of the bed portion 2. The arm portion 4 includes a spindle (not shown) inside. The sewing machine motor 112 rotationally drives the spindle.

As shown in FIG. 2, the sewing machine 1 includes a sewing portion 35 (see FIG. 4), a pressing rod 12, a pressing foot driving mechanism (not shown), a photographing portion 52, and the like at the front end portion 7 of the arm portion 4. The sewing portion 35 has a needle bar 10 to which the sewing needle 11 can be attached at the lower end, and a stitch can be formed on the object to be sewn. The needle bar 10 extends downward from the lower end of the front end portion 7. The presser bar 12 extends downward from the lower end of the front end portion 7 on the left side (back side in FIG. 2) of the needle bar 10, and the presser foot 13 can be attached to the lower end. The presser foot drive mechanism moves the presser bar 12 up and down in synchronization with the vertical movement of the needle bar 10 accompanying the rotational drive of the spindle.

The presser foot 13 is an intermittent presser foot that prevents the sewn object from floating upward by pressing the sewn object from above when the sewing needle 11 comes out of the sewn object. The lower end of the presser foot 13 is a cylindrical tubular portion 131. The tubular portion 131 intermittently comes into contact with the sewn object. The diameter of the tubular portion 131 varies depending on the type of the presser foot 13, and is, for example, 3 to 8 mm. The sewing needle 11 is pierced into the object to be sewn through the through hole of the tubular portion 131. The sewing needle 11 moves up and down through the needle hole 28 below the tubular portion 131.

The sewing machine 1 includes an auxiliary thread tensioner 15, a thread tensioner 16, thread guides 17, 18, a balance 19, and a thread guide 20 as a configuration for guiding the needle thread 55 to the right side surface of the front end portion 7 of the arm portion 4. The needle thread 55 is from a thread piece placed on a thread piece stand provided on a table 95 (see FIG. 1), a secondary thread tensioner 15, a thread tensioner 16, a thread guide 17, a thread guide 18, a balance 19, and a thread guide 20. It is inserted into the needle hole 111 of the sewing needle 11 via the above.

The photographing unit 52 is fixed to the support unit 51 provided on the machine frame of the sewing machine 1. The support portion 51 is provided in front of the needle bar 10. The photographing unit 52 is, for example, a well-known CMOS image sensor. The lens of the photographing unit 52 faces downward and photographs the groove 87 of the cloth holding frame 80.

The cloth holding frame 80 and the holding portion 70 will be described with reference to FIG. In the following description, the orientation of the cloth holding frame 80 follows the orientation of the sewing machine 1 when the holding portion 70 shown in FIG. 1 holds the cloth holding frame 80. The cloth holding frame 80 includes a rectangular plate-shaped lower plate 81 and an upper plate 82. The lower plate 81 and the upper plate 82 are made of synthetic resin. The lower plate 81 and the upper plate 82 may be made of metal, for example. The size of the upper plate 82 is smaller than the size of the lower plate 81.

The upper plate 82 has a groove 87 in the central portion. The groove 87 penetrates the upper plate 82 up and down. The length of the groove 87 in the width direction is longer than the diameter of the tubular portion 131 of the presser foot 13, for example, 5 to 20 mm. The width direction of the groove 87 is a direction orthogonal to the extending direction of the groove 87. The groove 87 surrounds the path 89 through which the sewing needle 11 passes during sewing.

The lower plate 81 is arranged below the upper plate 82. The rear end 83 of the lower plate 81 projects rearward of the rear end of the upper plate 82. The lower plate 81 includes a metal plate 84 extending in the left-right direction, a hinge 85, and a pair of pins 86 on the upper surface of the rear end portion 83. The upper plate 82 has two rear ends fixed to the metal plate 84 of the lower plate 81 with hinges 85. The front end of the upper plate 82 can swing in the vertical direction with the hinge 85 as a fulcrum. The pair of pins 86 are provided near the left and right ends of the metal plate 84. The pair of pins 86 project upward from the upper surface of the metal plate 84.

The lower plate 81 has a groove 88 and a recess (not shown) in the central portion. The groove 88 penetrates the lower plate 81 in the vertical direction. The groove 88 is a hole through which the sewing needle 11 passes during sewing. The shape of the groove 88 substantially matches the shape of the groove 87 of the upper plate 82. The recessed portion is a portion having a shape corresponding to a specific shape of the sewn object, which is recessed from the upper surface to the lower surface of the lower plate 81. The through hole is formed in the recess. The recessed portion prevents misalignment of the object to be sewn during sewing.

When holding the sewn object in the cloth holding frame 80, the user separates the lower surface of the upper plate 82 and the upper surface of the lower plate 81 and fits the sewn object into the recessed portion on the lower plate 81. The user brings the lower surface of the upper plate 82 and the upper surface of the lower plate 81 close to each other and sandwiches the sewn object between the upper plate 82 and the lower plate 81. When the cloth holding frame 80 is attached to the holding portion 70 and the upper surface of the cloth holding frame 80 is pressed by the pressing frame 63, the groove 87 is in the sewing area inside the pressing frame 63 (see FIG. 1). The shapes, sizes, and arrangements of the grooves 87 and 88 and the recesses differ depending on the type of the cloth holding frame 80.

The holding portion 70 includes a main body portion 71, an air cylinder 73, a pair of left and right connecting portions 74, a pair of left and right grip portions 75, and two sensors 76. The main body 71 extends in the left-right direction. The main body 71 has support grooves 72 at both left and right ends, with the main body 71 cut out rearward. Each support groove 72 has a substantially U-shape in a plan view, and the front end side opens to the side surface of the main body 71. The air cylinder 73 is provided at the center of the upper surface of the main body 71 in the left-right direction. The connecting portion 74 extends from the left and right ends of the air cylinder 73 to the left and right, respectively. The left connecting portion 74 is fixed to the air cylinder 73. The connecting portion 74 on the right side is fixed to the piston rod of the air cylinder 73. One end of the grip 75 is rotatably connected to the tip of each connecting 74. The shape of the other end of the grip portion 75 is hook-shaped. The grip portions 75 are arranged below the left and right end portions of the main body portion 71, respectively. The grip portion 75 is rotatably connected to the main body portion 71 at the central portion.

