JP2022060156A - Embroidery device, dyeing/embroidery system, and adjustment method of thread consumption amount - Google Patents

Abstract

To solve positional deviation of embroidery color on a cloth during an embroidery operation, even when an actual consumption amount of thread deviates from the assumption, in the case where a continuous thread in which color changes is used in an embroidery device.SOLUTION: An embroidery device which performs an embroidery operation according to embroidery data includes: a thread assumed consumption amount calculation part 505 for calculating an assumed consumption amount of thread in the embroidery action acquired from initial embroidery data inputted in advance; a thread consumption amount detection mechanism 6 for detecting an actual consumption amount of thread; and a thread consumption amount adjustment part 7 for adjusting the embroidery data to be outputted based on a difference between the calculated assumed consumption amount of thread and the detected actual consumption amount of thread, and for adjusting the actual consumption amount of thread in the embroidery operation.SELECTED DRAWING: Figure 7

Description

The present invention relates to an embroidery device, a dyeing / embroidery system, and a method for adjusting thread consumption.

It is known that in an embroidery device, the balance of tension between the needle thread and the bobbin thread is disturbed due to various factors, so that the balance of consumption of the needle thread and the bobbin thread is changed.

Therefore, Patent Document 1 proposes a technique for detecting the consumption amount of the needle thread in order to detect in advance a defect such as thread breakage due to a change in the consumption amount of the thread.

However, in Patent Document 1, although the thread consumption can be predicted, it cannot be corrected according to the embroidery situation.

On the other hand, as a control technique for an embroidery device, in Patent Document 2, when embroidering using continuous needle threads that change color, the upper thread is used so that the color change of the needle thread is not exposed on the embroidery surface. Embroidery data is set up to embroider the color change where the thread color changes so that it cannot be seen from the upper surface side.

However, even if the embroidery data for embroidering the color change of the needle thread so as not to be seen from the upper surface side is created as in Patent Document 2, the consumption amount of the needle thread changes from the prediction during the embroidery operation thereafter. If this happens, the position of the color change will shift.

Therefore, in view of the above circumstances, the present invention causes the position shift of the color of the embroidery on the cloth during the embroidery operation even if the actual consumption of the yarn deviates from the assumption when the continuous thread whose color changes is used. The purpose is to provide an embroidery device that eliminates the problem.

In order to solve the above problems, in one aspect of the present invention,
In an embroidery device that performs embroidery operations according to embroidery data
A thread estimated consumption calculation unit that calculates the estimated consumption of thread in the embroidery operation obtained from the initial embroidery data input in advance, and
A thread consumption detection mechanism that detects the actual thread consumption,
Thread consumption adjustment that adjusts the output embroidery data based on the difference between the calculated estimated consumption of the thread and the detected actual consumption of the thread to adjust the actual consumption of the thread in the embroidery operation. Provides an embroidery device, which is equipped with a thread.

According to one aspect, when a continuous thread whose color changes is used in the embroidery device, even if the actual consumption of the thread deviates from the assumption, the misalignment of the color of the embroidery on the cloth during the embroidery operation is caused. It can be resolved.

The schematic diagram of the embroidery apparatus which concerns on 1st Embodiment of this invention. The schematic block diagram of the embroidery apparatus which concerns on 1st Embodiment. The schematic diagram which shows the example of the seam of the upper surface side and the lower surface side of the upper thread and the lower thread with respect to the cloth. Schematic diagram of a cross section of a plurality of states of a seam with a needle thread and a bobbin thread for a cloth. The explanatory view of the sensor used for the consumption amount detection of the needle thread in the embroidery apparatus of this invention. The functional block diagram of the embroidery data editing mechanism and the arithmetic mechanism of the 1st control example of 1st Embodiment. The flowchart of the embroidery which concerns on the 1st control example of 1st Embodiment. An example of changing the stitch density and stitch length as a correction embroidery condition. Correction A table showing a simplified correction example when changing the stitch density as an embroidery condition. Correction A table showing a simplified correction example when changing the stitch length as an embroidery condition. An example of sewing on the back as a correction embroidery condition. Explanatory drawing of understitch in general embroidery. A table showing a simplified correction example when changing the stitch of the bottom stitch as a correction embroidery condition. An example of changing the stitch coordinates of the bottom stitch as a correction embroidery condition. The functional block diagram of the embroidery data editing mechanism and the arithmetic mechanism of the 2nd control example of 1st Embodiment. The flowchart of the embroidery which concerns on the 2nd control example of 1st Embodiment. The functional block diagram of the embroidery data editing mechanism and the arithmetic mechanism of the 3rd control example of 1st Embodiment. The flowchart of the embroidery which concerns on the 3rd control example of 1st Embodiment. The explanatory view of the sensor position of the optical sensor and the distance to the tip of a needle in the 3rd control example. The side schematic of the dyeing / embroidery system which concerns on 2nd Embodiment of this invention. The side schematic of the dyeing / embroidery system which concerns on 3rd Embodiment of this invention. The functional block diagram which concerns on the control of the superior control apparatus, the dyeing apparatus and the embroidery apparatus of the 3rd Embodiment.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. In the following drawings, the same components may be designated by the same reference numerals and duplicate explanations may be omitted.

<First Embodiment>
First, the embroidery device 1 will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic view of the embroidery device 1 according to the first embodiment of the present invention. FIG. 2 is a schematic block diagram of the embroidery device 1 according to the first embodiment of the present invention.

The embroidery device 1 shown in FIG. 1 includes a needle 11, a bobbin thread rotating body 12, a stage 13, a needle thread winding 14, a stitch sensor 15, a needle thread detection unit 16 of a usage amount detection mechanism, and an embroidery body 19. have.

The needle 11 has a needle thread N passed through a needle hole at the tip of the needle tip, and can be moved and driven in the vertical direction with respect to the cloth C.

The bobbin thread rotating body 12 has a bobbin thread bobbin 121, which is a bobbin thread supply means around which the bobbin thread B is wound, and a hook 122, and the bobbin thread bobbin 121 and the hook 122 are interlocked with the movement of the needle 11. And rotate. Although not shown, the bobbin thread rotating body 12 is also provided with a cylindrical inner hook for accommodating the bobbin thread bobbin 121, an outer hook on a bottomed cylinder, a cylindrical case integrated with the hook 122, and the like. Has been done. In addition, in FIG. 1, the bobbin bobbin 121 shows an example of a vertical rotation method (vertical full rotation kettle method, vertical half-rotation kettle method) in which the rotation direction is a vertical direction, but the bobbin thread bobbin 121 has a rotation direction. May be a horizontal rotation method (horizontal kettle method) in the horizontal direction.

The stage 13 is a table for holding the cloth C, and a hole 130 through which the needle 11 passes is formed. The stage 13 can move in the X direction and the Y direction for cloth feeding.

Hereinafter, the width direction of the embroidery device 1 is referred to as X, the depth direction of the embroidery device 1 is referred to as Y, and the height direction (vertical direction) is referred to as Z.

The needle thread winding 14 is a needle thread supply means in which the needle thread N is wound and the needle thread N is supplied to the needle 11.

The stitch sensor 15 is a sensor that detects the vertical movement of the needle 11, and is provided on a needle rod that holds the needle 11, for example, and corresponds to how many times the needle 11 moves up and down, that is, how many stitches it advances. Detect the number.

The needle thread detection unit 16 of the consumption amount detection mechanism includes the sensor 161 (166) (see FIG. 5), through which the needle thread N unwound from the needle thread winding 14 passes, and detects the actual consumption amount of the needle thread N. This is a means for detecting the transport speed or the transport timing of the needle thread N. The needle thread detection unit 16 and a part of the calculation mechanism 150 form a thread consumption detection mechanism 6 (see FIG. 6). The specific configuration of the needle thread detection unit 16 will be described in detail together with FIG.

The embroidery body 19 has an embroidery head 191 and a lower body 192. The embroidery head 191 is provided with a calculation mechanism 150 (see FIG. 2), and by controlling the movement (needle movement) of the needle 11 through which the needle thread N passes and the movement of the stage 13, the needle thread N and the upper thread N are controlled. The cloth C is embroidered using the bobbin thread B that is fed in response to the feed of the thread N. The lower body 192 is connected to the embroidery head 191 and is provided with a drive unit for driving the stage 13 and the bobbin thread rotating body 12.

Further, in the present invention, the "yarn" including the needle yarn and the bobbin yarn is a glass fiber yarn, a wool yarn, a cotton yarn, a synthetic yarn, a metal yarn, a wool, a cotton, a polymer, or a mixed yarn of a metal, a yarn, a filament, and the like. Alternatively, it is a linear member (continuous base material) to which liquid can be applied, and includes braids, flat cords, and the like.

Further, referring to FIG. 2, the embroidery device 1 has an embroidery data editing mechanism 140, a calculation mechanism 150, a drive driver 160, a drive motor 17, a needle up / down drive unit 181 as parts related to drive control. It has a bobbin thread rotation drive unit 182, an X-axis drive unit 183, and a Y-axis drive unit 184. Of these, at least the drive driver 160, the drive motor 17, and the needle vertical drive unit 181 are built in the embroidery head 191 on the upper side of the needle 11. Further, the embroidery data editing mechanism 140 and the calculation mechanism 150 may also be built in the embroidery head 191. On the other hand, the drive units 183 and 184 that move the stage 13 and the bobbin thread rotation drive unit 182 are provided on the lower body 192.

The embroidery data editing mechanism 140 acquires an embroidery image (embroidery file) that is the source of the embroidery data, and creates embroidery data (initial embroidery data) based on the embroidery image. Further, the embroidery data editing mechanism 140 outputs the created initial embroidery data or the modified embroidery data replaced from the initial embroidery data as necessary by the control of the calculation mechanism 150 to the drive driver 160 as embroidery data for output. ..

Here, the embroidery image is image data (embroidery design data) that is a manuscript of an embroidery pattern on a cloth. The embroidery data creation unit 402 of the embroidery data editing mechanism 140 decomposes the embroidery image, which is image information, for each color, and based on the size of the embroidery pattern on the cloth, the color of the thread to be used and each color on the thread. The continuation length is determined, and the embroidery data is created so that the thread of the determined color is used to form a stitch on the cloth.

