JP2023043080A - Print embroidery system, print embroidery apparatus, and embroidery adjustment method of print embroidery system - Google Patents

Abstract

To provide an apparatus which avoids misregistration of an embroidery color on cloth, and prevents deviation of a thread consumption amount from accumulating even if an actual consumed amount of the thread deviates from an estimate while performing embroidery using a thread whose color varies in a print embroidery system.SOLUTION: A print embroidery system includes: a dyeing data-processing part for inserting redundant data attached with a folding marker as a mark on a thread into a color change point where the color to dye by initial dying data changes; an embroidering data-processing part for inserting preliminary sewing data for sewing an under side of an embroidery region of a next color longer than the redundant data; a dying part for dying thread on the basis of a dying data containing the redundant data attached with the folding marker; and a preliminary sewing-controlling part for having a deviated amount between an estimated embroidery position and an actual embroidery position consumed by having preliminary sewing operation adjusted with a length so as to begin the preliminary sewing at a timing of reaching of estimated embroidery position on the embroidery data calculated from a stitch number to a color change point on the embroidery data, and make one reciprocation by returning at a returning marker as a mark performed.SELECTED DRAWING: Figure 11

Description

The present invention relates to a textile printing/embroidery system, a textile printing/embroidering apparatus, and an embroidery adjustment method for the textile printing/embroidery system.

In recent years, there has been known an embroidery system with a dyeing function that uses ink-jet technology to dye a needle thread so as to impart a color that changes in the conveying direction, and embroider using the dyed needle thread with an embroidery machine or a sewing machine. there is

In an embroidery machine with such an embroidery system, the balance of the consumption of the upper and lower threads changes due to the tension balance between the upper and lower threads being lost, the fabric being warped, and the thickness of the embroidery being uneven. As a result, positional deviation of the embroidery on the cloth may occur.

Therefore, in Patent Document 1, in order not to expose the color transition of the upper thread to the embroidery surface, the data for basting is inserted so that the color transition is positioned below the embroidery of the next color. , proposed to adjust the staining data.

Here, in Patent Document 1, the dyeing data is adjusted so that the basting portion of a predetermined length, including the color transition, is hidden in the planned embroidery area. If there is a change from the prediction, the position of the color transition will be shifted. If the amount of deviation from the actual consumption amount is large and the positional deviation accumulates, it can be assumed that even underlay of a predetermined length cannot cover the deviation amount.

SUMMARY OF THE INVENTION In view of the above circumstances, the present invention provides a method for avoiding misalignment of colors of embroidery on a cloth even if the actual amount of thread consumption deviates from expectations during an embroidery operation using continuous threads that change in color. To provide a textile printing/embroidering system that prevents the accumulation of deviations in thread consumption.

In order to solve the above problems, in one aspect of the present invention,
a printing device for printing threads;
a textile printing/embroidering system comprising: an embroidery device for embroidering a cloth with a needle based on embroidery data using the thread sent from the textile printing device;
Create the initial dyeing data that realizes the thread color of the embroidery data, and create redundant data with a turn-back marker as a mark on the thread at the color change point where the dyeing color changes with the initial dyeing data as necessary. a staining data processing unit to be inserted;
Underlying data for sewing the lower side of the embroidery area of the next scheduled color at the position where the redundant data is inserted on the dyeing data, which is a color change point on the embroidery data, is added to the redundant data. an embroidery data processing unit that inserts longer than
The textile printing device
Equipped with a dyeing section that prints yarn based on dyeing data including redundant data with turn-back markers,
The embroidery device is
Regardless of the actual embroidery position on the thread, basting is started at the timing when the assumed embroidery position on the embroidery data calculated from the number of stitches sewn by the needle reaches the color change point on the embroidery data. and a basting control unit that performs the basting operation adjusting the length so as to make one reciprocation by folding back using the turn-back marker as a mark, and consumes the difference between the assumed embroidery position and the actual embroidery position. We provide textile printing and embroidery systems.

According to one aspect, in a textile printing and embroidery system, during an embroidery operation using a continuous thread that changes color, even if the actual thread consumption deviates from the assumption, the color misregistration of the embroidery on the fabric is avoided. At the same time, it is possible to prevent accumulation of deviations in yarn consumption.

1 is a schematic side view of a dyeing/embroidering system according to a first embodiment of the present invention; FIG. 1 is a schematic side view of a dyeing section in a dyeing apparatus according to one embodiment of the present invention; FIG. Schematic bottom view of the staining section of one embodiment of the present invention. 1 is a schematic block diagram of a dyeing/embroidering system according to a first embodiment; FIG. FIG. 4 is a schematic diagram showing an example of seams on the top side and the bottom side of the upper thread and the bobbin thread on the cloth. FIG. 4 is a cross-sectional schematic diagram of a plurality of states of stitching with a needle thread and a bobbin thread on a cloth. FIG. 4 is an explanatory diagram of yarn consumption detection means in one embodiment of the present invention. FIG. 2 is a functional block diagram of an embroidery data processing unit, an embroidery data processing unit, and an arithmetic mechanism according to the first embodiment; An example of staining data with folding markers stained with the staining apparatus of the present invention. FIG. 4 is a sequence diagram showing exchanges between devices in the dyeing/embroidering flow of the present invention; 4 is a detailed flowchart showing the embroidery control operation of the present invention; FIG. 10 is a diagram showing a specific example of the redundant dyeing area on the dyed thread and the basting distance in the embroidery control operation of the present invention; FIG. 10 is a diagram showing a specific example of an embroidery pattern in which the embroidery control operation of the present invention is performed when the actual needle thread consumption is less than expected; FIG. 10 is a diagram showing a specific example of an embroidery pattern in which the embroidery control operation of the present invention is performed when the actual needle thread consumption is larger than expected; FIG. 5 is a diagram showing a modification of the embroidery device according to the first embodiment of the present invention; FIG. 5 is a schematic side view of a dyeing/embroidering system according to a second embodiment of the present invention; FIG. 11 is a functional block diagram relating to control of a host controller, a dyeing device, and an embroidery device according to the second embodiment; FIG. 8 is a schematic side view of a dyeing/embroidering apparatus according to a third embodiment of the present invention;

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated with reference to drawings. In each drawing below, the same components are denoted by the same reference numerals, and redundant description may be omitted.

<Overall composition>
First, a dyeing/embroidering system (textile printing/embroidering system) according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 4. FIG. FIG. 1 is a schematic side view of an example of a dyeing/embroidering system according to a first embodiment of the present invention. FIG. 2 is a schematic side view of the dyeing section in the dyeing apparatus of one embodiment of the present invention. FIG. 3 is a schematic bottom view of the staining section of one embodiment of the present invention. FIG. 4 is a schematic block diagram of the dyeing/embroidering system of the first embodiment.

Referring to FIG. 1, a dyeing/embroidering system 3 according to this embodiment includes a dyeing device 1 and an embroidery device 2 . In this system, the dyeing device 1 is electrically connected to the embroidery device 2 by wire or wireless communication so that information can be exchanged.

The dyeing apparatus 1 includes a needle thread spool 101 around which a needle thread N is wound, a dyeing section 103 , a fixing section 104 and a post-processing section 105 . The dyeing device 1 according to the present embodiment is a yarn coloring device that dyes yarn by liquid ejection.