When the air cylinder 73 is driven and the piston rod protrudes, the left connecting portion 74 moves to the left and the right connecting portion 74 moves to the right. When the pair of connecting portions 74 move to the left and right in response to the drive of the air cylinder 73, the pair of gripping portions 75 rotate around the connecting position of the main body portion 71, respectively. The grip portion 75 on the left side and the grip portion 75 on the right side rotate in opposite directions in a plan view. The grip portion 75 rotates between the open position and the grip position. The open position is a position in which the support groove 72 is open to the front of the main body 71. The gripping position is a position that closes the front end of the support groove 72. Each of the two sensors 76 is a well-known proximity sensor provided on the center side of the left and right ends of the main body 71.

When the cloth holding frame 80 is attached to the holding portion 70, the user drives the air cylinder 73 to open the grip portion 75 and fits each pin 86 of the cloth holding frame 80 into the corresponding support groove 72. The user drives the air cylinder 73 to put the grip portion 75 in the grip position, and grips the pin 86 of the cloth holding frame 80 with the grip portion 75 and the support groove 72. When the cloth holding frame 80 is attached to the holding portion 70, the two sensors 76 go from the off state to the on state. The holding portion 70 can be fitted with one cloth holding frame 80 selected from a plurality of types of cloth holding frames 80 having different shapes, sizes, and arrangements of the grooves 87 and 88 and the recessed portions.

The electrical configuration of the sewing machine 1 will be described with reference to FIG. The control device 21 of the sewing machine 1 includes a CPU 41, a ROM 42, a RAM 43, a storage device 44, an input / output interface (I / F) 106, drive circuits 113, 115, 117, and a communication I / F 127. The CPU 41, ROM 42, RAM 43, and storage device 44 are electrically connected to the input / output I / F 106 via the bus 105. The CPU 41 controls the sewing machine 1 and executes various operations and processes related to sewing according to various programs stored in the ROM 42. The ROM 42 stores various programs and various initial setting parameters. The RAM 43 temporarily stores the calculation result of the CPU 41, a pointer, a counter, and the like. The storage device 44 stores sewing data and the like described later for a plurality of patterns (sewing lines, stitch patterns, embroidery patterns, etc.).

The drive circuits 113, 115 and 117 are electrically connected to the input / output I / F 106. The drive circuit 113 is electrically connected to the sewing machine motor 112. The CPU 41 controls the sewing machine motor 112 via the drive circuit 113. The sewing machine motor 112 rotationally drives the spindle. The drive circuit 115 is electrically connected to the X-axis motor 114. The drive circuit 117 is electrically connected to the Y-axis motor 116. The CPU 41 controls the X-axis motor 114 and the Y-axis motor 116, respectively, via the drive circuits 115 and 117. The X-axis motor 114 and the Y-axis motor 116 are pulse motors, respectively, and move the cloth holding frame 80 in the X-axis direction and the Y-axis direction by driving the X-axis movement mechanism and the Y-axis movement mechanism, respectively. The CPU 41 drives the sewing machine motor 112 to rotate the spindle at the time of sewing, thereby controlling the vertical movement of the needle bar 10 and the presser bar 12 and the rotation of the vertical kettle. The CPU 41 controls the position of the cloth holding frame 80 by driving the X-axis motor 114 and the Y-axis motor 116 based on the sewing data at the same time as driving the sewing machine motor 112, and sew on the object to be sewn.

The communication I / F 127 is electrically connected to the input / output I / F 106. The communication I / F 127 is, for example, an interface for serial communication. The sewing machine 1 can be connected to an external device via the communication I / F 127. The sewing machine 1 is connected to the operation box 30 via a cable 9. The X-direction origin sensor 118, the Y-direction origin sensor 119, the start switch 121, the operation panel 8, the photographing unit 52, and the sensor 76 are electrically connected to the input / output I / F 106 of the sewing machine 1, respectively.

The X-direction origin sensor 118 is a sensor having a well-known configuration for setting the origin, and is provided in the X-axis moving mechanism. The Y-direction origin sensor 119 is a sensor having a well-known configuration for setting the origin, and is provided in the Y-axis moving mechanism. The start switch 121 is a pedal-type switch installed below the table 95 and connected to the sewing machine 1 with a cord. The user depresses the start switch 121 when starting various operations (for example, sewing process) of the sewing machine 1.

The operation panel 8 is provided on the table 95, and includes a group of keys for inputting various information and various instructions and a display for displaying information. The operation box 30 includes a key group for inputting various information and various instructions, and an LCD 32 as a display for displaying information, and the LCD 32 is connected to a CPU 41 or the like via a communication I / F 127. The user uses the operation panel 8 or the operation box 30 when inputting information or instructions. The operation panel 8 and the operation box 30 are connected to the control box (not shown) via a cord. The control box stores the control device 21 (see FIG. 4) below the table 95.

The storage device 44 stores sewing data edited by the user, various setting information input by the user, and the like. The sewing data is data for forming a seam along a path 89 inside the grooves 87 and 88 of the cloth holding frame 80. The sewing data is data showing the positions of a plurality of needle drop points (hereinafter, referred to as "needle drop positions") for forming a stitch along the path 89 as the relative positions of the cloth holding frame 80 with respect to the needle bar 10. Is. The needle drop position is the position of the sewn object that the sewing needle 11 is scheduled to pierce when the sewing needle 11 moves downward together with the needle bar 10.