More specifically, the embroidery data is "data that combines data on coordinates for moving the needle and items to be implemented at those coordinates". Specifically, the matters to be implemented at those coordinates are
(1) Insert the needle into the cloth, entangle it with the bobbin thread, return the needle to the surface of the cloth again, and then move it to the position where the needle should be inserted next.
(2) Ending or interrupting embroidery (including switching to another needle and cutting the thread to move to a distant place where the embroidery is not continuous),
(3) Moving to the initialization position (alignment position),
Etc. are included. Further, as the embroidery data file, formats such as ".dst" and ".pes" are generally known. The initial embroidery data is the data to be initially set and is the embroidery data before editing according to the thread consumption.

The calculation mechanism 150 calculates the estimated consumption of the needle thread based on the initial embroidery data, the progress of how many stitches have been advanced detected by the stitch sensor 15 and the like, and the actual upper thread detected by the thread consumption detection mechanism 6. With reference to the consumption amount of the thread N, the embroidery condition for correcting the deviation is set as necessary and output to the embroidery data editing mechanism 140.

The drive driver 160 drives and controls the drive motor 17 based on the embroidery data.

The needle vertical drive unit 181 is a so-called balance, and drives the vertical movement of the needle 11 through which the needle thread N is passed by converting the rotational movement of the upper shaft connected to the drive motor 17 into vertical movement.

The bobbin rotation drive unit 182 rotates the bobbin thread rotating body 12 in conjunction with the vertical movement of the needle 11 by the rotational movement of the upper shaft and the lower shaft connected via the belt cam crank.

The X-axis drive unit 183 and the Y-axis drive unit 184 are stage movement drive units (cloth feed units), and are interlocked with the vertical movement of the needle 11 and the rotation of the bobbin thread rotating body 12 by the rotational movement of the lower axis. Then, the movement of the stage 13 on which the cloth C is placed is driven in the X direction and the Y direction. At this time, as a method of feeding the cloth C, the entire stage 13 may be moved, or the feed dog provided in the hole 13O formed in the stage 13 may be moved.

The needle up / down drive unit 181, the bobbin thread rotation drive unit 182, the X-axis drive unit 183, and the Y-axis drive unit 184 are drive mechanisms 18 driven in conjunction with one drive motor 17. Therefore, the rotation of the drive motor 17 causes the needle 11 to move up and down, the bobbin thread rotating body 12 to rotate, and the cloth C to move XY on the stage 13. For example, one vertical movement of the needle 11 is linked to one or an integral number of rotational movements of the bobbin thread rotating body 12.

(Tension of needle thread and bobbin thread)
FIG. 3 is a schematic view showing an example of seams on the upper surface side and the lower surface side of the upper thread and the lower thread with respect to the cloth. In FIG. 3, (a) is a top view and (b) is a bottom view. FIG. 4 is a diagram illustrating a balance between a needle thread and a bobbin thread at a seam on a cloth. In FIG. 4, (a) shows the case where the tension balance between the needle thread and the bobbin thread is appropriate, (b) shows the case where the tension of the needle thread is large, and (c) shows the case where the tension of the bobbin thread is large.

In the embroidery device 1, when the needle 11 is lowered and the needle 11 penetrates the cloth C, the needle thread N is also drawn to the back side of the cloth C together with the needle 11. After that, when the needle 11 rises and is pulled out from the cloth C and returns to the front side of the cloth C, the needle thread N remains in a loop on the back side of the cloth C due to the frictional force between the needle 11 and the cloth C. At this time, the hook 122 is caught by the loop-shaped upper thread N due to the rotation of the lower thread rotating body 12, and the lower thread B passes through the loop of the upper thread N. Further, when the needle 11 rises above the cloth C, the position where the needle thread N and the bobbin thread B intersect is pulled up to the cloth C, so that a seam is formed on the cloth C.

An example of the seam thus formed is shown in FIG. FIG. 3 is an enlarged view of a seam embroidered with a pattern stitch (satin stitch) so as to fill the surface from top to bottom. In addition, in FIG. 3B on the back surface, in order to explain the relationship between the threads in an easy-to-understand manner, the hooked portion between the needle thread N and the bobbin thread B surrounded by the dotted line is loosely shown, but in reality, the hooked portion is the needle thread N. And the bobbin thread B are in contact with each other and are attracted to each other.

FIG. 4 is a cross-sectional view of the region shown by the alternate long and short dash line in FIG. In the cross section of the seam of FIG. 3, when the tension balance between the needle thread and the bobbin thread is appropriate, the cross section is as shown in FIG. 4 (a).

In the seam formed in this way, when the tension of the needle thread N is large, the needle thread N pulls the bobbin thread B as shown in FIG. 4 (b). Therefore, the amount of the needle thread N wrapping around to the back side of the cloth C is reduced. That is, the length BL of the bobbin thread on the back surface side is long, and the length NL of the needle thread is short. Therefore, if the tension of the needle thread continues to be high, the consumption amount (usage amount) of the needle thread becomes smaller than expected, and the consumption rate of the needle thread N becomes slower.

On the other hand, when the tension of the needle thread is small, the needle thread N is pulled by the bobbin thread B as shown in FIG. 4 (c). The amount of wraparound to the back side of the cloth C increases. That is, the length BL of the bobbin thread on the back surface side is short, and the length NL of the needle thread is long. Therefore, if the tension of the needle thread continues to be low, the consumption amount of the needle thread N becomes larger than expected, and the consumption rate of the needle thread N becomes faster.

As described above, the consumption rate of the needle thread N depends on the amount of wraparound to the back of the cloth C. As shown in FIGS. 4 (b) and 4 (c), when the amount of wraparound is different from the predicted amount, there is a large difference between the predicted amount of needle thread consumption and the cumulative amount of thread consumed as the embroidery is continued. Come out. Because the thread consumption is set according to the color of the needle thread, or because the needle thread is dyed for the predicted position of the thread consumption, if the colored thread is not placed in the correct position, the color after embroidery will be used. The position shifts and the embroidery pattern on the cloth collapses.

Therefore, in the present invention, the thread consumption is adjusted by detecting the consumption of the needle thread and adjusting the embroidery operation so as to reduce the difference from the predicted consumption.

As a method of detecting the difference in the consumption amount of the needle thread N, the actual needle thread consumption amount (detection information of the thread consumption amount detection mechanism 6) based on the actually detected detection information and how far the embroidery has progressed. The information (coordinate position information calculated from the stitch sensor 15) is compared with the estimated thread consumption amount predicted from the initial embroidery data. In the present invention, the actual amount of needle thread consumption is detected and calculated shortly before the change in the color of the thread that needs to be detected, and the amount of deviation in the consumption status of the needle thread is calculated by comparing with the assumed consumption amount. , The embroidery can be adjusted up to the thread switching position.

(Mechanism of needle thread consumption detection)
FIG. 5 is an explanatory diagram of a sensor used for detecting the consumption of the needle thread N in the embroidery device 1 of the present invention. In FIG. 5, (a) is a diagram in which the needle thread detection unit 16 is configured to include the rotary encoder 161 and (b) and (c) include the needle thread detection unit 16B and the optical sensor 166. It is a constructed figure. The rotary encoder 161 and the optical sensor 166 are called sensors.

In the detection method shown in FIG. 5A, the sensor 161 is a sensor provided on the transport roller 164 that accompanies the transport of the needle thread, and does not relate the detection of the needle thread N to the color. Note that FIG. 5A shows an example in which the transfer roller 165 is provided immediately before the needle thread N so that the needle thread N is appropriately wound around the transfer roller 164.

For example, the transfer roller 164 is provided with a rotary encoder 161 as a rotation sensor. The rotary encoder 161 is composed of an encoder wheel 162 that rotates together with a transfer roller 164 and an encoder sensor 163 that reads a slit of the encoder wheel 162.

In this configuration, when the needle thread N is conveyed, the transfer roller 164 guiding the needle thread N rotates, the encoder wheel 162 of the rotary encoder 161 rotates, and the linear speed of the needle thread N from the encoder sensor 163. An encoder pulse proportional to is generated and output.

Then, in the needle thread consumption calculation unit 504 (see FIG. 6) provided on the calculation mechanism 150 side, the cumulative transfer amount of the needle thread N is transferred from the rotation amount of the encoder pulse generated with the rotation of the transfer roller 164. By calculating, the yarn consumption is calculated. In this configuration, the needle thread detection unit 16 and the needle thread consumption amount calculation unit 504 constitute the thread consumption amount detection mechanism 6.

In the configuration of FIG. 5A, since the color change is not used for detecting the consumption amount of the needle thread N, for example, before a predetermined number of stitches when the color change position reaches the tip of the needle 11, which is assumed, etc. When detection is requested at a position where the same color continues, the consumption amount of the needle thread N can be detected at that timing even if there is no special color mark or boundary. The control using the sensor 161 will be described in detail with the flow of FIGS. 7 and 16 as a first control example and a second control example.

The optical sensor 166 shown in FIGS. 5 (b) and 5 (c) detects a specific color on the needle thread N by detecting the color of the needle thread N in a stretched state between the transport rollers 167 and 168. Read the timing.

In the detection method shown in FIG. 5B, the needle thread N is provided with a portion having a color different from that of the other portion serving as a mark. Then, the optical sensor 166 detects the timing at which the mark marker is read at the position facing the sensor (sensor position) as the detection timing of the needle thread N.

Since the marker is provided at a predetermined position on the yarn in advance, if the detection timing of the marker position is known, the previous transport distance, that is, the actual yarn consumption amount can be known. Here, if the distance from the detection position of the optical sensor 166 to the tip of the needle 11 and the embroidery position (where the embroidery is sewn) at the time of marker detection are known from the stitch sensor 15 or the drive driver 160, the detection timing From this, it is possible to calculate at which position of the actual embroidery the marker position comes. Then, if the marker detection timing is known, the estimated consumption amount up to the assumed marker position at that time can also be calculated.

In the detection method shown in FIG. 5 (c), the needle thread is continuously provided with different colors in the transport direction. Then, the optical sensor 166 detects the timing at which the boundary (color change position) of a different color is read at the position facing the sensor as the detection timing of the needle thread N.

Since the color change position is provided at a predetermined position on the yarn in advance, if the detection timing of the color change position is known, the previous transport distance, that is, the actual yarn consumption amount can be known. Here, if the distance from the detection position of the optical sensor 166 to the tip of the needle 11 and the embroidery position at the time of color change detection are known from the stitch sensor 15 or the drive driver 160, the color change position is in which position of the actual embroidery. Can be calculated. Then, if the detection timing of the color change position is known, the estimated consumption amount up to the assumed color change position at that time can also be calculated.