In the dyeing device 1 , the thread N pulled out from the upper thread spool 101 is guided by the supply roller 102 and the conveying roller 106 and continuously crawled to the embroidery head 20 of the embroidery device 2 .

The dyeing section 103 includes a plurality of ejection heads 30 (30K to 30Y) for ejecting and applying a liquid of a desired color to the yarn N that is pulled out from the upper thread spool 101 and conveyed, and maintenance of each of the ejection heads 30K to 30Y. maintenance unit 35 comprising a plurality of individual maintenance units 36 (36K to 36Y).

Hereinafter, the width direction of the dyeing/embroidering system 3 will be called X, the depth direction of the dyeing/embroidering system 3 will be called Y, and the height direction (vertical direction) will be called Z.

Referring to FIG. 2, a plurality of ejection heads 30K to 30Y are respectively dyeing means (yarn printing means) and ejection heads (dyeing heads) for ejecting different colors. For example, 30K is a head that ejects black (K) droplets (ink), 30C is a head that ejects cyan (C) droplets, 30M is a head that ejects magenta (M) droplets, and 30Y is yellow. A head for ejecting droplets of (Y). The order of colors shown in FIG. 2 is an example, and may be arranged in an order different from this description. Although not shown, the dyeing section 103 may include, at the most downstream side, an ejection head that ejects colorless liquid droplets for coating the needle thread after dyeing.

The maintenance units 36K to 36Y are provided below the ejection heads 30K to 30Y for each color, and perform maintenance and recovery operations such as capping the heads when they are not in use and idle ejection of droplets from the ejection head 30. It serves as a receiver, performs a suction circulation operation of the nozzles with the idle discharge receiver close to the head, or performs a wiping operation of the nozzles.

Here, as shown in FIG. 3, each of the ejection heads 30K to 30Y has a nozzle surface 33 formed with a nozzle row 32 in which a plurality of nozzles 31 for ejecting droplets are arranged. Each ejection head 30 is arranged so that the extending direction of the nozzle rows 32, which is the direction in which the nozzles 31 are arranged, is the direction in which the yarn N is conveyed. Although only one nozzle row 32 is shown on the nozzle surface 33 in FIG. 3 , a plurality of nozzle rows 32 may be arranged on the nozzle surface 33 .

Returning to FIG. 1, the fixing unit 104 performs a fixing process (drying process) of the liquid ejected from the dyeing unit 103 on the applied yarn N. As shown in FIG. The fixing section 104 includes heating means such as an infrared irradiation means and a warm air blowing means, and heats and dries the yarn N. As shown in FIG.

The post-processing unit 105 includes, for example, cleaning means for cleaning the yarn N, lubricant application means for applying lubricant to the surface of the yarn N, and the like.

In the dyeing apparatus 1 of the present invention, at least the dyeing section 103 for applying a colored liquid to the yarn N may be provided, and the fixing section 104 and the post-processing section 105 may not be provided.

The dyeing unit 103 in the dyeing apparatus 1 shown in FIGS. 1 to 3 shows a configuration example of a liquid ejection method for dyeing the upper yarn N by ejecting ink from the ejection heads 30Y to 30K. 103 may be a dyeing unit of a coating method in which the needle thread N is sandwiched between rollers or the like to apply ink and print the needle thread N. FIG.

The embroidery device 2 shown in FIG. 1 has a needle 21 , a bobbin thread rotor 22 , a stage 23 and an embroidery head 20 . The needle 21 has a needle thread N passed through a needle hole at the tip of the needle tip, and can be driven to move vertically with respect to the cloth C. As shown in FIG.

The bobbin thread rotating body 22 has a bobbin thread 221 around which the bobbin thread B is wound and a hook 222 , and the bobbin thread 221 and the hook 222 rotate in conjunction with the movement of the needle 21 . Although not shown, the bobbin thread rotating body 22 is also provided with a cylindrical inner hook for housing the bobbin thread 221, a bottomed cylindrical outer hook, and a cylindrical case integrated with the hook 222. It is In FIG. 1, the bobbin thread bobbin 221 is exemplified by a vertical rotation system (vertical full-rotation hook system, vertical half-rotation hook system) in which the rotation direction is the vertical direction. may be a horizontal rotation method (horizontal pot method) in the horizontal direction.

The stage 23 is a table that holds the cloth C, and is formed with a hole 23O (see FIG. 7) through which the needle passes. The stage 23 is movable in the X and Y directions for cloth feeding.

The embroidery head 20 is provided with a computing mechanism 25 (see FIG. 4). 2, an embroidery pattern is formed on the cloth C by embroidering the cloth C using the needle thread N and the bobbin thread B that is fed in accordance with the feed of the needle thread N.

In addition, "thread" means glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer or metal, yarn, filament, or linear member (continuous Base material), including braided cords and flat cords.

Further, referring to FIG. 4, the embroidery apparatus 2 according to the present embodiment includes an embroidery data processing unit 24, an arithmetic mechanism 25, a stitch counter 26, a colorimetric sensor 27, and a drive unit as parts related to drive control. It has a driver 28 , a drive motor 29 , a needle vertical drive section 291 , a bobbin thread rotation drive section 2922 , an X-axis drive section 293 and a Y-axis drive section 294 . At least the driving driver 28 , the driving motor 29 , and the needle vertical driving section 291 are built in the embroidery head 20 above the needles 21 . Also, the embroidery data processing section 24 and the computing mechanism 25 may be built in the embroidery head 20 . On the other hand, the drive units 293 and 294 for moving the stage 23 and the bobbin thread rotation drive unit 292 are provided below the stage 23 .

The dyeing apparatus 1 also includes a dyeing data processing unit 107 and an arithmetic mechanism 108 as parts related to dyeing control. The arithmetic mechanism 108 controls the head driver 39 that drives the ejection heads 30 (30K to 30Y) to control the dyeing operation, and also controls the inlet side motor 60 that drives the inlet side drive motor (yarn supply roller) 106 to rotate. to adjust the yarn transport speed.

The embroidery data processing unit 24 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 processing unit 24 adds underlay data to the color change position of the initial embroidery data created, and outputs the embroidery data and the underlay data to the drive driver 28 .

Here, the embroidery image is image data (embroidery design) that becomes the original of the embroidery pattern on the cloth. The initial embroidery data creation unit 402 (see FIG. 8) of the embroidery data processing unit 24 separates the embroidery image into colors (RGB values), based on the sizes of the embroidery patterns on the cloth, so that they can be sewn in a smooth order. First, the color of thread to be used and the length of continuation of each color on the thread are determined, and embroidery data is created so as to form stitches on the cloth using the thread of the determined color.

More specifically, the embroidery data is "data combining the needle movement coordinate data and the item to be executed at the coordinate data". Specifically, the matters to be carried out at the coordinates are:
(1) Poke the needle into the cloth, entangle it with the bobbin thread, return the needle to the surface of the cloth, and then move the needle to the next position to pierce;
(2) Ending or interrupting embroidery (including switching to another needle or cutting thread to move to a remote location where embroidery is not continuous);
(3) moving to the initialization position (alignment position);
etc. are included. As embroidery data files, formats such as “.dst” and “.pes” are generally known. The initial embroidery data is data that is set first, and is embroidery data before editing according to the thread consumption amount.

The arithmetic unit 25 calculates the main embroidery operation for forming the embroidery pattern on the cloth based on the embroidery data, the basting data, the number of stitches advanced as detected by the stitch counter 26 and the like, and the colorimetric sensor 27. The drive driver 28 is driven and controlled so as to adjust the thread consumption amount according to the turned-back instruction, and to perform the basting operation.