As shown in FIG. 3, the needle drop position is indicated by the coordinate data of the coordinate system 39. The coordinate system 39 is the coordinate system of the X-axis motor 114 and the Y-axis motor 116. The sewing data are arranged in order in association with the number of drive pulses (including the rotation direction) of each of the X-axis motor 114 and the Y-axis motor 116 and the type indicating "sewing" or "feed". "Sewing" is an operation of moving the cloth holding frame 80 and piercing the sewing needle 11 into the object to be sewn at the needle drop position to form a stitch. The “feed” is an operation in which the cloth holding frame 80 is only moved without forming a seam.

The origin (X, Y, Z) = (0, 0, 0) of the coordinate system 39 is such that the cloth holding frame 80 is attached to the holding portion 70, and the center point of the upper plate 82 of the cloth holding frame 80 is the sewing needle. It is defined as the position directly below No. 11 (see FIG. 3). That is, the origin of the coordinate system 39 is the position where the center point of the cloth holding frame 80 is directly below the needle hole 28. In the coordinate system 39, the X-axis plus direction is the direction from the left to the right of the sewing machine 1. The Y-axis plus direction is the direction from the front to the back of the sewing machine 1. The feed mechanism 6 does not move the cloth holding frame 80 in the Z direction, which is the vertical direction of the sewing machine 1, during sewing. Therefore, the Z coordinate of the coordinate data of the needle drop position is always zero.

The type of the cloth holding frame 80 and the sewing data are stored in the storage device 44 in association with each other. The CPU 41 reads sewing data in order, and performs sewing while moving the cloth holding frame 80 in order so that the needle drop position indicated by the coordinate data is located directly below the sewing needle 11. In addition to the above, the sewing data may be data in which the coordinate data of the needle drop position is associated with the type. The CPU 41 may calculate the rotation direction and the number of drive pulses of the X-axis motor 114 and the Y-axis motor 116 from the coordinate data each time the cloth holding frame 80 moves.

The photographing unit 52 outputs the image data of the divided image 25 in which the photographing range 45 (see FIG. 3) in front of the needle bar 10 is photographed to the CPU 41. The shooting coordinate system of the divided image 25 is associated with the world coordinate system in advance. The world coordinate system is a coordinate system that indicates the entire space, and is a coordinate system that is not affected by the center of gravity of the object to be photographed by the photographing unit 52. The sewing machine 1 converts the coordinates of the photographing coordinate system into the coordinates of the coordinate system 39 via the world coordinate system. The storage device 44 stores the correspondence between the shooting coordinate system in the shooting range 45 (see FIG. 3) and the world coordinate system. Therefore, the sewing machine 1 can execute various processes based on the coordinate system 39 obtained by converting the shooting coordinate system and the coordinate data of the corresponding sewing data coordinate system 39.

The outline of the sewing data correction process of the sewing machine 1 will be described with reference to FIGS. 5 to 8. The sewing machine 1 has a function as a sewing data processing device that processes sewing data. The sewing machine 1 creates sewing data for preventing the upper plate 82 of the cloth holding frame 80 from interfering with the sewing needle 11 attached to the needle bar 10 and the tubular portion 131 of the presser foot 13. The sewing machine 1 corrects the sewing data by using the statistical method described below.

The acquisition process of the entire image 68 will be described. Before sewing, the sewing machine 1 photographs, for example, the groove 87 of the cloth holding frame 80 corresponding to the needle drop position indicated by the sewing data for each stitch. At this time, the sewing machine 1 performs data conversion with a predetermined offset amount in the front-rear direction with respect to the needle drop position indicated by the sewing data. As the offset amount, the distance L1 (see FIG. 2) between the center position of the sewing needle 11 and the center position of the image sensor of the photographing unit 52 is applied in the front-rear direction.

At the time of shooting, the sewing machine 1 moves the cloth holding frame 80 based on sewing data (hereinafter, also referred to as “conversion data”) to which the distance L1 is applied. The cloth holding frame 80 moves forward by a distance L1 as compared with the case where the cloth holding frame 80 moves based on the original sewing data. As a result, the cloth holding frame 80 moves so that the groove 87 is located directly below the photographing unit 52. The sewing machine 1 converts the sewing data by using a predetermined position of the photographing range 45 of the photographing unit 52 as a virtual needle drop position of the sewing data.

The sewing machine 1 repeats the movement of the cloth holding frame 80 based on the conversion data and the photographing of the divided image 25 of the groove 87 of the cloth holding frame 80 by the photographing unit 52. The sewing machine 1 acquires a plurality of divided images 25 by photographing the groove 87 part by part by the photographing unit 52. The plurality of divided images 25 constitute an entire image 68 including the entire groove 87. For example, as shown in FIGS. 6 and 7, the entire image 68 is composed of divided images 25A to 25Z taken 26 times.

The binarization process will be described with reference to FIGS. 5 to 7. The sewing machine 1 executes binarization processing on a plurality of divided images 25. For example, the sewing machine 1 obtains an image showing the upper plate 82 of the cloth holding frame 80 in black and the sewn object exposed to the outside from the groove 87 of the upper plate 82 in white. The data of the plurality of divided images 25 that have been binarized are stored in the storage device 44 as the coordinate data of the coordinate system 39 corresponding to the shooting coordinate system.

The positional relationship between the groove 87 of one divided image 25A and the setting range C will be described with reference to FIGS. 5A and 5B. The setting range C shown in FIG. 5 is a circular range having a radius R centered on the virtual needle drop position P indicated by the sewing data. The setting range C includes a range in which the presser foot 13 of the sewing machine 1 intermittently contacts the sewn object. FIG. 5A assumes a case where the cloth holding frame 80 is arranged at an ideal position, and FIG. 5B shows a case where the cloth holding frame 80 is arranged from an ideal position due to the influence of dimensional error of the device or the like. It is assumed that they are arranged out of alignment.

In the divided image 25A shown in FIG. 5A, the setting range C does not include the portion shown in black, that is, the upper plate 82. Therefore, the sewing machine 1 determines that the virtual needle drop position P can be sewn because the set range C fits in the groove 87. In this case, the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other is low.