In the configuration using the sensor 166 shown in FIGS. 5 (b) and 5 (c), the needle thread detection unit 16B, the needle thread consumption calculation unit 504, and the color change position storage unit 513 (see FIG. 17) are used. It constitutes the thread consumption detection mechanism 6B. The control using the sensor 166 shown in FIGS. 5 (b) and 5 (c) will be described in detail as a third control example together with the flow of FIG. 18 and the explanatory diagram of FIG.

As described above, the actual consumption amount of the needle thread N can be obtained in the embroidery apparatus 1 of the present invention by using the sensors 161 and 166 having any configuration.

(Functional block of the first control example)
FIG. 6 is a functional block diagram of the embroidery data editing mechanism 140 and the arithmetic mechanism 150 of the embroidery device 1 in the first control example of the first embodiment. Both the embroidery data editing mechanism 140 and the arithmetic mechanism 150 are control devices, and are realized by information processing devices such as a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), and an FPGA (Field Programmable Gate Array). To.

The embroidery data editing mechanism 140 has an embroidery image acquisition unit 401, an embroidery data creation unit 402, a correction embroidery data creation unit 403, and an embroidery data replacement unit 404 in an executable manner.

The embroidery image acquisition unit 401 acquires an embroidery image (embroidery file) which is image data.

The embroidery data creation unit 402 creates embroidery data (initial embroidery data) based on the acquired embroidery image. The embroidery data is data in which coordinates for moving the needle 11 and what to do at that position are paired as described above. Although FIG. 6 shows an example in which the embroidery data editing mechanism 140 creates the initial embroidery data based on the embroidery image, the initial embroidery data may be directly input from the outside.

The modified embroidery data creating unit 403 creates modified embroidery data reflecting the correction embroidery conditions, if necessary, with respect to the initial embroidery data created by the embroidery data creating unit 402.

Initial embroidery data and modified embroidery data are input to the embroidery data replacement unit 404. If correction is not required, the initial embroidery data is sent to the drive driver 160 as embroidery data to be output, and if correction is required, it is sent to the drive driver 160. , The modified embroidery data is sent to the drive driver 160 as embroidery data to be output.

The calculation mechanism 150 includes a stitch data monitoring unit 501, a current embroidery position grasping unit 502, a consumption amount detection stitch number extraction unit 503, a needle thread consumption amount calculation unit 504, a needle thread estimated consumption amount calculation unit 505, and a consumption amount deviation amount calculation unit. It has 506, a correction threshold storage unit 507, a deviation correction necessity determination unit 508, a predetermined color thread remaining amount calculation unit 509, and a deviation correction embroidery condition setting unit 510.

The stitch data monitoring unit 501 acquires stitch data (number of stitches), which is data of how many stitches are output from the stitch sensor 15, that is, which stitch is currently being sewn, in real time.

The current embroidery position grasping unit 502 calculates the current embroidery position data, which is the extent to which the embroidery is recommended from the initial embroidery data and the stitch data.

Based on the initial embroidery data, the consumption detection stitch number extraction unit 503 is a time point that is several tens of stitches before the time point t2 at the position on the thread of the mark or the boundary color in the continuous needle thread N whose color changes. The thread consumption up to t1 and the number of stitches corresponding to the consumption up to the position on the thread are extracted and stored.

Then, the stitch data monitoring unit 501 sends a detection instruction to the sensor 161 at the timing t1 when the number of stitches detected by the stitch sensor 15 reaches the number of consumption detection stitches extracted by the consumption amount detection stitch number extraction unit 503. .. The sensor 161 which is a rotary encoder detects the cumulative transfer amount at the time point t1.

The needle thread consumption calculation unit (thread consumption calculation unit) 504 calculates the actual consumption amount of the needle thread 101 based on the number of stitches and the cumulative transfer amount detected by the sensor 161. As a result, the needle thread consumption calculation unit 504 calculates the actual thread consumption at the time point t1 (current time), which is several tens of stitches before the time point t2 at which the assumed color is switched.

The needle thread estimated consumption calculation unit (thread estimated consumption calculation unit) 505 is estimated for each needle advance based on the initial embroidery data and the current stitch data (data indicating how many stitches have been advanced). Predict thread consumption (estimated consumption). The assumed consumption of the needle thread N is, for example, large when the stitch between the stitches is long and the moving distance of the cloth C on the stage 13 is long, and the stitch is short, and the moving distance of the cloth C on the stage 13 is long. Is reduced when short embroidery continues.

Specifically, the needle thread estimated consumption amount calculation unit 505 calculates the estimated consumption amount of the thread at the time point t1. Further, in the dyeing region of the predetermined color before the color on the yarn is switched, the cumulative estimated consumption of the yarn of the predetermined color up to the time t2 when the assumed color is switched is also calculated.

The consumption amount deviation amount calculation unit 506 acquires the current embroidery position data from the current embroidery position grasping unit 502, and the actual needle thread consumption amount calculated by the needle thread consumption amount calculation unit 504 (detected and calculated at time point t1). The amount of deviation from the estimated consumption amount at the time point t1 predicted by the needle thread estimated consumption amount calculation unit 505 of the actual yarn consumption amount) is calculated.

The correction threshold storage unit 507 stores a threshold value (predetermined value) for the amount of deviation of the needle thread consumption that requires correction of the initial embroidery data.

The deviation correction necessity determination unit 508 compares the deviation amount calculated by the consumption amount deviation amount calculation unit 506 with the threshold value of the deviation amount stored in the correction threshold storage unit 507, and determines whether or not the initial embroidery data needs to be corrected. Is determined.

The predetermined color thread remaining amount calculation unit 509 continues the predetermined color from the time point t1 to the color switching position on the thread from the actual consumption amount of the thread at the time point t1 calculated by the needle thread consumption amount calculation unit 504. Calculate the remaining amount of thread (remaining thread amount).

The deviation correction embroidery condition setting unit 510 sets various embroidery conditions for correcting the initial embroidery data when the deviation correction necessity determination unit 508 determines that the initial embroidery data needs to be corrected. The embroidery conditions for correction are, for example, stitch density adjustment (FIG. 8 and 9), stitch length adjustment (FIG. 8 and FIG. 10), stitch increase / decrease (back stitching), and stitch coordinate adjustment of understitch (FIG. 13). , FIG. 14), etc., adjust the sewing method from the initial embroidery data.

At this time, the misalignment correction embroidery condition setting unit 510 is assumed to be the cumulative consumption of the actual thread of the predetermined color at the time t2'when the color is actually switched in the dyed region of the predetermined color before the color on the thread is switched. In the period T12 from the time point t1 to the time point t2'which is the actual color change position based on the difference in the consumption amount so that the cumulative estimated consumption amount of the yarn of the predetermined color at the time point t2 when the color is switched is the same. , Set the embroidery conditions to properly consume the remaining thread amount. The details of each embroidery condition will be described in detail together with FIGS. 8 to 14.

Then, when the initial embroidery data needs to be corrected, the correction embroidery data creation unit 403 applies the correction embroidery condition set by the deviation correction embroidery condition setting unit 510 to a part of the initial embroidery data. , Create modified embroidery data.

The embroidery data replacement unit 404 refers to the current embroidery position grasped by the current embroidery position grasping unit 502, and replaces the modified embroidery in the period T12 from the time point t1 to the time point t2'which is the actual color change position. The data is sent to the drive driver 160 as embroidery data for output. In the period other than the above, the embroidery data replacement unit 404 sends the initial embroidery data to the drive driver 160 as embroidery data for output.

In the present embodiment, the consumption amount deviation amount calculation unit 506, the correction threshold storage unit 507, the deviation correction necessity determination unit 508, the predetermined color thread remaining amount calculation unit 509, the deviation correction embroidery condition setting unit 510, and the correction in the embroidery device 1. The embroidery data creation unit 403 and the embroidery data replacement unit 404 function as the thread consumption adjustment unit 7. Further, in the thread consumption adjustment unit 7, the predetermined color thread remaining amount calculation unit 509, the deviation correction embroidery condition setting unit 510, the correction embroidery data creation unit 403, and the embroidery data replacement unit 404 function as the embroidery amount adjustment unit 8. do.

(Flow chart of the first control example)
FIG. 7 is a flowchart of embroidery according to the first control example of the first embodiment of the present invention. This flow is applied when the rotary encoder 161 shown in FIG. 5A is used as a sensor of the yarn consumption detection mechanism.

In step S101, the embroidery device 1 acquires an embroidery image.

In step S102, the embroidery data editing mechanism 140 creates initial embroidery data, and the calculation mechanism 150 calculates the estimated consumption of the needle thread for each needle (for each stitch).

In step S103, the embroidery device 1 starts the embroidery operation according to the initial embroidery data, and the stitch sensor 15 starts the detection (counting) of the number of stitches of the needle 11.

When the number of stitches counted in step S104 reaches the number of consumption detection stitches before the predetermined number of stitches at the color change position, in step S105, the thread consumption detection mechanism 6 determines the actual consumption of the needle thread N. Detect and calculate. The predetermined number of stitches before the color change position means, for example, 10 to several tens of stitches before the color change position.

In step S106, the calculation mechanism 150 assumes the needle thread to be associated with the actual consumption of the needle thread N detected and calculated in S105 and the number of stitches reached in S104 out of the estimated consumption calculated in S102. The deviation amount of the consumption amount is calculated by comparing with the consumption amount. That is, in S106, the actual consumption of the thread at the time point t1 (current time), which is several tens of stitches before the (future) time point t2 at which the assumed color is switched, and the estimated consumption amount at that time point t1 (current time). To compare.

In step S107, if the deviation amount calculated in S106 is greater than or equal to the predetermined amount (YES), the process proceeds to S108, and if the deviation amount is less than the predetermined amount (NO in S107), the process proceeds to S114 and the initial embroidery data remains. Continue embroidery.

In step S108, the calculation mechanism 150 sets the embroidery condition in order to correct the deviation amount.

Therefore, as an embroidery condition, from the time point t1 (current time) so that the actual consumption amount of the thread at the future time point t2'when the color on the thread is switched becomes the same as the estimated consumption amount at the future time point t2'. Adjust the consumption in the (future) period T12 up to the future time point t2'. The future time point t2'used for adjustment is the time when the stitch reaches the position where the color on the actual thread is switched, and is the time when the remaining amount of thread and the method of adjusting the embroidery change. For example, if the actual consumption at the current t1 is less than the assumed consumption, the consumption during the period T12 is increased, and if the actual consumption at the current t1 is larger than the assumed consumption, the consumption during the period T12 is increased. Set embroidery conditions to reduce.