The stitch counter 26 is a sensor that detects the vertical movement of the needle 21. The stitch counter 26 is provided, for example, on a needle bar that holds the needle 21. The stitch counter 26 corresponds to how many stitches the needle 21 has moved up and down, that is, how many stitches it has advanced. Detect numbers.

The colorimetric sensor 27 is a sensor that detects the color of the thread at the needle drop position, and detects the turn-back marker of the basting and the color of the start of embroidery. Note that the colorimetric sensor 27 may not be provided (see the modified example of FIG. 15).

The driving driver 28 drives and controls the driving motor 29 based on the bottom stitching embroidery data.

The needle vertical drive unit 291 is called a balance, and converts rotational motion of an upper shaft connected to the drive motor 29 into vertical motion, thereby driving the needle 21 through which the upper thread N is passed.

The bobbin thread rotation driving section 292 rotates the bobbin thread rotor 22 in conjunction with the up-and-down movement of the needle 21 by the rotational movement of the upper shaft and the lower shaft connected via the belt-cam-crank.

The X-axis driving portion 293 and the Y-axis driving portion 294 are stage movement driving portions (cloth feeding portions), and are interlocked with the vertical movement of the needle 21 and the rotation of the bobbin thread rotating body 22 by the rotary motion of the lower shaft. , the stage 23 on which the cloth C is placed is driven to move in the X and Y directions. At this time, as a method of feeding the cloth C, the entire stage 23 may be moved, or a feed dog provided in a hole 23O (see FIG. 7) formed in the stage 23 may be moved.

The needle vertical driving section 291 , the bobbin thread rotating driving section 292 , the X-axis driving section 293 , and the Y-axis driving section 294 constitute a driving mechanism driven in conjunction with one driving motor 29 . Therefore, the rotation of the driving motor 29 causes vertical movement of the needle 21, rotational movement of the bobbin thread rotor 22, and XY movement of the cloth C on the stage 23. FIG. For example, one up-and-down motion of the needle 21 is interlocked with one or integral number of rotations of the bobbin thread rotor 22 .

(Tension of needle thread and bobbin thread)
FIG. 5 is a schematic diagram showing an example of stitches on the upper surface side and the lower surface side of the needle thread and the bobbin thread with respect to the cloth. In FIG. 5, (a) is a top view and (b) is a bottom view. FIG. 6 is a diagram for explaining the balance between the needle thread and the bobbin thread in the stitches on the cloth. In FIG. 6, (a) shows a case where the tension balance between the needle thread and the bobbin thread is proper, (b) shows a case where the tension of the needle thread is large, and (c) shows a case where the tension of the bobbin thread is large.

In the embroidery device 2, when the needle 21 is lowered and penetrates the cloth C, the upper thread N is also drawn to the back side of the cloth C together with the needle 21. - 特許庁Thereafter, when the needle 21 rises and is pulled out of the cloth C and returns to the front side of the cloth C, the needle thread N forms a loop and remains on the back side of the cloth C due to the frictional force with the cloth C. - 特許庁At this time, the looped needle thread N is hooked by the hook 222 due to the rotation of the bobbin thread rotating body 22, and the bobbin thread B passes through the loop of the needle thread N. Furthermore, when the needle 21 rises above the cloth C, a stitch is formed on the cloth C by pulling up to the cloth C the position where the needle thread N and the bobbin thread B intersect.

An example of a seam formed in this way is shown in FIG. FIG. 5 is an enlarged view of a stitch embroidered by pattern stitching (satin stitch) so as to fill the surface from top to bottom. In FIG. 5B on the back side, in order to explain the relationship of the threads in an easy-to-understand manner, the hooked portion between the needle thread N and the bobbin thread B surrounded by a dotted line is shown loosely. and bobbin thread B are in contact with each other and attract each other.

FIG. 6 is a cross-sectional view of the area indicated by the dashed-dotted line in FIG. When the tension balance between the needle thread and the bobbin thread is proper, the cross section of the seam shown in FIG. 5 becomes as shown in FIG. 6(a).

In the seams 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. 6(b). As a result, the amount of the needle thread N wrapped around the back side of the cloth C is reduced. That is, the length BL of the bobbin thread becomes long and the length NL of the needle thread becomes short on the back side. Therefore, if the tension of the needle thread continues to be high, the needle thread consumption (used amount) becomes smaller than expected, and the consumption speed of the needle thread N slows down.

On the other hand, when the needle thread tension is small, the needle thread N is pulled by the bobbin thread B as shown in FIG. 6(c). The wrap-around amount to the back side of the cloth C increases. That is, the length BL of the bobbin thread is short and the length NL of the needle thread is long on the back side. Therefore, if the tension of the needle thread continues to be small, the consumption of the needle thread N becomes larger than expected, and the consumption speed of the needle thread N increases.

Thus, the consumption speed of the needle thread N depends on the amount of wrap around the cloth C to the back side. As shown in Fig. 6(b) and Fig. 6(c), when the wrap-around amount is different from the predicted amount, as embroidery continues, the predicted amount of upper thread consumption and the actual cumulative amount of thread consumed will greatly differ. difference comes out. In the present invention, the dyeing of the needle thread in the dyeing device 1 on the upstream side of the embroidery is performed with respect to the predicted position of the thread consumption amount. , the image of the embroidery pattern on the cloth collapses.

Therefore, in the present invention, the basting is started from the assumed position at the change of the color of the thread, and the basting is performed by turning back at the detected position of the turn-back marker on the thread and performing the basting so as to go back and forth. The amount of thread consumption is adjusted by performing the basting operation with the length adjusted so as to absorb the amount of deviation between the actual embroidery position and the actual embroidery position. A method of detecting the color turn-up marker (actual thread consumption) of the upper thread N will be described with reference to FIG. 7 below.

(detection means)
FIG. 7 is an explanatory diagram of the detection means of the present invention. 7, the embroidery head 20 and the bobbin thread rotor 22 are omitted. In FIG. 7, (a) shows an example in which the colorimetric sensor and the stitch counter are separate units, and (b) shows an example of integrated detection means.

The separate detection means shown in FIG. 7(a) detects the current position and the amount of consumption in the embroidery data by means of a stitch counter 26 that counts the number of stitches and a colorimetric sensor 27 that detects the color of the thread. Realized.

The colorimetric sensor 27 is, for example, an optical sensor such as a color laser sensor, and is a sensor capable of detecting at least the color of the yarn. A color laser sensor is a type of photoelectric sensor that emits light from a light-projecting part and detects light reflected by a detection object with a light-receiving part. The color laser sensor can detect the amount of light received for each of red, blue, and green, so it is possible to distinguish the color of the object (the color of the needle and thread). It can detect turn-around markers.

In this configuration, an independent stitch counter 26 that counts the number of stitches is provided in order to grasp the current position during the embroidery operation and detect the assumed position of the color change point. The stitch counter 26 is a sensor that detects the vertical movement of the needle 21. The stitch counter 26 is provided, for example, on a needle bar that holds the needle 21. The stitch counter 26 corresponds to how many stitches the needle 21 has moved up and down, that is, how many stitches it has advanced. Detect numbers.