In the divided image 25A shown in FIG. 5B, the setting range C partially overlaps with the black portion, that is, the upper plate 82. In this case, the sewing machine 1 determines that the virtual needle drop position P cannot be sewn because the set range C does not fit in the groove 87. In this case, there is a high possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other.

For example, the sewing machine 1 sets the positional relationship with the set range C for each virtual needle drop position P in the sewing data with respect to all the divided images 25A to 25Z constituting the entire image 68 (see FIG. 6) of the groove 87. I will judge. For example, with respect to the divided images 25A to 25Z shown in FIG. 6, it is determined whether or not the set range C and the cloth holding frame 80 overlap.

The ratio calculation process will be described. The sewing machine 1 determines whether the set range C of the corresponding virtual needle drop position P fits in the groove 87 for all the divided images 25. The sewing machine 1 calculates the ratio of the divided images 25 that are determined that the set range C fits in the groove 87 among all the divided images 25. The ratio calculated by the sewing machine 1 is stored in the storage device 44.

The setting range C shown in FIG. 6A does not interfere with the black portion showing the upper plate 82 of the divided image 25A. The setting range C shown in FIG. 6B interferes with the black portion showing the upper plate 82 of the divided image 25J. The setting range C shown in FIG. 6C interferes with the black portion of the upper plate 82 of the divided image 25C. For example, it is assumed that the set range C does not overlap with the portion shown in black in the other divided image 25, that is, the upper plate 82. The total number of images of all the divided images 25A to 25Z is 26, and the set range C and the upper plate 82 do not overlap with the set range C and the upper plate 82 in the 24 divided images 25 other than the divided images 25J and 25Z. At this time, the sewing machine 1 calculates that the ratio of the divided images 25 in which the sewing needle 11 does not interfere with the cloth holding frame 80 is about 92% with respect to all the divided images 25A to 25Z.

If the calculated ratio is not 100%, the sewing machine 1 is likely to interfere with the sewing needle 11 and the cloth holding frame 80 when sewing is executed based on the sewing data. On the other hand, when the calculated ratio of the sewing machine 1 is 100%, if the sewing machine 1 executes sewing based on the sewing data, there is a high possibility that the sewing needle 11 and the cloth holding frame 80 can be sewn without interfering with each other.

The movement amount (X, Y, θ) will be described. The sewing machine 1 can apply the movement amount indicated by the predetermined Cartesian coordinate system (X, Y) and the polar coordinate system (θ) to the sewing data. The sewing machine 1 moves the relative position of the virtual needle drop position P of the coordinate data with respect to the position of each groove 87 of the plurality of divided images 25 according to a predetermined movement amount (X, Y, θ). The details will be described below.

The θ application process for applying the inclination in the rotation direction will be described. The sewing machine 1 creates a plurality of sewing data with the movement amount (θ) as a parameter. In the polar coordinate system, the movement amount (θ) is assumed to be, for example, from -3 ° to 3 ° with the center position of the sewing data, that is, the origin of the coordinate system 39 in FIG. 3 as the center in a plan view. The sewing data to which the movement amount of the movement amount (θ) is applied is -3 ° clockwise in the counterclockwise direction with the origin (X, Y, θ) = (0, 0, 0) as the center in the plan view. Rotate the sewing data up to 3 ° in the direction. For example, for sewing data, 6 patterns are generated by applying the amount of movement (θ) in the rotation direction every 1 ° from -3 ° to 3 °.

Next, the sewing machine 1 executes a ratio calculation process for the sewing data to which the movement amount (θ) is applied. For example, the sewing machine 1 executes a ratio calculation process for each sewing data of 6 patterns to which the movement amount (θ) is applied. As shown in FIG. 8, the calculation result of the ratio by the ratio calculation process is, for example, 58% when the movement amount (θ) is -3 °, 85% when the movement amount (θ) is -2 °, and the movement amount. When (θ) is -1 °, 91%, when the movement amount (θ) is 0 °, 93%, when the movement amount (θ) is 1 °, 95%, and when the movement amount (θ) is 2 °. It is assumed that the case is 98% and the movement amount (θ) is 93 °. In this case, the sewing machine 1 determines that the optimum movement amount (θ) having the highest ratio is 2 °. When sewing is executed with sewing data to which the movement amount (θ) is corrected to 2 °, the virtual needle drop position P and the upper plate 82 of the cloth holding frame 80 are most unlikely to interfere with each other.

The XY identification process for determining the amount of movement (X, Y) in the XY direction will be described. The sewing machine 1 determines the optimum amount of movement (X, Y) in the XY directions in the Cartesian coordinate system. In this case, the sewing machine 1 generates sewing data by further applying the movement amount (X, Y) in the X direction and the Y direction to the sewing data to which the movement amount (θ) determined in the θ application process is applied. To do.

The sewing machine 1 can apply the amount of movement corresponding to each pixel of the image sensor of the photographing unit 52 to the sewing data. The range of the amount of movement in the X direction is, for example, a range of −5 to 5 pixels centered on the origin of the cloth holding frame 80. The range of the amount of movement in the Y direction is, for example, a range of −5 to 5 pixels centered on the origin of the cloth holding frame 80. The sewing machine 1 combines 10 movement amounts (X, Y) in the X direction and 10 movement amounts (X, Y) in the Y direction. At this time, the sewing machine 1 generates sewing data to which 100 patterns of movement amounts (X, Y) are applied.

A more detailed description will be given assuming that the optimum movement amount (θ) is 2 °. In the sewing machine 1, the movement amount in the X direction is set to -5, and the movement amount in the Y direction is used as a parameter, and (X, Y, θ) = (-5, -5, 2 °), (-5, -4, 2 °) ... (-5, 3, 2 °), (-5, 4, 2 °), (5, 5, 2 °) Sewing data applying 10 patterns of movement amount Is calculated. Next, the sewing machine 1 sets the amount of movement in the X direction to -4 and sets the amount of movement in the Y direction as a parameter, and (X, Y, θ) = (-4, -5, 2 °), ( -4, -4, 2 °) ... (-4, 3, 2 °), (-4, 4, 2 °), (-4, 5, 2 °) 10 patterns of movement amount Calculate the applied sewing data. In this way, the sewing machine 1 calculates the sewing data in which the movement amount in the X direction is added by 1 pixel and the movement amount in the Y direction is moved by −5 to 5 pixels. By repeating this process, the sewing machine 1 creates sewing data of 100 patterns.