In step S109, the embroidery data editing mechanism 140 creates corrected embroidery data (corrected embroidery data) by reflecting the correction embroidery conditions in the initial embroidery data.

In step S110, the embroidery data to be output by the embroidery data editing mechanism 140 is replaced with the modified embroidery data from the initial embroidery data and output to the drive driver 160.

In step S111, the drive driver 160 drives the drive motor 17 based on the replaced embroidery data (corrected embroidery data) during the period T12 until the point t2'of the actual color change position is reached at the tip of the needle 11 in S112. Control and embroider.

When the timing (time point t2') at which the actual color change position on the thread reaches the tip of the needle 11 in step S112 is reached, the initial embroidery data is returned to and embroidery is performed in step S113.

Then, in S115, when the number of stitches reaches the number of consumption detection stitches (t1a) before the predetermined number of stitches (t1a) at the time of the next color change position (t2a), the consumption amount of S105 to S114 is calculated and the embroidery data is calculated. Adjustment is performed, and stitching according to the stitch data is executed until all stitch data is completed in step S116.

When all the embroidery data is completed in step S116, the embroidery in the embroidery device 1 is completed.

As described above, in this control example, the estimated consumption amount of the needle thread associated with the number of stitches calculated from the initial embroidery data and the actual consumption amount of the needle thread detected and calculated by counting the number of stitches. According to the difference between the above, the embroidery conditions are set for the initial embroidery data, the modified embroidery data is created, and the needle thread N is consumed by embroidering according to the modified stitch data.

For example, in the embroidery device 1, when the bobbin thread 121 is rotated according to the interval of the vertical movement of the needle 11 by the drive motor 17 which is a single drive source as described above, the needle thread and the bobbin thread are threaded at the seam. However, it is adjusted to maintain the right balance. Here, the tension of the needle thread N suddenly fluctuates at the timing when the amount of needle thread used in the embroidery device 1 changes significantly, such as when the length of the stitch changes significantly. However, the tension of the needle thread N immediately after unwinding cannot be changed suddenly due to the rotational inertia force of the needle thread winding 14, but the tension of the bobbin thread is changed at the timing when the amount of the needle thread used changes drastically. Since it changes according to the rotation of 121, an imbalance in the balance between the needle thread and the bobbin thread at the seam occurs due to the difference in tension between the needle thread and the bobbin thread. As a result, the actual consumption of the needle thread temporarily increases or decreases from the assumed value.

Therefore, in the present invention, the consumption amount of the thread used for embroidery is adjusted by synthesizing the embroidery data so as to adjust the sewing method itself of the needle thread in another portion. With such control, when the embroidery device 1 uses continuous needle threads that change color, even if the amount of needle threads used differs from the assumption due to the tension difference between the upper and lower threads, the embroidery device 1 It is possible to eliminate the color misalignment caused by the consumption shift.

(Example of embroidery conditions for correction)
The embroidery conditions for correction will be described with reference to FIGS. 8 to 14 below.

FIG. 8 shows an example of changing the stitch density and the stitch length as the correction embroidery condition. 8 (a) is a diagram showing an example of embroidery with color change, and FIGS. 8 (b) to 8 (d) are patterns so as to fill the surface of the embroidery area of FIG. 8 (a). It is an enlarged view of the seam embroidered by the stitch (satin stitch). FIG. 8B is an enlarged view of a reference seam embroidered according to the initial embroidery data without any deviation in the consumption amount. FIG. 8C is an enlarged view of the seams embroidered by adjusting the seam density of the initial embroidery data. FIG. 8D is an enlarged view of the seam embroidered by adjusting the seam width (stitch length) of the initial embroidery data.

FIG. 9 is a table showing a simplified correction example when the stitch density is changed as the correction embroidery condition. FIG. 10 is a table showing a simplified correction example when the stitch length is changed as the correction embroidery condition. In the tables of FIGS. 9 and 10, the first row L1 of the row shows the initial embroidery data, the second row L2 shows the needle thread consumption state, and the third row L3 shows the adjusted stitch width (stitch length). In the fourth row L4, the adjusted stitch interval is shown, in the fifth row L5, the state of occurrence without adjustment is shown, and in the sixth row L6, the adjusted stitch state is shown. Further, in the second and subsequent rows, the first column C1 in the column shows the case where the consumption amount is small, the second column C2 shows the case where the consumption amount does not need to be corrected, and the third column C3 shows the case where the consumption amount is large. ing.

Here, in FIG. 8, when the embroidery proceeds from the left side, the color switching position by the continuous needle thread whose color changes is examined. Considering the embroidery as shown in FIG. 8A, the enlarged view of the reference seam embroidered according to the initial embroidery data without any deviation in the consumption amount is as shown in FIG. 8B. An example in which the time point t1 and later in FIG. 8B is simplified and embodied is the initial embroidery data shown in L1 in the tables of FIGS. 9 and 10.

Here, if the actual consumption of the needle thread detected and calculated is different from the prediction and the actual needle thread consumption is less than the assumed consumption amount, the needle thread will be left over if adjustment is not performed, and FIGS. 9 and 10 show. As shown in L5C1 of, the color switching position moves to the right.

On the other hand, when the actual consumption of the needle thread is larger than the expected consumption, if the adjustment is not performed, the needle thread will be insufficient and the needle thread will be excessive, and the color switching position will be as shown in L5C3 of FIGS. 9 and 10. Move to the left.

(Correction example 1)
In order to prevent such a situation, for example, in the example shown in FIGS. 8 (c) and 9 as one correction example, the consumption amount of the needle thread is adjusted by adjusting the sewing density of the thread up to the color switching position. do. This adjustment can be performed when the density of the embroidery stitch is greater than or equal to the value specified by the user.

In the example of FIG. 8, in the embroidery according to the initial embroidery data of FIG. 8B, the black area is filled with the stitches of 23 stitches, but the actual needle thread consumption is larger than the assumed consumption. In the adjusted embroidery of 8 (c), the black area is filled with 25 stitches.

Further, in the example of FIG. 9, in the embroidery according to the initial embroidery data of L1 and the embroidery when the actual and assumed deviation amount shown in C2 is within a predetermined amount, the stitch interval is 0. The black area is filled with 11 stitches at 3 mm.

When the actual needle thread consumption in FIG. 9 is less than the assumed consumption, in the adjusted embroidery shown in C1L6, the black area between t1t2'is filled with a stitch interval of 0.2 mm and 15 stitches. There is.

In this way, if the actual amount of thread used is less than expected at the time t1 several tens of stitches before the expected color switching time t2 due to the tension difference between the upper and lower threads, the color switching The remaining amount of thread to the position is large. Therefore, in the correction period (the period from t1 to t2') until the actual thread color switching position is reached, the amount of thread used can be increased by increasing the density of embroidery.

As a result, in the black dyed region of the yarn (the region before the color change), the actual cumulative consumption of the yarn at the future time point t2'where the color actually changes and the future time point t2 which is the assumed color switching position. Is the same as the cumulative estimated consumption of yarn in. Therefore, the actual continuous thread color switching position can be aligned with the color switching position on the embroidery image.

Since the table in FIG. 9 is simplified, there is a discrepancy in the picture regarding the remaining thread length of black in L5 and L6, but in actual control, t1 to the state that occurs without the adjustment shown in L5. The thread length (black) before the color change of t2 (corresponding to the cumulative estimated consumption of the thread at the future time point t2) is the state after the adjustment shown in L6 before the color change (black) after t1 to t2'. The yarn length (of) is controlled to be equal to the actual yarn consumption at the future time point t2'.

On the other hand, when the actual needle thread consumption is larger than the assumed consumption in FIG. 9, in the adjusted embroidery shown in C3L6, the stitch interval is 0.4 mm, the stitches are 7 stitches, and the black area between t1t2'. Is filled.

In this way, if the actual amount of thread used is larger than expected at the time t1 several tens of stitches before the expected color switching time t2 due to the tension difference between the upper and lower threads, the color switching The remaining amount of thread to the position is low. Therefore, in the correction period (the period from t1 to t2') until the actual thread color switching position is reached, the thread usage can be reduced by reducing the embroidery density.

As a result, in the black dyed region of the yarn (the region before the color change), the actual cumulative consumption of the yarn at the future time point t2'where the color actually changes and the future time point t2 which is the assumed color switching position. Is the same as the cumulative estimated consumption of yarn in. As a result, the actual continuous thread color switching position can be aligned with the color switching position on the embroidery image.

Here, in the correction for adjusting the stitch density when the actual amount of thread used is smaller than expected as in L6C1 of FIGS. 8 (c) and 9, the actual color switching time point t2'is assumed. It arrives later than the time t2 when the color is switched. On the other hand, as in L6C3 of FIG. 9, when the actual amount of yarn used is larger than expected, the actual color switching time point t2'reaches earlier than the expected color switching time point t2.

In this control, the thread consumption assumed from the data (stitch data) and the initial embroidery data of which stitch is sewn at the time point t1 before several tens of stitches at the future time point t2 which is the assumed color switching position. Detects the difference between the amount and the actual consumption. Then, based on the difference, when the difference is equal to or larger than the threshold value, in the period (correction period) T12 from the detection time point t1 to the future time point t2'which is the actual color change position, FIGS. 8 (c) and 9 As shown in L4C1 and L4C3 of the above, by adjusting the stitch interval, the output embroidery data is replaced with the modified embroidery data in which the stitch density of the embroidery is changed.

When controlling the stitches inside the embroidery device 1 as in the first embodiment, the data of the number of stitches indicating which stitch is sewn may be automatically acquired from the drive control timing of the drive driver 160, or may be obtained. , It may be detected from the number of stitches by the stitch sensor 15.

(Correction example 2)
Further, as another correction example, as shown in FIGS. 8D and 10, the width of the embroidery (the width of the seam), that is, the length of the stitch is visually determined only in the black portion (the area before the color change). Adjust the amount of needle thread consumption by increasing or decreasing in millimeters so that you do not know. This adjustment can be performed when the length of the embroidery stitch (seam width) is greater than or equal to the value specified by the user.

In the example of FIG. 8, since the actual needle thread consumption is smaller than the assumed consumption, the adjusted embroidery of FIG. 8 (d) is more than the stitch length of the embroidery according to the initial embroidery data of FIG. 8 (b). Has a longer stitch length. By such adjustment, the amount of yarn used can be increased in the correction period until the actual yarn color switching position.