In this configuration, the colorimetric sensor 27, which is a color laser sensor, detects the color at the needle drop timing when the needle 21 pierces the cloth C detected by the stitch counter 26, thereby determining the number of stitches and the needle hole of the needle. The color of the thread at the position can be sensed at the same time.

The integrated detection means 270 shown in FIG. 7(b) is, for example, a color laser sensor with a memory function. As shown in FIG. 7(b), the detection means 270 defines the needle drop position where the needle N sticks into the cloth C as the irradiation range of the object. to detect As a result, the integral detection means 270 can detect the number of stitches by counting the number of needle drops, and simultaneously detect the color of the thread at the timing used to form the seams (stitches) on the cloth. be able to.

FIG. 7 shows an example in which both the separate type and the integrated type have the means for detecting the number of stitches. Alternatively, the number of stitches corresponding to the current position may be called from the driving driver 28 driven based on the embroidery data without providing the stitch counter function. At the needle drop timing when the needle 21 pierces the cloth C, the number of stitches corresponding to the assumed color change point may be counted inside the arithmetic mechanism 25 in the subsequent stage in conjunction with the operation of the driver 28. .

As a result, regardless of which detection method is used, during the embroidery operation, the needle 21 used for the embroidery is used for turning back markers on the thread, which are the points where the color of the thread changes, and during the embroidery operation for counting color change points. can be grasped in real time without time error.

(function block)
FIG. 8 is a functional block diagram of a dyeing data processing unit, an embroidery data processing unit, and an arithmetic mechanism relating to dyeing and embroidery operations according to the first embodiment.

In this embodiment, an example in which the embroidery data processing section is provided in the embroidery device and the dyeing data processing section is provided in the embroidery device will be described.

The dyeing data processing unit 107 of the dyeing apparatus 1 includes an embroidery image/embroidery data acquisition unit 701 , an initial dyeing data creation unit 702 , a redundant data presence/absence determination unit 703 , a color difference threshold storage unit 704 , and a duration threshold storage unit 705 . , a redundant data/turning marker setting unit 706 and a redundant data/turning marker-included staining data creating unit 707 so as to be executable.

The embroidery data processing unit 24 of the embroidery device 2 includes an embroidery image acquisition unit 401 , an initial embroidery data creation unit 402 , an underlay data creation unit 403 , and an underlay embroidery data creation unit 404 .

The arithmetic unit 25 of the embroidery device 2 includes a stitch position calculation unit 501, a current position grasping unit 502, an underlay start position storage unit 503, an underlay start instructing unit 504, a forward underlay counting unit 505, and a forward stitch. It has a number storage unit 506 , an basting backward count unit 507 , an basting turn-back instruction unit 508 , a turn-back marker color storage unit 509 , an embroidery start instruction unit 510 , and an embroidery start color storage unit 511 .

The computing mechanism 25 functions as a basting control section.

The embroidery image acquisition unit 401 of the embroidery data processing unit 24 of the embroidery device 2 acquires an embroidery image (embroidery file) that is image data.

The initial embroidery data creation unit 402 creates embroidery data (initial embroidery data) based on the acquired embroidery image. Embroidery data is a pair of coordinate data for moving the needle 21 and what to do at that position, as described above. Although FIG. 8 shows an example in which embroidery data is created based on an embroidery image in the embroidery data processing unit 24, embroidery data (initial embroidery data) may be input directly from the outside.

The embroidery image/embroidery data acquisition unit 701 of the dyeing device 1 acquires the embroidery image and the embroidery data from the embroidery device 2 .

The initial dyeing data creation unit 702 creates dyeing data (initial dyeing data) based on the embroidery image and the embroidery data. Specifically, the initial dyeing data creation unit 702 determines the blending amount of each KCMY color used for dyeing to realize the thread color and the dyeing continuation length of each color in the KCMY ejection heads 30K to 30Y, which are included in the embroidery data. Create staining data containing information on

A redundant data presence/absence determination unit 703 determines whether to insert redundant data at the color change position of the created dyeing data.

The color difference threshold storage unit 704 stores color difference thresholds of adjacent two colors that require redundant data. The continuation length threshold storage unit 705 stores thresholds for the continuation lengths of two adjacent colors that require redundant data.

The redundant data presence/absence determination unit 703 inserts (inserts) redundant data from among a plurality of color transition points based on the color difference between two adjacent colors at a color transition point (color transition point) in the dyeing data. Select the change of . For example, when the color difference is very small or in the case of gradation, the positional deviation of thread colors in embroidery on cloth is not a concern. Therefore, the redundant data presence/absence determination unit 703 inserts redundant data when the color difference between two adjacent colors at the color change point exceeds a certain threshold value stored in the color difference threshold storage unit 704. is not inserted.

The redundant data presence/absence determination unit 703 selects whether or not to insert redundant data in the dyeing data based on the continuous length of dyeing of two adjacent colors at the point of color change. In the present invention, since the amount of thread consumption is adjusted by the underlay that sews the underside of the embroidery area of the next scheduled color, the underlay can be hidden by the main embroidery unless the next thread color continues for a certain length. Can not. Further, since the difference between the calculated thread consumption amount and the actual thread consumption amount increases as the embroidery progresses, the positional deviation between the embroidery and the thread color is small and not noticeable in the case of extremely short-distance embroidery. Therefore, the redundant data presence/absence determination unit 703 inserts redundant data when the lengths of the two adjacent colors at the color change point both exceed a certain threshold value stored in the continuation length threshold value storage unit 705. In the following, it is decided not to insert redundant data.

A redundant data/turn-back marker setting unit 706 sets a turn-back marker position in the redundant data. The position of the turn-back marker, which serves as a mark for turning back on the thread, is set at the midpoint of the redundant marker. In addition, since the turn-back marker is a direction adjustment stitch in the basting, it is preferable to set the length of the direction adjustment stitch to about one stitch and less than two stitches in consideration of positional deviation and folding. be.

A redundant data/turning marker-incorporated staining data creation unit 707 creates staining data by adding redundant data including folding markers to the color change points of the initial staining data, if necessary.

Processing of dyeing data in the dyeing apparatus 1 of the present invention will now be described with reference to the schematic diagram of FIG. In FIG. 9, (a) shows the initial staining data, and (b) shows the staining data with redundant data and folding markers.

Specifically, FIG. 9A shows the initial dyeing data before redundant data insertion, and the initial dyeing data corresponds to the dyeing data obtained by calculation assuming that the thread is ideally consumed. In this case, the embroidery start point is A, the color change point on the embroidery design is B, and the embroidery end point is C. As shown in FIG. However, in actual embroidery, thread consumption changes moment by moment due to the deflection and thickness variation of the cloth to be embroidered, variation in the tension of the bobbin and upper threads as shown in FIG. 6, external environment, and the like.

Therefore, in the present invention, in consideration of the case where the yarn consumption is larger than expected, dyeing is performed so as to insert redundant data into the dyeing data so as to absorb the next shortage of the yarn consumption variation.

FIG. 9(b) shows edited staining data after insertion of redundant data, in which BB′ of redundant data is inserted at the position corresponding to point B before insertion in FIG. 9(a). As will be described later, in the present invention, the redundant dyeing area dyed along the redundant data and the thread consumption variation are consumed by reciprocating underlay to adjust the amount of thread consumption. A turn-back marker D is inserted at the midpoint of BB' as a mark for turning back the basting.