Next, the sewing machine 1 executes the above-mentioned ratio calculation process for each sewing data to which the movement amount (X, Y) in the XY directions is applied and the position of the groove 87. For example, the sewing machine 1 calculates a ratio by a ratio calculation process for sewing data of 100 patterns to which the movement amount (X, Y) is applied.

The maximum ratio identification process will be described. The sewing machine 1 selects the highest ratio among the calculated ratios for the sewing data of 100 patterns to which the movement amount (X, Y, θ) is applied. In this case, the highest ratio may be only one or a plurality. When only one of the highest ratios is specified, the sewing machine 1 determines the movement amount (X, Y, θ) corresponding to the specified one ratio as the correction amount. That is, the CPU 41 calculates the correction amount (X, Y, θ) according to the movement amount of the maximum ratio among the plurality of detected ratios.

The average value acquisition process will be described. When the sewing machine 1 has a plurality of the highest ratios, the sewing machine 1 further executes an XY correction process for the plurality of movement amounts (X, Y, θ). In the XY correction process, the sewing machine 1 calculates the average value of the movement amounts in the X direction and the Y direction for each of the plurality of highest ratios of movement amounts of XY (X, Y). The sewing machine 1 determines the calculated average value as the movement amount (X, Y). As a result, the sewing machine 1 determines the determined movement amount (X, Y, θ) as a correction amount.

For example, the sewing machine 1 determines the movement amount (3, 1, 2 °) as the correction amount (see FIG. 7). In this case, the setting range C including the virtual needle drop position P is in a state of not interfering with the black portion indicating the upper plate 82 of the divided images 25A to 25Z. In this case, the ratio calculated by the sewing machine 1 in the ratio calculation process is 100%. In this case, when the sewing machine 1 is sewn based on the sewing data to which the correction amount (X, Y, θ) = (3, 1, 2 °) is applied, it is unlikely that the sewing needle 11 and the cloth holding frame 80 interfere with each other. ..

<Flowchart>
The main processing of the sewing machine 1 will be described with reference to FIGS. 9 and 10. When the user operates the operation panel 8 or the operation box 30 of the sewing machine 1 to turn on the power, the sewing machine 1 reads the sewing program stored in the ROM 42 and executes the main process. When the main process is executed, the CPU 41 determines whether or not the cloth holding frame 80 is attached to the holding portion 70 (S1). The CPU 41 determines whether or not the cloth holding frame 80 is attached to the holding portion 70 based on the output value of the sensor 76. The CPU 41 continues the determination of S1 until it detects the on signal output by the sensor 76 (S1: NO). The user attaches the cloth holding frame 80 on which the sewn object is placed to the holding portion 70. When it is determined that the cloth holding frame 80 is attached to the holding portion 70, that is, when the on signal output by the sensor 76 is detected (S1: YES), the CPU 41 detects the center point of the cloth holding frame 80. The origin is detected (S3). In this case, the CPU 41 drives the cloth holding frame 80 and detects the origin from the outputs of the X-direction origin sensor 118 and the Y-direction origin sensor 119.

The CPU 41 acquires sewing data and sewing conditions. Sewing data, sewing conditions, etc. are selected by the user. The user operates the operation panel 8 or the operation box 30 to specify sewing data and sewing conditions according to the type of the cloth holding frame 80. As a result, the CPU 41 acquires the sewing data and the sewing conditions specified by the user (S3). The sewing conditions include the setting of the setting range C, the setting of the threshold value of the binarization process, and the like. In the setting of the setting range C, the user can set the radius R of the circle centered on the virtual needle drop position P. In setting the threshold value, the user can set the threshold value to be used when the divided image 25 is binarized. The user may change the radius R and the threshold value as appropriate.

The CPU 41 executes the sewing data correction process (see FIG. 10) based on the sewing data acquired in S5 and the sewing conditions (S7). When the sewing data correction process is started, the CPU 41 generates conversion data (S101). The CPU 41 sets the variable n to 1 (S103). The variable n is a variable for reading the coordinate data of the virtual needle drop position P included in the sewing data acquired in the process of S5 in the sewing order. When the variable n is 1, the CPU 41 moves the cloth holding frame 80 to a position where the shooting range 45 (see FIG. 3) of the shooting unit 52 can shoot the first needle drop position based on the conversion data. (S105). When the variable n is 1, the CPU 41 controls the photographing unit 52, photographs the vicinity of the first needle drop position, and acquires the image data of the divided image 25A (S107). In this case, the acquired image data is stored in the storage device 44.

The CPU 41 determines whether the variable n is a value corresponding to the last needle drop position in the sewing data acquired in the process of S5 (S109). For example, in FIG. 6, the variable n corresponding to the last needle drop position is 26, which corresponds to the divided image 25Z. When the variable n is not a value corresponding to the last needle drop position (S109: NO), the CPU 41 increments the variable n (S111) and returns the process to S105. The CPU 41 photographs the groove 87 while moving the cloth holding frame 80 in the XY directions with respect to the needle drop position for each stitch indicated by the conversion data in the processes of S105 to S111.

On the other hand, when the variable n is the final value (S109: YES), the CPU 41 performs binarization processing on each of the plurality of divided images 25 using the threshold value preset by the user in the processing of S5. Execute (S113). As a result, the CPU 41 detects the position of the groove 87 in each of the plurality of divided images 25.

The CPU 41 executes the θ application process (S115). The CPU 41 generates a plurality of sewing data to which the movement amount (θ) is applied. The CPU 41 executes a ratio calculation process for a plurality of sewing data to which the movement amount (θ) is applied (S117). As a result, the CPU 41 calculates the ratio of the divided images 25 that are determined to fit in the groove 87 among all the acquired divided images 25. The CPU 41 determines the movement amount (θ) at which the calculated ratio is maximized (S119).