Further, in the example of FIG. 10, in the embroidery according to the initial embroidery data of L1 and the embroidery when the actual and assumed deviation amount shown in C2 is within a predetermined amount, the stitch length is 10 mm between t1t2 and t1t2'. The black area is filled with.

In FIG. 10, when the actual needle thread consumption is smaller than the assumed consumption, in the adjusted embroidery, as shown in C1L6, the stitch length (seam width) is 11 mm and the black region between t1t2'. Is filled. By such adjustment, the amount of yarn used can be increased during the correction period.

On the other hand, when the needle thread consumption is larger than the assumed consumption, in the adjusted embroidery, as shown in C3L6, the stitch length (stitch width) is 9 mm, and the black area between t1t2'is filled. By such adjustment, the amount of yarn used can be reduced during the correction period.

In this control, the thread consumption assumed from the data (stitch data) and the initial embroidery data of which stitch is sewn at the time point t1 before several tens of stitches at the future time point t2 which is the assumed color switching position. Detects the difference between the amount and the actual consumption. Then, based on the difference, when the difference is equal to or greater than the threshold value, the embroidery width (stitch length) is set in the period (correction period) T12 from the detection time point t1 to the future time point t2'which is the actual color change position. Replace the output embroidery data with the changed modified embroidery data.

In this correction example, the stitch length is changed, but the number of stitches does not change. Therefore, even if the embroidery is adjusted, the embroidery time required for the correction period is almost the same as that before the correction.

Since the table in FIG. 10 is shown in a simplified manner, there is a discrepancy in the picture regarding the remaining thread length of black in L5 and L6, but in actual control, t1 to the state that occurs without the adjustment shown in L5. The thread length (black) before the color change of t2 (corresponding to the cumulative estimated consumption of the thread at the future time point t2) is the state after the adjustment shown in L6 before the color change (black) after t1 to t2'. The yarn length (of) is controlled to be equal to the actual yarn consumption at the future time point t2'.

In this way, by adjusting the stitch length (stitch width) during the correction period, the actual continuous thread color switching position can be aligned with the color switching position on the embroidery image.

In this way, in Correction Example 1 and Correction Example 2, the embroidery density and embroidery width are used as data for the embroidery conditions for correction, and are adjusted in real time immediately before the color switching and during the period until the color switching. By replacing the output embroidery data, the consumption of thread used for embroidery is adjusted. With such control, when the embroidery device 1 uses continuous needle threads that change color, even if the amount of needle thread used is different from the expected amount, it is a slight adjustment of the period until the color is switched. Therefore, it is possible to eliminate the color misalignment caused by the consumption shift in the embroidery apparatus 1 with almost no change in the embroidery area in the embroidery image.

(Correction example 3)
FIG. 11 shows an example of sewing on the back as a correction embroidery condition. If the detected thread consumption is less than the expected consumption, the initial embroidery data may be replaced so that the thread is sewn under the embroidery to be embroidered next. In FIG. 11, since the actual consumption of the black thread on the left side is small, the black thread is sewn on the back of the embroidery just before the embroidery of the gray thread on the right side starts, and the black thread is consumed. By this adjustment, the amount of yarn used can be increased.

In this control, embroidery is performed according to the initial embroidery data from the detection time t1 to the future time point t2, which is the assumed color switching position, and the future time point t2', which is the position where the color actually switches from the time point t2. Until then, the back stitch consumes the thread. As a result, in the black dyed region of the yarn, the actual cumulative consumption of the yarn at the future time point t2'where the color actually switches becomes the same as the cumulative estimated consumption of the yarn at the assumed future time point t2. Therefore, the actual continuous thread color switching position can be aligned with the color switching position on the embroidery image.

In this control, the difference between the assumed thread consumption amount and the actual consumption amount is detected at the time point t1 before several tens of stitches at the future time point t2, which is the assumed color switching position, and the actual consumption amount is detected. If there is little, embroidery is performed with the initial embroidery data up to the color change position, and by adding a stitch to sew down immediately after the color change position, the needle thread is consumed and the switching position is on the right side. It prevents it from shifting.

This stitching correction to the back is a correction performed when the measured consumption amount is smaller than the initial embroidery data, and the pattern is small, the stitch width is short or coarse, etc. in the set initial embroidery data. It is suitable for adjustment when it is not suitable to change the density and width of the stitches as shown in FIGS. 8 to 10.

(Correction example 4)
FIG. 12 is an explanatory diagram of understitching in general embroidery. FIG. 12A is an explanatory diagram showing a state after understitching, and FIG. 12B is an explanatory diagram showing a state in which a region is roundly filled by embroidery after understitching.

Generally, in embroidery, embroidery for reinforcement called understitching is performed to prevent the cloth from being distorted during embroidery. For example, in the case of circular embroidery as shown in FIG. 12 (b), by sewing first (understitching) as shown by the black line in FIG. Can be prevented from appearing.

In the present invention, the stitch length adjustment of the bottom stitch can be used to adjust the consumption amount of the needle thread. The stitch length adjustment (thread amount adjustment) of the undersew can be executed when the user specifies the undersew stitch to be used for the adjustment and the change range thereof.

FIG. 13 is a table showing a simplified correction example when the bottom stitch is adjusted as the correction embroidery condition. In the table of FIG. 13, the first row L1 of the row shows the initial embroidery data, the second row L2 shows the needle thread consumption state, and the third row L3 shows the adjusted stitch width (stitch length). The line L4 shows the stitch interval after adjustment, the fifth line L5 shows the amount of undersewn thread, the sixth line L6 shows the state of occurrence without adjustment, and the seventh line L7 shows the state of the adjusted stitch. There is. Further, in the second and subsequent rows, the first column C1 in the column indicates a case where the consumption amount is small, the second column C2 indicates a case where the consumption amount does not need to be corrected, and the third column C3 indicates a case where the consumption amount is large. ing.

In the example of FIG. 13, in the embroidery according to the initial embroidery data of L1 and the embroidery when the actual and assumed deviation amount shown in C2 is within a predetermined amount, the stitch width is 10 mm and the stitch interval is between t1t2 and t1t2'. The black area is filled with 0.3 mm, and the amount of underlay thread is 10 mm.

In the adjusted embroidery when the actual needle thread consumption is smaller than the assumed consumption, the bottom stitch thread amount is increased to 12 mm without changing the stitch width and spacing, as shown in C1L7. By such adjustment, the amount of yarn used can be increased in the correction period t1t2'up to the actual color switching position of the yarn.

On the other hand, when the needle thread consumption is larger than the assumed consumption, in the adjusted embroidery, as shown in C3L7, the bottom stitch thread amount is reduced to 8 mm without changing the stitch width and spacing. By such adjustment, the amount of yarn used can be reduced in the correction period t1t2'.

It should be noted that, as an embroidery for performing understitching, it is often performed when a wide range of patterns are sewn, but if the underlaying is white, colored parts and white parts appear alternately in continuous threads. In that case, the undersew also includes a colored part like the initial embroidery data so that it can be adjusted without changing the pattern stitch when there is a slight deviation, especially when the embroidery thread is consumed longer than it should be and the thread is insufficient. Therefore, it is preferable to lengthen the stained area a little in advance.

In this control, the thread consumption assumed from the data (stitch data) and the initial embroidery data of which stitch is sewn at the time point t1 before several tens of stitches at the future time point t2 which is the assumed color switching position. Detects the difference between the amount and the actual consumption. Then, based on the difference, when the difference is equal to or greater than the threshold value, the length (thread amount) of the understitch is set in the period (correction period) T12 from the detection time point t1 to the future time point t2'which is the actual color change position. Replace the output embroidery data with the modified embroidery data.

In this correction, the thread amount of the underlay is changed, but the number of stitches does not change, so even if the embroidery is adjusted, there is almost no change in the correction time. Furthermore, since an embroidery pattern is formed on the bottom stitch, adjusting the thread amount of the bottom stitch has no effect on the appearance, so the density and width of the stitch are changed as shown in FIGS. 8 to 10. Suitable for adjusting embroidery when it is not suitable.

In addition, since the table of FIG. 14 is shown in a simplified manner, there is a discrepancy in the picture regarding the remaining thread length of (bobbin thread + black) in L6 and L7, but in actual control, the adjustment shown in L5 is not performed. The yarn length (corresponding to the cumulative estimated consumption of yarn at the future time point t2) before the color change of t1 to t2 in the waking state is t1 to t2'in the adjusted state shown in L6. It is controlled so as to be equal to the thread length (cumulative consumption of the actual thread at the future time point t2') before the subsequent color change (bob thread + black).

In this way, by adjusting the thread amount of the underlay in the correction period, the actual continuous thread color switching position can be aligned with the color switching position on the embroidery image.

Further, if the amount of deviation of the needle thread consumption is large and the amount of deviation cannot be absorbed even if the adjustment is made by the bottom stitch, especially when the thread is insufficient, in addition to the adjustment of the stitch coordinates of the bottom stitch, FIG. -The density and length of the pattern stitch may be adjusted as shown in FIG.

Here, as an application example of the correction of the underlay, it is assumed that the embroidery is divided into a plurality of areas as shown in FIG. FIG. 14 shows an example in which a plurality of color regions are embroidered as a correction embroidery condition, and the stitch coordinates of the underlay are changed.

It is assumed that the white part in each region is the understitch, and the threads are dyed in the order of α → β → γ → δ, and the embroidery is performed in this order. The filled area is, for example, α is red, β is blue, γ is green, and δ is blue.

And in the order of embroidery,
(1) Underlaying of area α → (2) Pattern sewing of area α → (3) Underlaying of area β → (4) Pattern sewing of area β → (5) Underlaying of area γ → (6) Area γ Pattern sewing → (7) Underlaying of area δ → (8) Pattern sewing of area δ. The bottom stitch is usually performed with white thread.

When the needle thread is consumed longer than it should be when embroidering the area of step (2), the thread is insufficient and the area β of the next step (4) is originally dyed blue in the embroidery of the pattern stitch. The white thread of the underlay of the region β of the step (3) is mixed in the thread to be sewn.

Therefore, if the consumption is already large at the time of the step (2) at the time of the understitching of the region β of the step (3), the position (stitch) at which the needle 11 is struck in the understitching of the region β of the step (3). By changing the coordinates), the amount of thread used for the underlay of the area β in the step (3) is reduced, and the amount of thread consumed is adjusted.

On the other hand, if it is consumed shortly, in the understitching of the next step, the thread consumption is increased by increasing the amount of thread used for the underlaying by changing the position (stitch coordinates) at which the needle 11 is struck. Can be adjusted.