Further, as shown in FIG. 9B, the redundant data inserted into the staining data is an area with the same color as the color before color change in the first half, and the color after color change in the latter half, with the turn-back marker as a boundary. is the same color region as And the length of the first half and the second half are almost equal.

Also, in the staining data, the turn-around marker inserted at the color boundary has a different color from the two adjacent colors at the color change point. The color of the folding marker, which serves as a mark, is different from the colors of the two adjacent colors, so that the boundary can be clearly recognized even if the boundary is difficult to see depending on the adjacent colors.

In the present invention, the turn-back marker on the thread serves as a mark detected by the colorimetric sensor 27 or visually by the user, and the turn-back marker serves as the starting point of the turn-back timing of the basting. By detecting the turn-up marker on the thread at the needle drop point, the actual amount of thread consumption up to the turn-up marker on the thread can be detected regardless of the progress of the embroidery data.

The redundant data/turning marker-inclusive dyeing data creation unit 707 outputs the edited dyeing data, which is the redundant data/turning-up marker-inclusive dyeing data created in this way, to the arithmetic unit 108 and the underlay data creation unit 403 of the embroidery apparatus. do.

Returning to FIG. 8, the arithmetic mechanism 108 of the dyeing apparatus 1 drives and controls the head driver 39 to dye the needle yarn at a predetermined conveying speed according to the dyeing data, and the ejection heads 30K of the dyeing section 103 are driven. to 30Y to discharge the dyeing liquid.

The underlay data creation unit 403 in the embroidery data processing unit 24 of the embroidery device 2 creates underlay data based on the staining data including the redundant markers and the folding markers created by the dyeing data including redundant data/turning-back markers creating unit 707 . create. The underlay data is set for underlay to be hidden under the next color thread's intended embroidery area for a distance sufficiently longer than the length of the redundant dyed area to be dyed along the redundant data. . In the present invention, the length of the underlay is increased or decreased in order to adjust the consumption of the needle thread. It is preferable to set it so that it is hidden under the embroidery pattern of the next color even if it is sewn.

Note that the basting data is set so that the route is the same in the outward and return passes, and the stitch lengths of the stitches in the return pass are set in the reverse order of the forward pass. Also, during execution of the forward basting, the starting position of the backward basting data when the forward basting data is interrupted and turned back to start the backward basting corresponds to the discontinuation point of the forward basting data. position. That is, the return basting data is cut from the original turning point to the position corresponding to the interrupting point, and the return basting is performed based on the return basting data along the sewn part of the forward basting that has already been painted. do embroidery.

The underlay embroidery data creation unit 404 inserts (inserts) the created underlay data into the embroidery data.

In the arithmetic unit 25 of the embroidery apparatus 2, the stitch position calculator 501 calculates stitch data (cumulative number of stitches) that is output from the stitch counter 26 and indicates how many stitches have been sewn, i.e., which stitch is currently being sewn. is obtained in real time. Note that the stitch position calculator 501 may calculate the current embroidery position in the embroidery data based on information from the drive driver 28 instead of the stitch counter.

A current position grasping unit 502 calculates the current embroidery position, which indicates how far the embroidery has progressed in the embroidery data, from the embroidery data and the stitch data, and grasps the progress of the embroidery.

The underlay start position storage unit 503 stores in advance the start position of the underlay data inserted at the color change point of the embroidery data.

When the current embroidery position data calculated from the number of stitches reaches the color change position and the underlay data exists at the color change position, the basting start instructing unit 504 notifies the driving driver 28 to The sewing operation is stopped and the basting operation is started.

A forward basting count unit 505 counts the number of stitches in the forward basting at the same time as the start of basting.

The colorimetric sensor 27 for detecting a change in the color of the surface of the needle thread is connected to the basting turn-back instructing section 508 and the embroidery start instructing section 510 .

The embroidery start color storage unit 511 stores an embroidery color for starting embroidery (lock stitching operation).

When the colorimetry sensor 27 detects the color for starting embroidery, the embroidery start instructing section 510 notifies the drive driver 28 to start the lockstitching operation.

A turn-around marker color storage unit 509 stores the colors of turn-around markers provided in the redundant data.

When the colorimetry sensor 27 detects the color of the turn-up marker stored in the turn-back marker color storage unit 509, the underlay turn-back instruction unit 508 notifies the drive driver 28 to turn back the underlay operation and instructs the turn-back. is notified to the outward stitch number storage unit 506 and the basting backward stitch count unit 507 .

When the turn-back instruction arrives, the driving driver 28 interrupts the forward basting route and starts the backward basting route. In the return basting, return to the basting start point so that the route is the same as the outward trip (follow the outward trip), and the stitch length of each stitch is in reverse order from the outward trip along the sewing part of the outward trip. The needle is moved up to

A forward stitch number storage unit 506 stores the number of outward stitches of the basting that are counted from the start of the basting to the turn-back marker when the basting turn-back instruction by the turn-back marker is received.

A basting return trip count unit 507 counts the number of stitches in the basting return trip from the step next to the basting turn-back instruction, and when the number of stitches reaches the same number as that of the basting outward trip, the basting is notified to the driving driver 28 to start the basting. Finish and start the main embroidery of the next color. According to the basting data, the stitch length of each stitch of the sewing part in the return pass is the same as the stitch length of the sewing part of the forward pass that is adjacently translated. The underlay lengths of the outward and return passes are equal.

In this example, the current position during basting is grasped by counting the number of stitches, and the lengths of the outward and return passes are aligned. The forward and return paths may be of the same length.

In the present invention, in a dyeing/embroidering system that performs embroidery while dyeing with changing colors, dyeing data is created so as to insert redundant data with turn-back markers as needed for the required length at color change points. , During embroidery, when the underlay reaches the turn-around marker at the midpoint of the redundant dyeing area dyed according to the redundant data, the length of the underlay is adjusted by turning back without depending on the forward length of the underlay , the needle thread consumption can be adjusted.

In the present embodiment, when the embroidery position reaches the turn-back marker on the thread, the thread color detection device, which is provided near the needle 21 of the embroidery head 20 as shown in FIG. 7, detects the thread color. Detected by the color sensor 27 . As described above, in the present embodiment, the basting turn-back signal is generated based on the colorimetric sensor 27, so that the basting can be accurately completed within the apparatus without the user's confirmation in the flow of the embroidery operation. can be made

(Embroidery position adjustment operation)
FIG. 10 is a sequence diagram showing exchanges between devices in the dyeing/embroidering flow of the present invention.

When an embroidery image is input in step S101, embroidery data (initial embroidery data) is created in the embroidery device in step S102.

In step S<b>103 , the embroidery image and embroidery data are sent to the dyeing apparatus 1 .

In step S104, the dyeing apparatus 1 creates dyeing data (initial dyeing data) to be dyed in a color that changes with each continuation length along the initial embroidery data.

In step S105, it is determined whether it is necessary to insert redundant data at the color change point of the dyed data based on the color difference before and after the color change point of the dyed data and the length of continuation of the colors before and after the color change point of the dyed data.

In step S106, if redundant data is required, the length of redundant data to be inserted at the color change point and the color of the turn-back marker are set based on the continuous length of the color before and after the color change point.

In step S107, staining data (edited staining data) in which the set redundant data with turn-back markers are inserted is created.

In step S108, the dyeing data including the redundant data and the turn-back marker is sent to the embroidery device 2. FIG.

In step S109, embroidery data including underlay data (edited embroidery data) is created.