The CPU 41 executes an XY identification process for specifying the amount of movement (X, Y) in the XY directions (S121). As a result, for example, the CPU 41 generates 100 patterns of sewing data in which a movement amount (X, Y) of -5 to 5 pixels is applied in each of the XY directions. The CPU 41 executes a ratio calculation process when the movement amount (X, Y) in the XY directions is applied (S123). The CPU 41 specifies the combination that maximizes the ratio (S125). The combination means a combination of the movement amount (θ) determined in the processing of S119 and the movement amount (X, Y) in the XY directions applied in the processing of S121 to S123.

The CPU 41 determines whether or not there is a plurality of combinations having the maximum ratio specified in the process of S125 (S127). When it is determined that the combination having the maximum ratio is one (S127: NO), the CPU 41 determines the combination having the maximum ratio as the correction amount (S129). On the other hand, when it is determined that there are a plurality of combinations having the maximum ratio (S127: YES), the CPU 41 executes the average value acquisition process (S131). That is, when the CPU 41 determines that there are a plurality of maximum ratios, the CPU 41 determines the correction amount (X, Y, θ) according to the plurality of movement amounts corresponding to the plurality of maximum ratios. The CPU 41 determines the movement amount (X, Y, θ) between the movement amount (θ) determined in S119 and the average value (X, Y) acquired in S131 as the correction amount (S129). The CPU 41 applies the correction amount (X, Y, θ) determined in S129 to correct the sewing data (S133). The CPU 41 ends the sewing data correction process, returns the process to the main process (see FIG. 9), and executes the process of S9.

The CPU 41 determines whether or not the needle drop position of the sewing data to which the correction amount (X, Y, θ) is applied is included in the position of the groove 87 in the acquired overall image 68 (S9). That is, the CPU 41 determines whether the needle drop position of the sewing data to which the correction amount is applied may interfere with the cloth holding frame 80.

When it is determined that the needle drop position is not included in the position of the groove 87, that is, when it is determined that there is a high possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other (S9: NO), the CPU 41 determines that the groove 87 has a needle drop position. Notifies the needle drop position that is not included in the position (S23). For example, the CPU 41 displays an error message on the LCD 32 as a method of notifying the user. The CPU 41 corrects the needle drop position that is not included in the position of the groove 87 so that it is included in the groove 87 (S26). Specifically, the CPU 41 specifies the position of the groove 87 closest to the needle drop position not included in the groove 87 position, and offsets the needle drop position in the direction toward the position. At this time, the CPU 41 offsets the needle drop position until it is included in the groove 87, and corrects the sewing data by using the needle drop position when the needle drop position is included in the groove 87 as the corrected needle drop position. The CPU 41 returns the process to S1.

On the other hand, when it is determined in the process of S9 that the needle drop position is included in the position of the groove 87, that is, the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other is low (S9: YES), the CPU 41 is sewn. It is determined whether the start instruction has been obtained (S11). When the user is ready for sewing, he / she depresses the start switch 121 to input an instruction to start sewing. When the sewing start instruction is not acquired (S11: NO), the CPU 41 waits for the sewing start instruction. When the user depresses the start switch 121 and obtains the instruction to start sewing (S11: YES), the CPU 41 sets the variable N to 1 (S13). The variable N is a variable for reading out the coordinates of the needle drop position included in the sewing data to which the correction amount (X, Y, θ) determined in S129 is applied, in the sewing order. The total number of needle drop positions in the sewing data after applying the correction amount (X, Y, θ) is equal to the total number of needle drop positions in the sewing data before applying the correction amount (X, Y, θ). Therefore, the last value of the variable N is the same as the last value of the variable n. The CPU 41 drives the X-axis motor 114 and the Y-axis motor 116 to sew the needle drop position in the Nth sewing order. Therefore, the cloth holding frame 80 is based on the sewing data to which the correction amount (X, Y, θ) is applied. (S15).

The CPU 41 sews the Nth needle drop position (S17). Next, the CPU 41 determines whether the variable N is the last value (S19). When it is determined that the variable N is not the last value (S19: NO), the CPU 41 increments N (S21). The CPU 41 returns the process to S15. The CPU 41 repeats the processes of S15 to S21 until the variable N reaches the final value, and executes sewing based on the sewing data to which the correction amount (X, Y, θ) is applied. When the variable N is determined to be the last value (S19: YES), the CPU 41 returns the process to S1 assuming that sewing is completed.

<Effect>
As described above, the CPU 41 detects the positional relationship between the position of the groove 87 of the overall image 68 and the virtual needle drop position P of the coordinate data (S115, S121). The CPU 41 calculates the correction amount (X, Y, θ) of the sewing data by analyzing the positional relationship by a statistical method (S113 to S129) (S129). The CPU 41 applies the calculated correction amount (X, Y, θ) to correct the sewing data (S133). Therefore, the sewing machine 1 can reduce the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other.

The CPU 41 acquires a plurality of divided images 25 generated by the photographing unit 52 photographing the groove 87 one by one a plurality of times as the entire image 68 (S105 to S111). The CPU 41 sets the relative position of the needle drop position of the coordinate data with respect to the position of each groove 87 of the plurality of divided images 25 according to the movement amount (X, Y, θ) indicated by a predetermined Cartesian coordinate system and polar coordinate system. Move (S115, S121). The CPU 41 detects the ratio of the divided images 25 in which the relative position of the virtual needle drop position P is included in the position of the groove 87 among the plurality of divided images 25 in a state where the relative position is moved by the amount of movement (S117, S123). The CPU 41 repeats the movement of the relative position of the virtual needle drop position P according to the movement amount and the detection of the ratio for each of the plurality of movement amounts. The CPU 41 calculates a correction amount (X, Y, θ) according to the movement amount of the maximum ratio among the plurality of detected ratios (S129). Therefore, the sewing machine 1 can reduce the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other.