Here, the amount of thread consumed is significantly higher in the pattern stitch that fills the area than in the understitch. Therefore, in the case of such adjustment of the underlay, the difference between the assumed thread consumption amount and the actual consumption amount is detected before the pattern sewing is completed several tens of stitches as the color switching position. Then, in the subsequent underlaying process, the initial embroidery data is replaced with the data in which the embroidery width (stitch length) is changed.

In this control, the pattern stitch is located on the outermost surface, and the bottom stitch is hidden under the pattern stitch. The starting point of (8) is considered to be a future time point t2β, t2γ, t2δ which is an assumed color switching position. Further, since the number of stitches in the understitch is small, the time points t1α, t1β, and t1γ for detecting the difference in consumption before several tens of stitches at the time points t2β, t2γ, and t2δ are set during the execution period of the pattern stitching in the previous colored region. Equivalent to.

Then, in this control, the total process of (1) + (2) + (3), the total process of (4) + (5), and the total of (6) + (7), which is the total area of colored dyeing and white. In each of the steps, the actual cumulative consumption of the yarn at the future time points t2β', t2γ', and t2δ' where the color actually changes, and the cumulative estimated consumption of the yarn at the assumed future time points t2β, t2γ, and t2δ. Adjust the bottom stitch so that is the same.

By adjusting the thread amount of the underlay in this way, it is possible to align the start position of pattern sewing, which is the actual color switching position of continuous threads, with the color switching position on the embroidery image in each area. can.

(Correction example 5)
In addition, although not shown, when the needle thread N is surplus, the consumption amount of the needle thread may be increased by consuming the thread other than the intended embroidery for which the excess thread is originally intended to be performed. The consumption of threads other than the desired embroidery means that the excess thread is (1) embroidered outside the embroidery area where the desired embroidery is to be performed, and (2) the thread is cut after the embroidery is performed outside the desired embroidery area. This includes the consumption of yarn due to (3) winding and cutting excess yarn. Also in this method, the length to the color change position of the thread can be adjusted (adjusted so as to increase) to prevent the color shift of the thread.

(Second control example)
FIG. 15 is a functional block diagram of the embroidery data editing mechanism and the calculation mechanism in the second control example of the first embodiment. In the first control example, the number of stitches before a predetermined number of stitches at the color switching position, which requires detection of the cumulative consumption of threads, was grasped by counting the number of stitches, but in the second control example, the color switching is performed. By counting the embroidery time, it is possible to grasp the position before a predetermined number of stitches. Only the differences from FIG. 6 will be described below.

In the embroidery device that can execute this control example, a constant velocity mode in which the operation for each stitch is made constant velocity can be set. The user can specify the drive speed (rpm) in the needle up / down drive unit 181 how many times the needle is dropped in the constant velocity mode. In addition, rpm is a parameter related to productivity, and the tension on the needle thread becomes stronger at the earliest, and the picture tends to collapse and the thread breaks easily, but the thread can be sewn quickly.

In the constant velocity mode, embroidery is basically executed at the specified drive speed rpm. Therefore, in such a constant velocity mode, it is possible to determine when and which stitch is sewn from the embroidery data before sewing. However, if the position where the needle is dropped suddenly becomes far away, the speed is switched to a reasonable speed inside the embroidery device 1. For example, the speed is switched internally on the machine side so that the needle does not break. In that case, the speed information is fed back.

In this control example, the calculation mechanism 150A has a consumption detection time calculation unit 511 and an embroidery time counting unit 512 instead of the consumption detection stitch number extraction unit 503.

Based on the initial embroidery data, the consumption detection time calculation unit 511 has a time point t1 that is several tens of stitches before the time point t2 at the position on the thread of the mark or the boundary color in the continuous needle thread N whose color changes. The amount of thread consumed up to and the number of stitches corresponding to the amount of consumption up to the position on the thread are extracted, and the time corresponding to the number of stitches is stored as the consumption amount detection time t1.

Further, the stitch data monitoring unit 501 notifies the embroidery time counting unit 512 when there is a change in the needle drop speed.

The embroidery time counting unit 512 counts the embroidery time, and when the embroidery time reaches the consumption detection time t1, sends a detection instruction to the sensor 161. When the needle drop speed is changed, the embroidery time counting unit 512 reflects the information and counts the embroidery time.

The sensor 161 which is a rotary encoder detects the cumulative transfer amount at the time point t1 as the needle thread consumption amount.

In this control example, the subsequent operations are the same as in the first control example, and the actual needle thread consumption detected by counting the embroidery time and the time calculated from the input initial embroidery data ( By setting embroidery conditions for the initial embroidery data and creating modified embroidery data according to the difference between the estimated consumption of needle thread associated with the number of stitches), and embroidering according to the modified embroidery data. , Adjust the consumption of needle thread N.

FIG. 16 is a flowchart of embroidery according to the second control example of the first embodiment. Only the differences from FIG. 7 will be described below.

In this flow, in step S203, the number of stitches is detected and the embroidery time is counted.

When the embroidery time counted in steps S204 and S215 reaches the consumption amount detection time corresponding to a predetermined number of stitches before the color change position, in step S205, the thread consumption detection mechanism 6 actually performs the needle thread N. Detects and calculates consumption.

Then, in step S206, the actual consumption amount of the needle thread N detected and calculated by the calculation mechanism 150A using the embroidery time as a trigger in S205, and the number of stitches reached in S204 out of the estimated consumption amount calculated in S202. The deviation amount of the consumption amount is calculated by comparing with the assumed consumption amount of the associated needle thread. That is, in S206, the actual consumption of the thread at the time point t1 (current time), which is several tens of stitches before the (future) time point t2 at which the assumed color is switched, and the estimated consumption amount at that time point t1 (current time). To compare.

In this control example, the subsequent operations are the same as in the first control example, and if the deviation amount is equal to or greater than the threshold value based on the deviation amount, the future time point t2 which is the actual color change position from the detection time point t1. 'The embroidery condition is adjusted in the period (correction period) T12, and the embroidery data to be output is replaced with the modified embroidery data changed from the initial embroidery data. The embroidery conditions for correction are, for example, stitch density adjustment (FIGS. 8 and 9), stitch length adjustment (FIGS. 8 and 10), and stitch increase / decrease (back stitching), as in the first control example. , Adjusting the stitch coordinates of the bottom stitch (FIGS. 13 and 14), etc., adjusts the sewing method from the initial embroidery data.

Due to such control, even in the second control example, when a continuous needle thread whose color changes is used in the embroidery device, the amount of the needle thread used is different from the assumption due to the tension difference between the upper and lower threads and the like. However, it is possible to eliminate the color misalignment caused by the misalignment of the thread consumption in the embroidery device.

(Third control example)
FIG. 17 is a functional block diagram of the embroidery data editing mechanism and the calculation mechanism of the third control example of the first embodiment. The third control example is a control example in which the optical sensor 166 shown in FIGS. 5 (b) and 5 (c) is used as a sensor of the consumption detection mechanism. Only the differences from the following first and second control examples will be described.

In the third control example, the sensor detected to calculate the needle thread consumption is not instructed from the outside at the detection timing, but when the optical sensor 166 detects the color change position or the mark, the needle thread is detected. Calculate consumption.

Therefore, in this control example, the timing instruction is not input to the optical sensor 166, and the calculation mechanism 150B refers to the color change position detected by the optical sensor 166, so that the color change position storage unit 51 have. In this configuration, the sensor 166 (upper thread detection unit 16B), the upper thread consumption calculation unit 504B, and the color change position storage unit 513 constitute the thread consumption detection mechanism 6B.

In this control example, the sensor 166 detects when the color change position or the marker position reaches the sensor position facing the sensor 166, and sends the time information of the detection timing (t1) to the needle thread consumption calculation unit 504B.

Further, the color change position storage unit 513 stores the distance from the position at the start point to the color change position, or the distance from the previous color change position to the current color change position.

The needle thread consumption calculation unit (thread consumption calculation unit) 504B calculates the actual consumption amount of the needle thread 101 based on the detection timing detected by the sensor 166 and the information in the color change position storage unit 513. .. For example, the needle thread consumption calculation unit 504B determines the actual thread consumption at the time point t1 (current time), which corresponds to the distance D shown in FIG. 19 and is several tens of stitches before the time point t2 at which the assumed color is switched. calculate.

FIG. 18 is a flowchart of embroidery according to a third control example of the first embodiment of the present invention. Since the optical sensor 166 applied to the third control example detects the timing (time information) by detecting the change in the color of the needle thread N as described above, it cannot be detected at the timing when the color does not change. Therefore, the method of calculating the yarn consumption using the sensor detection information is different from the flow of FIG. 7.

In this flow, when the color change position or the marker position reaches the sensor position facing the optical sensor 166 in step S304, it is detected at the timing (t1).

Here, FIG. 19 shows an explanatory diagram of the sensor position of the optical sensor 166 in the third control example and the distance to the tip of the needle 11. In this control example, as shown in FIGS. 8 to 14 above, the timing shortly before the color change position reaches the cloth C (tip of the needle 11) (for example, before several tens of stitches) is the optical sensor. It is an assumed timing that the color change position or the marker position of the needle thread N reaches the sensor position of 166. Therefore, in this control example, the distance D from the sensor position to the tip of the needle 11 is the length of the thread that can be used for the assumed embroidery adjustment to the color change position, that is, the predetermined number of stitches (several tens of stitches). It is the length of the thread that is expected to be consumed.

In the first control example and the second control example, the detection timing was a fixed time timing before the assumed predetermined stitch, but in this control example, as shown in FIG. 19, the tip of the needle 11 is from the sensor position. Since the distance D to is fixed, the detection timing is a fixed distance and time variation timing in which the distance from the start position or the previous color change position to the current color change position is fixed.

Therefore, when the thread consumption is large and the transfer speed is high, the detection timing at which the color change position or the marker position reaches the sensor position arrives earlier than expected, and when the thread consumption is small and the transfer speed is slow. Will reach the sensor position later than expected.

Then, in step S305, the needle thread consumption calculation unit 504B calls the thread distance from the color change position storage unit 513 to the color change position or the marker position as the actual thread consumption at the detection timing. Output (calculate). At the same time, the needle thread estimated consumption amount calculation unit 505 calculates the estimated consumption amount at the detection timing by using the detection timing, the actual embroidery position, and the initial embroidery data.