In step S110, the embroidery start color and the color of the turn-back marker are stored, and the basting start position in the edited embroidery data is stored.

In step S111, the needle 21 and the stage 23 of the embroidery device 2 are set at the embroidery start position.

In step S112, when the embroidery device 2 notifies that the embroidery preparation is completed, in step S113, the dyeing device 1 starts dyeing and conveying the thread.

After detecting the embroidery start color of the dyed and supplied thread in the embroidery device 2, the embroidery operation is started in step S114.

Thereafter, in step S115, an embroidery control operation is performed. Details of this embroidery control operation will be described later with reference to FIG.

At step S116, when the edited dyeing data is finished, the dyeing device and the needle thread conveying operation are finished.

Also, in step S117, when the edited embroidery data is finished, the embroidery operation is finished.

As can be seen from FIG. 10, information is exchanged between the dyeing device 1 and the embroidery device 2 before the dyeing/embroidering operation is started. Therefore, the embroidery adjustment operation by the underlay of the present invention can be performed without complicating the control during operation of the dyeing/embroidering system 3 .

FIG. 11 is a detailed flowchart relating to control during embroidery operation according to the present invention. This flowchart is a detailed flowchart of step S115 in FIG.

When the embroidery device 2 detects that the supplied upper thread reaches the embroidery start color, the embroidery operation is started, and this flow is started (step S114 in FIG. 10).

When the embroidery operation is started, the embroidery device 2 starts the actual embroidery operation visible on the outermost surface of the cloth in accordance with the embroidery data in step S501.

In this embroidery operation, if there is no color change in the embroidery data in step S502 (NO), that is, if embroidery is to be completed with one color, the process proceeds to step S512 without executing the subsequent control. This embroidery operation is continued until the end of the data.

In step S502, if there is a color change in the embroidery data (YES), the process advances to step S503 to perform the subsequent embroidery operations.

In step S503, when the arithmetic unit 25 of the embroidery device 2 detects that the current embroidery position (assumed embroidery position) on the embroidery data calculated from the number of stitches has reached the color change point on the embroidery data, step Proceeding to S504, it is checked whether basting data is inserted at the color change position.

If the basting data is not inserted in step S504 (NO), the process proceeds to step S511 without performing the subsequent basting operation, and after the main embroidery of the current color is finished, the next color is sewn without performing the basting. Starts book embroidery.

If the underlay data is inserted in step S504 (YES), the process advances to step S505 to proceed with the underlay operation of the present invention.

In step S505, after the main embroidery based on the embroidery data of the current color is finished, the forward basting is started and the number of stitches of the forward basting is started to be counted. If the underlay data is inserted, the underlay data is calculated based on the number of stitches in S503, and at the timing when the embroidery position assumed on the embroidery data reaches the color change point of the embroidery data, the underlay data is calculated in step S505. In order to start the sewing operation, if there is no deviation in thread consumption, the basting forward path is started at the timing when the embroidery reaches the redundant dyeing area. Also, if the thread consumption is slow, the underlay forward pass will start even if the embroidery has not reached the redundant dyeing area, and if the thread consumption is fast, the underlaying will start after the embroidery reaches the redundant dyeing area. start the outbound route.

In step S506, when the colorimetric sensor 27 detects the turn-back marker, the forward basting is finished in step S507, and the course adjustment stitch, which is the turning point, is sewn, and the count of stitches in the forward basting is finished. Store the counted forward stitch number.

If there is no deviation in the amount of thread consumption, the embroidery distance of the forward basting is the same length as the redundant dyeing area of the forward basting in FIG. is the number of stitches.

In addition, when the thread consumption is slow, the embroidery distance in the outbound underlay is longer than the outbound redundant dyeing area, and the number of outbound stitches is greater than the number assumed in the underlay data.

On the other hand, when the amount of thread consumption is high, the embroidery distance in the outbound underlay is shorter than the outbound redundant dyeing area, and the number of outbound stitches is less than the number assumed in the underlay data.

After one course adjustment stitch has been sewn, in step S508, the return basting is started so as to follow the same path as the forward basting after turning back from the forward basting, and the number of stitches in the return basting is counted. . When forming a sewing part so as to follow the path of the forward basting in the backward basting, the stitch length of each stitch in the backward basting is the same as the stitch length of the forward basting that is adjacent in parallel. , in the backward basting, the stitch length of each stitch is reversed from that in the outward, and the same distance as in the outward is sewn back to the basting start point.

In step S509, when the counted number of stitches in the backward stitch of the basting reaches the stored number of forward stitches, the basting is assumed to have returned to the starting position, and in step S510, the basting is finished, and the book of the next color is sewn. Start embroidering.

By doing this, it is possible to sew the same number of stitches on the return pass as the number of stitches on the forward pass. The needle will come back.

If there is no deviation in thread consumption, the total embroidery distance for underlay embroidery is the same length as the redundant dyeing area in FIG. The number of stitches is the same, and the main embroidery of the next color starts from the end position of the backward redundant area, which is the start position of the next color dyed according to the initial dyeing data.

Also, if the amount of thread consumption is small and it is slower than expected, the total embroidery distance of the basting embroidery will be longer than the redundant dyeing area, and the main embroidery of the next color will be performed after the return path redundant area is completed. It is started with a slight delay from the starting position of the next color dyed along the initial dyeing data. As a result, the consumption of the needle thread, which tends to be delayed, is increased in advance at the start of the next color, so that the adjustment distance at the next color change point can be shortened.

In addition, if the amount of thread consumption is large and earlier than planned, the total embroidery distance of the underlay embroidery will be shorter than the redundant dyeing area, and the main embroidery of the next color will be completed before the end of the backward redundant area. , starting earlier than the position of the beginning of the next color dyed along the initial dyeing data.

In step S511, it is determined whether or not there is a color change (underlay data) on the subsequent embroidery data. If so, return to before S503, perform S503 to S511 in the same manner as in the current basting period, perform basting operations using turn-around points, and reflect this, repeating this loop. If the color change point is not reached, the embroidery operation is continued until the end of the embroidery data in step S513.

(Concrete example of consumption adjustment by basting)
Next, the dyeing area (redundant dyeing area) according to the redundant data and the effect of the underlay using the turn-back marker will be described with reference to the schematic diagrams of FIGS. 12 to 14. FIG.

FIG. 12 is a diagram showing a specific example of the basting length in the embroidery control operation of the present invention. In FIG. 12, (a) shows a case where there is no shift in the embroidery position, (b) shows a case where assumed thread consumption < actual thread consumption, and (c) shows a case where assumed thread consumption > actual thread. A consumption case is shown.

First, as shown in FIG. 12(a), when there is no misalignment in the embroidery position, that is, when the estimated thread consumption=actual thread consumption, the embroidery is calculated from the number of stitches, which is the timing to start basting. The timing at which the position reaches the color change point E on the embroidery data is the same timing as the timing ts at which the embroidery position reaches the redundant dyeing region from the dyeing region according to the needle thread dyeing data.

When the colorimetric sensor 27 detects the turn-back marker, the forward basting stitch is finished, and the course adjustment stitch which is the turning point is sewn, and the count of the forward stitches of the basting is finished and the counted number of outward stitches is stored. In FIG. 12A, the embroidery distance ED of the forward underlay is the same length as the forward redundant dyeing area BD (ED=BD), and the number of forward stitches is the number of stitches assumed from the underlay data.