The CPU 41 specifies whether or not there is a plurality of maximum ratios among the plurality of detected ratios (S127). When the CPU 41 determines that there are a plurality of maximum ratios (S127: YES), the CPU 41 determines a correction amount (X, Y, θ) according to a plurality of movement amounts corresponding to the plurality of maximum ratios (S127: YES). S129). Therefore, the sewing machine 1 can further reduce the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other.

The CPU 41 determines whether or not the needle drop position of the corrected sewing data is included in the position of the groove 87 in the acquired overall image 68 (S9). When the CPU 41 determines that the needle drop position is not included in the groove 87 position (S9: NO), the CPU 41 notifies the needle drop position not included in the groove 87 position (S23). Since the sewing machine 1 notifies the user of the needle drop position that is not included in the position of the groove 87, it is possible to notify the user of the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other regarding the corrected needle drop position.

When the CPU 41 determines that the needle drop position is not included in the groove 87 position (S9: NO), the CPU 41 corrects the needle drop position not included in the groove 87 position so that it is included in the groove 87. (S26). Therefore, the sewing machine 1 can further reduce the possibility that the cloth holding frame 80 and the sewing needle 11 interfere with each other.

The CPU 41 drives the feed mechanism 6 based on the conversion data to move the cloth holding frame 80 (S105). The CPU 41 drives the feed mechanism 6 to move the cloth holding frame 80, photographs the groove 87 of the cloth holding frame 80, and acquires the entire image 68 (S105 to S111). Therefore, the sewing machine 1 can efficiently photograph the entire groove 87 of the cloth holding frame 80 by driving the feed mechanism 6 based on the conversion data.

When the feed mechanism 6 is driven to move the cloth holding frame 80, the CPU 41 converts the sewing data into a predetermined position of the photographing range 45 of the photographing unit 52 as a virtual needle drop position of the sewing data (S101). .. Therefore, the sewing machine 1 can determine whether the virtual needle drop position and the cloth holding frame 80 interfere with each other without directly photographing the needle drop position of the sewing needle 11.

<Modification example>
In addition to the above embodiments, the present invention can be modified in various ways. The size, shape, color, etc. of the cloth holding frame 80 may be changed as appropriate. The shapes, sizes, arrangements, etc. of the grooves 87 and 88 and the recesses may be appropriately changed. The cloth holding frame 80 is attached to the holding portion 70 of the sewing machine 1 by the user, but the present invention is not limited to this, and the supply device for supplying the cloth holding frame 80 may supply the cloth holding frame 80 to the holding portion 70. The type, arrangement position, size of the photographing range, and the like of the image pickup element of the photographing unit 52 may be appropriately changed. For example, the type of the image sensor is a CMOS image sensor, but other elements such as a CCD may be used. Further, the arrangement position of the photographing unit 52 is not limited to the arrangement position at the lower end of the support portion 51, and the groove 87 of the cloth holding frame 80 may be arranged at a position where photography is possible. Although the photographing unit 52 has photographed the range indicated by the photographing range 45 (see FIG. 3), the photographing unit 52 may photograph a range smaller than the range indicated by the photographing range 45, or may photograph a large range. The various numerical values given in the embodiments are merely examples and can be changed as appropriate. Although the holding portion 70 is driven by the air cylinder 73, it may be electrically driven by using a motor, an actuator, or the like.

When the sewing machine 1 is capable of photographing the presser foot 13, the sewing machine 1 acquires the size of the tubular portion 131 of the presser foot 13 from the divided image 25, and automatically sets the setting range C according to the acquired size. May be good. At that time, the conversion data does not have to be generated. The setting range C may be a circular range, an elliptical range including a needle drop point, or a polygonal range. The sewing machine 1 does not have to be able to set the setting range C. The default value may be used for the setting range C. The sewing machine 1 does not have to be able to set a threshold value. The default value may be used for the threshold value. The threshold value may be, for example, the threshold value of an image processing filter capable of extracting a portion of a shade value in a predetermined range.

The sewing machine 1 does not generate the entire image 68 (see FIG. 6) of the groove 87 from the plurality of divided images 25 taken, and the photographing unit 52 executes the shooting once, and the groove 87 is formed from one image. The whole image 68 including the whole may be taken.

The binarization process is executed on a plurality of divided images 25 after acquiring the entire image 68, but the present invention is not limited to this, and the binarization process may be performed while acquiring the divided images 25. In the θ application process, the center position of the sewing data (that is, the origin of the cloth holding frame 80) is set as the center of rotation. For example, the center of rotation may be the center position 84A of the metal plate 84 (see FIG. 3). The center of rotation may be appropriately set as needed. Further, the rotation direction is not limited to the counterclockwise or clockwise rotation in the plan view, but may be set clockwise or counterclockwise around the origin in the side view. The movement amount (θ) is set in the range of -3 ° to 3 °, but is not limited to this, and may be appropriately set as needed. The sewing data is generated by applying the movement amount (θ) every 1 °, but it may be set appropriately such as every 0.1 °.

In the XY determination process, the amount of movement (X, Y) in the XY directions is determined based on the average value, but the present invention is not limited to this, and the median value may be acquired or the like. The average value acquisition process does not have to be executed. At that time, any one of the movement amounts having a plurality of maximum movements may be determined as the correction amount. In the sewing data correction process, the CPU 41 specifies the optimum movement amount (θ) and then specifies the movement amount (X, Y) in the XY directions, but the present invention is not limited to this. The CPU 41 may first specify the movement amount (X, Y) in the XY directions, and then specify the optimum movement amount (θ). The amount of movement (X, Y) is in the range of -5 to 5 pixels, respectively, but is not limited to this, and may be appropriately set such as -10 to 10 pixels.

The notified error message may be displayed on the display of the operation panel 8 instead of the LCD 32. The CPU 41 may notify an error by transmitting a warning sound of a buzzer or emitting a light of a lamp. The display unit for displaying the error message may be provided on the operation panel 8 or may be provided on the main body of the sewing machine 1 (for example, the upper part of the arm unit 4).