In step S306, the deviation amount between the actual yarn consumption amount and the assumed consumption amount at the detection timing is calculated. Then, in step S307, if the deviation amount calculated in S306 is equal to or more than a predetermined amount, the process proceeds to S308, and if the deviation amount is less than the predetermined amount, the process proceeds to step S314 to continue embroidery with the initial embroidery data.

In step S308, the calculation mechanism 150B sets the embroidery condition in order to correct the deviation amount. Also in this example, the color change position is adjusted so as to actually reach the tip of the needle 11 at the actual timing (t2') when the color change position reaches the tip of the needle 11.

In this example, as shown in FIG. 19, the length that can be used for the adjustment to the assumed color change position is the length of the thread from the sensor position to the tip of the needle 11, so that the time that can be used for the adjustment ( T12) is the period from when the actual color change position or marker position arrives at the sensor position to when it reaches the needle tip.

If the actual thread consumption is less than expected, the color change position or marker position arrives at the sensor position later, so the length of the thread that can be used for adjustment to the actual color change position is longer than the distance D. Therefore, it is adjusted to increase consumption. On the other hand, when the actual thread consumption is larger than expected, the color change position or the marker position reaches the sensor position quickly, so that the length that can be actually used for adjustment to the color change position is shorter than the distance D. Therefore, it is adjusted to reduce consumption. By this control, in the dyeing region of the predetermined color before the color on the thread is switched, the cumulative consumption of the actual thread of the predetermined color at the time point t2'when the color is actually switched and the predetermined time at the time point t2 when the assumed color is switched. Adjusted so that the cumulative estimated consumption of colored threads is the same.

Then, in S309, the modified embroidery data is created so as to reflect the embroidery condition for correction in the initial embroidery data, in S310, the embroidery data for output is replaced with the modified embroidery data and output, and in S312, the needle is output. Embroidery is performed according to the embroidery data (corrected embroidery data) replaced in S311 until the actual color change position on the thread reaches the tip of 11.

When the timing at which the actual color change position on the thread reaches the tip of the needle 11 in step S312, the embroidery data output in step S313 is returned to the initial embroidery data and embroidery is performed.

After that, in step S315, when the next color change position or marker position reaches the sensor position facing the optical sensor 166, it is detected at that timing. Then, the consumption amount of S305 to S314 is calculated and the embroidery data is adjusted. In the calculation of the actual consumption amount using the detection results from the second time onward, the distance of the thread from the previous (S304) color change position or marker position to the current (S315) color change position or marker position is called. Therefore, it is calculated as the actual thread consumption at the detection timing.

Then, the consumption amount of S305 to S314 is calculated and the embroidery data is adjusted. Embroidery according to the embroidery data (initial embroidery data or modified embroidery data) is executed until the embroidery data is completed in step S316, and when all the embroidery data is completed in S316, the embroidery in the embroidery device 1 is completed.

Even in this control, in order to set embroidery conditions for correction such as increase / decrease in embroidery density and embroidery width, addition of back stitch, adjustment of understitch stitch coordinate position, etc., the actual usage amount immediately before color switching The amount of thread used for embroidery is adjusted by detecting, calculating the deviation from the prediction, and adjusting in real time to replace the embroidery data. Due to such control, when the embroidery device 1 uses a continuous needle thread whose color changes, even if the amount of the needle thread used is different from the expected amount, the color due to the deviation of the consumption amount in the embroidery device 1 is used. The misalignment can be eliminated.

<Second Embodiment>
FIG. 20 is a schematic side view of the dyeing / embroidery system 100 according to the second embodiment of the present invention. In this system, a dyeing device 3 that imparts a color that changes in the transport direction to the needle thread wound from the needle thread winding is provided in front of the embroidery device 1C.

In the present embodiment, the needle thread winding 31 is provided not in the embroidery device 1C but in the dyeing device 3 on the upstream side in the transport direction.

Here, the dyeing apparatus 3 mainly includes a bobbin winding 31 around which the needle thread N is wound, a dyeing section 32, a fixing section 33, and a post-processing section 34.

In the dyeing device 3, the needle thread N drawn from the needle thread winding 31 is guided by rollers 351, 352 and continuously crawls through the dyeing section 32 to the embroidery device 1A.

The dyeing unit 32 includes a plurality of heads 321 (321K to 321Y) that discharge and apply a liquid of a required color to the needle thread N that is drawn out from the needle thread winding 31 and is conveyed, and a plurality of heads 321 that perform maintenance. It is equipped with an individual maintenance unit 322 (322K to 322Y).

The plurality of heads 321K to 321Y are discharge heads that discharge different colors from each other. For example, 321K is a head that ejects black (K) droplets (ink), 321C is a head that ejects cyan (C) droplets, 321M is a head that ejects magenta (M) droplets, and 321Y is yellow. A head that ejects the droplet of (Y).

The order of the colors is an example, and the colors may be arranged in an order different from this description. Further, in this example, an example in which the heads 321K to 321Y of four colors are provided is shown, but in the present invention, the continuous needle yarns may be dyed with a plurality of colors changing in the transport direction, and therefore at least two. The number of heads may be any number as long as the heads corresponding to a plurality of colors of colors or more are provided. Although not shown, the dyeing unit 32 may include a discharge head for discharging colorless droplets for coating the needle thread after dyeing in the most downstream portion, or the upper part before dyeing. A discharge head for discharging colorless droplets for coating the thread may be included in the uppermost stream.

Further, the maintenance units 322K to 322Y are provided under the heads 321K to 321Y of each color, and as a maintenance recovery operation, capping the head when not in use or receiving an empty droplet from the head 321. Or, the suction circulation operation of the nozzle is performed with the empty discharge receiver close to the head, and the wiping operation of the nozzle is performed.

The dyeing unit 32 in the dyeing apparatus 3 shown in FIG. 20 shows a configuration example of a liquid ejection method that dyes the needle thread N by ejecting ink from the head 321, but the dyeing unit 32 is a roller or the like. It may be a dyeing part of a coating method which applies ink by sandwiching the needle thread N.

The fixing unit 33 performs a fixing process (drying process) on the needle thread N of the ink ejected from the dyeing unit 32. The fixing portion 33 includes heating means such as an infrared irradiation means and a warm air blowing means, and heats and dries the needle thread N.

The post-treatment unit 34 includes, for example, a cleaning means for cleaning the needle thread N, a lubricant applying means for applying a lubricant to the surface of the needle thread N, and the like.

The dyeing apparatus 3 of the present invention may be provided with at least a dyeing unit 32 for applying a colored liquid to the needle thread N, and the fixing unit 33 and the post-processing unit 34 may not be provided. ..

Further, the dyeing apparatus 3 is also provided with a calculation mechanism 37 for controlling dyeing. The calculation mechanism 37 is electrically connected to the calculation mechanism on the embroidery device 1C side, and creates dyeing data including color and dyeing length information for the needle thread N based on the embroidery image acquired by the embroidery device 1C. And output to the dyeing unit 32. Then, the dyeing unit 32 dyes the needle thread N with a color and a dyeing length corresponding to the dyeing data.

<Third Embodiment>
FIG. 21 is a schematic side view of the dyeing / embroidery system according to the third embodiment of the present invention. In the present embodiment, the upper control device 2 which is the upper device is connected to the dyeing / embroidery system 100D. The host control device 2 is an information processing device such as a computer.

In the system according to the present embodiment, the needle thread detection unit 36 in the speed detection mechanism is provided not on the embroidery device 1B but on the dyeing device 3D side. As shown in FIGS. 20 and 21, the sensor units 16 and 36 of the consumption amount detection mechanism in the present invention may be mounted on either a dyeing device or an embroidery device.

FIG. 22 is a functional block diagram of a part related to the control of the upper control device 2, the dyeing device 3D, and the embroidery device 1D according to the third embodiment. The same part as in FIG. 7 is omitted from the description.

In the present embodiment, a part of the function of the calculation mechanism 150 of the embroidery device 1 of FIG. 7 is realized by the calculation unit 220 of the upper control device 2.

In the present embodiment, the calculation mechanism 150D of the embroidery apparatus 1D has a stitch data monitoring unit 501 and a current embroidery position grasping unit 502, which are involved in actual embroidery execution.

Further, the upper control device 2 has an embroidery data editing unit 210, a calculation unit 220, and a dyeing data creation unit. The embroidery data editing unit 210 has substantially the same function as the embroidery data editing mechanism 140 of FIG. 7.

The calculation unit 220 includes a consumption amount detection stitch number extraction unit 221, a needle thread consumption amount calculation unit 222, a needle thread estimated consumption amount calculation unit 223, a consumption amount deviation amount calculation unit 224, a correction threshold storage unit 225, and a deviation correction necessity determination. A unit 226, a predetermined color thread remaining amount calculation unit 227, and a deviation correction embroidery condition setting unit 228 are executably provided.

Further, the dyeing apparatus 3D has a calculation mechanism 37 having a dyeing control unit 371 and a sensor 361 (366). The sensor 361 (366) is a sensor having the same function as the sensor 161 (166) of the consumption detection mechanism shown in FIG.

In the present embodiment, the sensor 361 (366), the consumption amount detection stitch number extraction unit 221 and the needle thread consumption calculation unit 222 of the upper control device 2 detect the actual consumption amount of the needle thread. Functions as a detection mechanism 6D. Note that FIG. 22 shows a functional block diagram in the case of performing the same control as in the first control example, but in the case of performing the same control as in the second control example, the upper control device 2 calculates the consumption detection time. A unit and a consumption time counting unit are provided, and when the same control as in the third control example is performed, the upper control device 2 is provided with a color change position storage unit.

Further, in the present embodiment, the consumption amount deviation amount calculation unit 224, the correction threshold storage unit 225, the deviation correction necessity determination unit 226, the predetermined color thread remaining amount calculation unit 227, and the deviation correction embroidery condition setting unit in the upper control device 2 The 228, the embroidery data synthesis unit 213, and the embroidery data output unit 214 function as the thread consumption adjustment unit 7D. Further, in the thread consumption adjustment unit 7B, the predetermined color thread remaining amount calculation unit 227, the deviation correction embroidery condition setting unit 228, the embroidery data synthesis unit 213, and the embroidery data output unit 214 function as the embroidery amount adjustment unit 8D.

In the present invention, the needle thread estimated consumption amount calculation unit 505 (223) and the thread consumption amount adjustment unit 7 (7D) are a dyeing device, an embroidery device, or a higher-level control device that can be connected to the dyeing / embroidery system. It may be installed in either one.