Then, the stitch at the point D where the turn-back marker is detected at the needle drop position is sewn by one stitch at a position where the direction is bent in order to turn back from the forward path of the basting as a course adjustment stitch.

After the course adjustment stitches, the reverse underlay stitches are started and the count of reverse underlay stitches is started. When the counted number of stitches in the return pass of underlaying reaches the stored number of outbound pass stitches, the underlaying is finished and the main embroidery of the next color is started. By doing this, you can sew the same number of stitches as the number of stitches in the forward stitch, and use the return marker as a boundary to sew the underlay of the current color thread. (BD=DB').

In this example, the timing at which the embroidery position reaches the basting end point E' on the embroidery data is the same timing as the timing te at which the embroidery position reaches the redundant dyeing region of the upper thread. Therefore, the embroidery distance DE' in the outward path of underlaying becomes the same length as the outward path redundant dyeing area DB' (DE'=DB'), so that the distance of underlaying in FIG. Yarn consumption is equal to the length of the redundant dyeing area (EE'=BB').

Also, as shown in FIG. 12(b), in the case of assumed thread consumption<actual thread consumption, stitching is performed before the timing ts at which the actual embroidery position reaches the tip B of the redundant dyeing region of the needle thread. The embroidery position calculated from the number reaches the color change point (assumed color change point) E on the embroidery data. That is, the redundant dye area on the actual yarn arrives later than expected.

Since color change is started from an assumed color change point E, which is before the tip B of the actual redundant dyeing area, and the colorimetric sensor 27 detects the turn-back marker, the forward path of underlay is performed. The embroidery distance ED in the outward path of underlay in the example consumes more needle thread than the outward redundant dyeing area BD by the embroidery length corresponding to position E to position B. FIG.

Then, after the course adjustment stitch at the turn-back marker detection point D, the underlay of the return path is performed by the same distance as the outward path. Therefore, in this example, the timing at which the embroidery position calculated from the number of stitches reaches the basting end point E' on the embroidery data is the timing when the actual embroidery position is the end of the redundant dyeing area of the upper thread and the next color. It arrives later than the timing te at which the dyeing area along the staining data is reached. Therefore, in FIG. 12(b), the amount of upper thread consumption by underlaying corresponds to the embroidery length corresponding to position E to position B and position B' to position E' rather than the length BB' of the redundant dyeing area. It will be longer by the length of the embroidery to be done.

Therefore, when the basting is finished, the length corresponding to the position E' to position B' of the next main embroidery has already been consumed. It can be subtracted from the thread consumption consumed at the top and adjust the consumption of the top thread to eliminate or reduce the delay in the next color change.

In addition, as shown in FIG. 12(c), when the assumed thread consumption > the actual thread consumption, the actual embroidery position reaches the tip B of the redundant dyeing region of the needle thread after the timing ts, the number of stitches reaches the color change point (assumed color change point) E on the embroidery data. That is, the redundant dye area on the actual yarn arrives sooner than expected.

Since the color change is started from the assumed color change time point E after the tip B of the actual redundant dyeing area, and the forward path of the basting is performed until the colorimetric sensor 27 detects the turn-back marker, this The needle thread consumption of the embroidery distance ED in the outward path of the underlay in the example is smaller than that of the outward redundant dyeing area BD by the embroidery length corresponding to positions B to E. FIG.

Then, after the course adjustment stitch at the turn-back marker detection point D, the underlay of the return path is performed by the same distance as the outward path. Therefore, in this example, the timing at which the embroidery position calculated from the number of stitches reaches the basting end point E' on the embroidery data is the timing when the actual embroidery position is the end of the redundant dyeing area of the upper thread and the next color. It arrives earlier than the timing te at which the dyeing area along the staining data is reached. Therefore, in FIG. 12(c), the amount of upper thread consumption by underlaying corresponds to the embroidery length corresponding to position B to position E and position E' to position B' rather than the length BB' of the redundant dyeing area. It will be shortened by the embroidery length to be sewn.

Therefore, when the basting is finished, the length of the redundant dyeing area corresponding to the position E' to the position B' is not yet consumed, so the amount of thread consumption for that amount is reduced to the continuation length of the next color. Since it is added to the thread consumption that is consumed, the top thread consumption can be adjusted to eliminate or reduce the advance in the color change in the next color.

Such underlay control ensures that the upper thread near the end of the dyed region of the current color is consumed before the dyed region of the next color starts, and the thread near the dyed region of the next color By adjusting the length, it is possible to adjust the consumption so as to avoid misalignment at the next color change point. As a result, it is possible to avoid misalignment of the color of the embroidery on the cloth and prevent the accumulation of misalignment of thread consumption, so that the exposure of the upper thread color change to the embroidery surface and the embroidery pattern on the cloth can be prevented. It is possible to prevent the image from collapsing.

Here, since the lengths of the first half and the second half of the redundant dyeing area corresponding to the underlay to be folded back are equal, the adjustment of the needle thread consumption of the present invention is based on the length AB of the dyeing area of the current color and The more the length B'C of the dyeing area of the next color is equal, the more effective it becomes.

FIG. 13 is a diagram showing a specific example of an embroidery pattern in which the embroidery control operation of the present invention is performed when the actual needle thread consumption is less than expected. Here, as an example, it is assumed that the color of the thread currently being embroidered is blue thread, and the color of the thread to be embroidered next after the color change is red thread.

In FIG. 13, (a) is a diagram showing a desired embroidery image, (b) is a diagram showing the state at the end of actual main embroidery with the current blue thread, and (c) is a diagram showing the state of the turning point of the basting. FIG. 10(d) is a view showing the state at the end of basting, and (d) is a view showing the state after the next red main embroidery is started.

Time points t1 to t4 in FIG. 13 correspond to time points t1 to t4 in FIG. 12(b).

At the end of the current blue thread embroidery at t1 in FIG. 13(b), the amount of blue needle thread dyed according to the dyeing data is low, and there is a surplus of needle thread. Sew the tip of the next red embroidery area with blue thread.

Therefore, underlay stitching is started on the lower side of the red thread embroidery area (embroidery scheduled area), and forward underlay stitching is performed with blue thread up to the turn-back marker. At this time, a blue thread dyed according to the dyeing data and a blue thread dyed according to the redundant data are used to underlay the blue thread, which is the current thread color, in the forward path.

As shown in FIG. 13(c), when the underlay reaches the turn-back marker at t2, one course adjustment stitch is sewn to turn back the underlay and start the return path of the underlay.

Then, from the turn-back marker, red thread is used to underlay the return path for the same distance as the blue thread. At this time, the red thread dyed according to the redundant data and the red thread dyed according to the dyeing data are used, and the red thread of the next thread color is used for underlay in the return pass.

As shown in FIG. 13(d), when the basting reaches the original position at t3, that is, when the number of backward stitches becomes equal to the number of outward stitches, the main embroidery is performed with the next thread color, red. . In the return basting, as shown in FIG. 13(d), the basting is sewn along the sewing part of the forward so that the stitch length of each stitch is reversed from that of the forward so that the route is the same as that of the outward. The hand is moved until it returns to the starting position. Therefore, the length of underlay in the forward and return passes is equal, and the amount of consumption of blue thread and red thread in the underlay is equal. to perform the underlay. Therefore, at t3 in this example, as shown in FIG. 13D, the main embroidery is started after the red thread for the main embroidery has been consumed to some extent by the basting.