Each of the acquisition method, acquisition route, and device for storing various programs may be appropriately changed. The program for executing the main process may be received from another device via a cable or wireless communication and stored in a non-volatile memory or the like before the CPU 41 executes the program. Other devices include, for example, PCs, servers connected via a network, and the like. The sewing data processing device may be a dedicated device, a general-purpose device such as a PC, or, for example, the operation box 30 may function as a sewing data processing device.

Each process of the sewing process of the sewing machine 1 is not limited to the example executed by the CPU 41, and a part or the whole may be executed by another electronic device (for example, ASIC). Each process of the main process may be distributed by a plurality of electronic devices (for example, a plurality of CPUs). Each step of the sewing process can be reordered, steps omitted, and added as needed. The scope of the present disclosure also includes a mode in which an operating system (OS) or the like running on the sewing machine 1 performs a part or all of the main processing according to a command from the CPU 41.

In the above embodiment, the sewing machine 1 is an example of the sewing data processing device and the sewing machine of the present invention. The central position of the image sensor of the photographing unit 52 is an example of a predetermined position of the present invention. The CPU 41 that executes the processes of S107 to S111 is an example of the photographing control unit of the present invention. The CPU 41 that executes S129 is an example of the first calculation unit of the present invention. The CPU 41 that executes S133 is an example of the first correction unit of the present invention. The CPU 41 that executes S115 and S121 is an example of the first detection unit of the present invention. The CPU 41 that executes S117 and S123 is an example of the second detection unit of the present invention. The CPU 41 that executes S115 and S121 is an example of the third detection unit of the present invention. The CPU 41 that executes S127 is an example of a specific part of the present invention. The CPU 41 that executes S9 is an example of the determination unit of the present invention. The CPU 41 that executes S23 is an example of the notification unit of the present invention. The CPU 41 that executes S26 is an example of the second correction unit of the present invention. The CPU 41 that executes S101 is an example of the conversion unit of the present invention. The CPU 41 that executes S15 to S21 is an example of the sewing control unit of the present invention.

1: Sewing machine 6: Moving part 10: Needle bar 11: Sewing needle 30: Operation box 32: LCD
41: CPU
42: ROM
43: RAM
44: Storage device 52: Photographing unit 80: Cloth holding frame 81: Lower plate 82: Upper plate 87, 88: Groove

Claims (8)

In a sewing data processing device that processes sewing data for sewing a sewn object,
A photographing control unit formed on a cloth holding frame for holding the sewn object, photographing a groove through which the sewing needle of the sewing machine can be inserted by the photographing unit, and acquiring an entire image which is a photographed image including the entire groove.
Based on the whole image acquired by the photographing control unit and the coordinate data indicating the needle drop position of the sewing needle included in the sewing data, the groove position of the whole image and the needle drop position of the coordinate data And the detector that detects the positional relationship of
The first calculation unit that calculates the correction amount of the sewing data by analyzing the positional relationship detected by the detection unit by a statistical method.
A sewing data processing apparatus including a first correction unit that corrects the sewing data by applying the correction amount calculated by the first calculation unit. The imaging control unit
A plurality of divided images generated by the photographing unit photographing the groove one by one a plurality of times are acquired as the whole image.
The detection unit
A first detection unit that moves the relative position of the needle drop position of the coordinate data with respect to the position of the groove in each of the plurality of divided images according to the amount of movement indicated by a predetermined Cartesian coordinate system and a polar coordinate system.
In a state where the relative position is moved by the movement amount by the first detection unit, the ratio of the divided image in which the relative position of the needle drop position is included in the groove position among the plurality of divided images is determined. The second detector to detect and
With the third detection unit, the movement of the relative position of the needle drop position according to the movement amount by the first detection unit and the detection of the ratio by the second detection unit are repeated for each of the plurality of movement amounts. With
The first calculation unit
The sewing data processing apparatus according to claim 1, wherein the correction amount is calculated according to the movement amount of the ratio that becomes the maximum among the plurality of the ratios detected by the third detection unit. The first calculation unit
A specific unit for specifying whether or not there is a plurality of the maximum ratios among the plurality of ratios detected by the third detection unit is provided.
The first calculation unit
2. The second aspect of the present invention is that when it is determined that there are a plurality of the ratios at which the specific portion is maximized, the correction amount is determined according to the plurality of movement amounts corresponding to the plurality of maximum ratios. The sewing data processing device described in. A determination unit for determining whether or not the needle drop position of the sewing data after correction by the first correction unit is included in the groove position in the overall image acquired by the imaging control unit.
The claim is characterized in that when the determination unit determines that the needle drop position is not included in the groove position, the determination unit includes a notification unit that notifies the needle drop position that is not included in the groove position. Item 4. The sewing data processing apparatus according to any one of Items 1 to 3. A determination unit for determining whether or not the needle drop position of the coordinate data after correction by the first correction unit is included in the groove position in the overall image acquired by the imaging control unit.
Claims 1 to 4 include a second correction unit that corrects the needle drop position determined by the determination unit not to be included in the groove position to a position included in the groove position. The sewing data processing apparatus according to any one of the above. The imaging control unit
Claims 1 to 5 are characterized in that when the sewing machine drives a feed mechanism based on the sewing data to move the cloth holding frame, the groove of the cloth holding frame is photographed and the entire image is acquired. The sewing data processing device according to any one of the above. When the sewing machine drives the feed mechanism to move the cloth holding frame, a conversion unit that converts the sewing data by setting a predetermined position in the imaging range of the imaging unit as a virtual needle drop position of the sewing data. The sewing data processing apparatus according to claim 6, wherein the sewing data processing apparatus is provided. The sewing data processing device according to any one of claims 1 to 7.
A sewing machine including a sewing control unit that sews the sewn object based on the sewn data corrected by the sewn data processing device.

Images