In the present embodiment, the initial embroidery data is color-coded with reference to the initial embroidery data created by the upper control device 2 and the detection stitch data created by the embroidery device 1B or the current embroidery position data grasped from the embroidery status. The period up to the replacement position is replaced with the corrected embroidery data and output.

In the configuration in which the dyeing device by on-demand printing on the needle thread is provided as in the second embodiment and the third embodiment, it is necessary to match the dyeing position of the thread with the embroidery position. Dyeing is performed according to the initial embroidery data. However, after dyeing, if the tension difference between the needle thread and the bobbin thread in the embroidery device 1C (1D) deviates, the consumption amount of the needle thread deviates from the prediction and a misalignment occurs. By editing the initial embroidery data and adjusting the sewing method itself in the embroidery operation so that the remaining amount of thread up to the color switching position is consumed exactly, it is possible to eliminate the misalignment of embroidery that occurs after dyeing. can.

Although the preferred embodiments and examples of the present invention have been described above, the present invention is not limited to the above-described embodiments and examples. Further, the present invention can be variously modified or modified in light of the appended claims.

1,1C, 1D Embroidery device 2 Upper control device 3,3C, 3D Dyeing device 6,6B, 6D Thread consumption detection mechanism 7,7D Thread consumption adjustment unit 8,8D Embroidery amount adjustment unit 100, 100D Dyeing / embroidery system 11 Needle 12 Bobbin thread rotary body 121 Bobbin thread bobbin 122 Hook 13 Stage 14 Upper thread thread winding 140 Embroidery data editing mechanism 15 Stitch sensor 150, 150A, 150B Calculation mechanism 16, 16B Upper thread detector 161 Sensor (rotary encoder, sensor)
166 Optical sensor (sensor)
17 Drive motor 18 Drive mechanism 140 Embroidery data editing mechanism 150 Calculation mechanism 160 Drive driver 210 Embroidery data editing unit 220 Calculation unit 221 Consumption amount detection Stitch number extraction unit (thread consumption calculation unit)
223 Upper thread estimated consumption amount calculation unit (thread estimated consumption amount calculation unit)
504,504B Needle thread consumption calculation unit (thread consumption calculation unit)
505 Estimated needle thread consumption calculation unit (Estimated thread consumption calculation unit)
31 Bobbin winding 32 Dyeing unit 36 Upper thread detection unit 361 Sensor (rotary encoder, sensor)
366 Optical sensor (sensor)
B bobbin thread C cloth N upper thread

Japanese Unexamined Patent Publication No. 2004-201946 Japanese Unexamined Patent Publication No. 2008-289522

Claims (17)

In an embroidery device that performs embroidery operations according to embroidery data
A thread estimated consumption calculation unit that calculates the estimated consumption of thread in the embroidery operation obtained from the initial embroidery data input in advance, and
A thread consumption detection mechanism that detects the actual thread consumption,
Thread consumption adjustment that adjusts the output embroidery data based on the difference between the calculated estimated consumption of the thread and the detected actual consumption of the thread to adjust the actual consumption of the thread in the embroidery operation. An embroidery device equipped with a part. The embroidery device causes the cloth to perform embroidery using the needle thread passed through the needle and the bobbin thread sent in response to the feed of the needle thread.
The thread consumption detection mechanism detects the actual consumption of the needle thread and determines the actual consumption.
The thread estimated consumption calculation unit calculates the estimated consumption of the needle thread.
The embroidery device according to claim 1, wherein the thread consumption adjusting unit adjusts the consumption of the needle thread based on the difference between the estimated consumption amount of the needle thread and the detected actual consumption amount of the needle thread. The thread estimated consumption calculation unit predicts the estimated consumption of the thread from the data of the position on the cloth corresponding to the number of stitches of the needle sewn with respect to the cloth and the history of the position in the initial embroidery data. The embroidery device according to claim 1, wherein the amount is calculated. The yarn consumption detection mechanism includes a detection sensor provided on a roller accompanying the yarn to detect the cumulative amount of yarn conveyed, and a yarn consumption calculation unit.
The detection sensor detects the cumulative amount of yarn conveyed at a time before a predetermined number of stitches from the time when the expected color of the yarn is switched.
The embroidery device according to any one of claims 1 to 3, wherein the thread consumption calculation unit calculates an actual thread consumption based on a cumulative thread transfer amount. The thread consumption adjusting unit is
The difference between the detected actual consumption of the thread and the estimated consumption of the thread at the time t1 is compared at the time t1 which is a predetermined number of stitches before the time t2 when the color of the assumed thread is switched. Consumption deviation amount calculation unit and
In the dyed region of the predetermined color before the color on the thread is switched, the cumulative consumption of the actual thread of the predetermined color at the time t2'when the color is actually switched and the cumulative consumption of the predetermined color at the time t2 when the assumed color is switched From the initial embroidery data to the modified embroidery data in the period T12 from the time point t1 to the time point t2'which is the actual color change position based on the difference in the consumption amount so that the cumulative estimated consumption amount of the thread becomes the same. The embroidery apparatus according to any one of claims 1 to 3, further comprising an embroidery amount adjusting unit that replaces the output embroidery data and adjusts the embroidery operation on the cloth. The embroidery apparatus according to claim 5, wherein by counting the number of stitches, a time point before a predetermined number of stitches is detected before the time when the expected thread color is switched. When performing embroidery in constant speed mode
The embroidery apparatus according to claim 5, wherein by counting the embroidery time, a time point before a predetermined number of stitches is detected before the time point when the expected thread color is switched. The thread consumption detection mechanism includes an optical detection sensor for detecting a change in the color of the thread and a thread consumption calculation unit.
The distance from the sensor position detected by the optical detection sensor to the tip of the needle is set to a distance that is expected to be consumed by a predetermined number of stitches.
The optical detection sensor detects a color change position at the sensor position and determines the color change position.
The thread consumption calculation unit calls a fixed distance from the start position of the color change position detected by the optical detection sensor to obtain the actual thread consumption.
The thread estimated consumption calculation unit is based on the data of the position on the cloth corresponding to the number of stitches at the detection timing time t1 of the actual color change position detected by the optical detection sensor and the history of the position in the initial embroidery data. The embroidery apparatus according to any one of claims 1 to 3, which calculates the estimated consumption amount of the thread predicted at the detection timing time point t1. The thread consumption adjusting unit is
At the detection timing time t1 of the actual color change position detected by the thread consumption detection mechanism, the difference between the detected actual consumption of the thread and the estimated consumption of the thread at that time t1 is compared and consumed. The amount deviation amount calculation unit and
In the dyed region of the predetermined color before the color on the thread is switched, the cumulative consumption of the actual thread of the predetermined color at the time t2'when the color is actually switched and the cumulative consumption of the predetermined color at the time t2 when the assumed color is switched From the initial embroidery data to the modified embroidery data in the period T12 from the time point t1 to the time point t2'which is the actual color change position based on the difference in the consumption amount so that the cumulative estimated consumption amount of the thread becomes the same. The embroidery apparatus according to claim 8, further comprising an embroidery amount adjusting unit that replaces the output embroidery data and adjusts the embroidery operation on the cloth. The embroidery amount adjusting unit is
When the actual consumption of the thread at the time point t1 is smaller than the assumed consumption of the thread, the embroidery condition is set so as to increase the consumption of the thread at the period T12.
Any of claims 5 to 7, 9 in which the embroidery condition is set so as to reduce the consumption of the thread in the period T12 when the actual consumption of the thread at the time point t1 is smaller than the assumed consumption of the thread. The embroidery device described in item 1. The embroidery amount adjusting unit uses the modified embroidery data in which the stitch length of the initial embroidery data is changed as embroidery data to be output in the period T12 from the time point t1 to the time point t2'which is the actual color change position. Item 5. The embroidery device according to any one of Items 5 to 7, 9, and 10. The embroidery amount adjusting unit uses the modified embroidery data in which the thread sewing density is changed from the initial embroidery data as the embroidery data to be output in the period T12 from the time point t1 to the time point t2'which is the actual color change position. Item 5. The embroidery device according to any one of Items 5 to 7, 9, and 10. The embroidery amount adjusting unit adds or partially deletes stitches that were not originally input from the initial embroidery data in the period T12 from the time point t1 to the time point t2'which is the actual color change position. The embroidery device according to any one of claims 5 to 7, 9, and 10, which is the embroidery data to be output. The embroidery amount adjusting unit consumes the thread in a region other than the target embroidery, cuts the thread after consumption, or cuts the thread after winding, thereby adjusting the correction embroidery so as to increase the consumption of the thread. The embroidery device according to any one of claims 5 to 7 and 9 to 13, wherein the data is the embroidery data to be output in the period T12 from the time point t1 to the time point t2'which is the actual color change position. A dyeing device that dyes the needle thread and
A dyeing / embroidery system comprising the needle thread sent from the dyeing device and an embroidery device that performs an embroidery operation on a cloth according to embroidery data using the bobbin thread sent in response to the feed of the needle thread. There,
A consumption detection mechanism that detects the actual consumption of needle thread,
An estimated consumption amount calculation unit that calculates the estimated consumption amount of thread obtained from the initial embroidery data input in advance,
Thread consumption adjustment that adjusts the output embroidery data based on the difference between the calculated estimated consumption of the thread and the detected actual consumption of the thread to adjust the actual consumption of the thread in the embroidery operation. With a part,
The dyeing apparatus has a dyeing unit that imparts a color that changes in the transport direction of the needle thread to the needle thread.
The consumption detection mechanism is mounted on the dyeing device or the embroidery device.
The assumed consumption amount calculation unit and the thread consumption amount adjustment unit are a dyeing / embroidery system mounted on the dyeing device, the embroidery device, or a higher-level control device that can be connected to the dyeing / embroidery system. The embroidery device has a stitch sensor that detects the number of stitches of how many times the needle has sewn.
The estimated consumption calculation unit is
The dyeing / embroidery system according to claim 15, wherein the estimated consumption of the thread is calculated from the number of stitches of how many times the needle has been sewn detected by the embroidery device and the history of the position in the initial embroidery data. .. It is a thread adjustment method in an embroidery device that performs embroidery operation according to embroidery data.
Estimated consumption calculation step to calculate the estimated consumption of thread obtained from the initial embroidery data input in advance, and
A consumption detection step that detects the actual consumption of yarn,
An adjustment step of adjusting the output embroidery data based on the difference between the calculated estimated consumption of the thread and the detected actual consumption of the thread to adjust the actual consumption of the thread in the embroidery operation. How to adjust the consumption of yarn.

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