Then, as shown in FIG. 13(e), the main embroidery of the next color is continued while using the dyeing area according to the dyeing data that has been shortened by the basting for the main embroidery.

In this example, the upper thread is consumed in the basting and the amount of deviation is absorbed, so that the deviation of the thread consumption amount at the end point is also reduced. Even when the main embroidery and the underlay at the color change point are repeated thereafter, the consumption can be adjusted to the end by repeating the same underlay.

FIG. 14 is a diagram showing a specific example of an embroidery pattern in which the embroidery control operation of the present invention is performed when the actual needle thread consumption is larger than expected.

In FIG. 14, (a) is a diagram showing the desired embroidery image, (b) is a diagram showing the state at the end of the main embroidery of the blue thread predicted from the number of stitches, and (c) is the state of the turning point of the basting. (d) is a diagram showing the state at the end of basting, and (d) is a diagram showing the state after the next red main embroidery is started.

Time corresponding to B in FIG. 14 indicates a state slightly before time t1 in FIG. 12(c), and time t2 to t4 correspond to time t2 to t4 in FIG. 12(c).

At the start position B of the redundant dyeing area in FIG. 14(b), the consumption of the blue thread of the needle thread dyed according to the dyeing data is large, and if there is no underlay, the end of the blue embroidery area will be the next red thread. sew with thread.

Therefore, underlaying is started, and forward underlaying is performed with blue thread up to the turn-back marker. At this time, using the blue thread dyed according to the redundant data, the forward stitching of the blue thread of the current thread color is performed.

As shown in FIG. 14(c), when the underlay reaches the turn-back marker at t2, one course adjustment stitch is sewn, the underlay is turned back, and the return path of the underlay is started.

Then, from the turn-back marker, red thread is used to underlay the return path for the same distance as the blue thread. At this time, the red thread dyed according to the redundant data is used, and the red thread of the next thread color is used for the underlay of the return pass.

As shown in FIG. 14(d), at t3, when the basting reaches the original position, that is, when the number of backward stitches becomes equal to the number of outward stitches, the main embroidery is performed with the next thread color, red. . In the return basting, as shown in FIG. 14(d), the basting is sewn along the sewing portion of the outward so that the stitch length of each stitch is reversed from that of the outward so that the route is the same as that of the outward. The hand is moved until it returns to the starting point. Therefore, the length of the underlay in the forward and return passes is equal, and the amount of consumption of the blue thread and the red thread in the underlay is equal. Therefore, in this example, the underlay is performed only in the dyeing area according to the redundant data.

Then, as shown in FIG. 14E, the main embroidery of the next color is continued while also using the dyeing area according to the redundant data for the main embroidery. In this example, the red thread dyed according to the redundant data for underlay is used, and the actual embroidery of the red embroidery area is started before reaching the red thread dyed according to the dyeing data.

In this example, less needle thread is consumed for basting, and the difference in thread consumption at the end point is also reduced by the amount of deviation absorbed. Even if the main embroidery and the underlay at the color change point are repeated thereafter, the amount of consumption can be adjusted to the end by repeating the same underlay.

In this way, in the present invention, underlay is sewn back and forth once at the lower part of the next sewn part (embroidery area), which does not appear in the embroidery design, based on the inserted turning point, thereby reducing the calculated thread consumption. and the deviation of the actual thread consumption amount to adjust the embroidery color deviation. As a result, in a textile printing/embroidery system that embroiders while dyeing so that the color changes, in addition to adjusting the embroidery position at the current color change, it is possible to prevent the embroidery position from shifting at the next color change point. can be adjusted.

(Modification)
FIG. 15 is a diagram showing a modification of the embroidery apparatus according to the first embodiment of the invention.

In the above, an example in which the underlay turn-back marker is detected by the colorimetric sensor has been described, but the underlay turn-back marker may be arbitrarily selected by the user.

In this modification, when the user visually detects that the turn-back marker has reached the needle drop position, for example, by operating the button 201 shown in FIG. 15, the basting turn-back signal is issued.

In this modification, the operator visually detects that the embroidery position has reached the turn-back marker. Therefore, in the existing embroidery apparatus 2A, it is possible to adjust the needle thread consumption by the underlay adjustment of the present invention without adding a colorimetric sensor.

<Second embodiment>
FIG. 16 is a schematic side view of a dyeing/embroidering system (textile printing/embroidering system) according to a second embodiment of the present invention. In this embodiment, a host controller 4 is connected to the dyeing/embroidering system 3B. The host control device 4 is an information processing device such as a computer.

FIG. 17 is a functional block diagram of parts related to control of the host controller 4, the dyeing apparatus 1B, and the embroidery apparatus 2B according to the third embodiment. The description of the same parts as in FIG. 8 is omitted.

In this embodiment, the host controller 4 implements the functions of the dyeing data processing section of the dyeing device 1 and the embroidery data processing section of the embroidery device 2 shown in FIG.

The host controller 4 has an input section 410, a dyeing data processing section 420, and an embroidery data processing section 430 so that they can execute.

The input unit 410 has an embroidery image input unit 411 and an underlay amount selection unit 412 as necessary. In the above example, the presence or absence of redundant data insertion and the length of redundant data are determined by the dyeing data processing unit. .

The staining data processing unit 420 includes an initial staining data creation unit 421, a redundant data presence/absence determination unit 422, a color difference threshold storage unit 423, a continuation length threshold storage unit 424, a redundant data/folding marker setting unit 425, and a redundant data - It has a dyeing data creation unit 426 including folding markers so that it can be executed.

The embroidery data processing unit 430 has an initial embroidery data creation unit 431 , an underlay data creation unit 432 , and an underlay data insertion unit 433 .

Since the host controller 4 has a dyeing data processing unit for dyeing and an embroidery data processing unit for embroidery in the same device, there is no need for a communication unit or an acquisition unit for exchanging data. Become.

In the dyeing/embroidering system having such a configuration, the host controller 4 creates dyeing data and embroidery data before starting an embroidery operation, transmits the dyeing data to the dyeing device 1B, and transmits the embroidery data to the embroidery device 2B. . After the embroidery operation is started, the dyeing apparatus 1B and the embroidery apparatus 2B operate independently.

In this system as well, in the dyeing data based on the embroidery data, redundant markers with turn-back markers are inserted as necessary, and if underlay data exists at the color change point on the embroidery data, The length is adjusted so as to absorb the amount of deviation between the assumed embroidery position and the actual embroidery position by starting sewing, folding back with the turn-back marker on the thread, and making a round trip underlay. Perform the basting operation. As a result, even if the actual amount of thread consumption deviates from the expected amount during the embroidery operation using continuous thread that changes color, the positional deviation of the embroidery color on the cloth at the current color change point can be avoided. It is possible to prevent the accumulation of deviations in yarn consumption amounts at subsequent color change points. As a result, it is possible to prevent the needle thread from being exposed to the embroidered surface when the color changes, and prevent the embroidered pattern from collapsing on the cloth.

<Third Embodiment>
FIG. 18 is a schematic side view of a dyeing/embroidering apparatus according to a third embodiment of the present invention.

The dyeing/embroidering device (textile printing/embroidering device) 5 of the present embodiment is an in-line integrated device having a dyeing unit 51, an embroidery unit 52, and an arithmetic mechanism 53 in one housing.

In this embodiment, since the dyeing unit 51 and the embroidery unit 52 are provided in the same apparatus, the functions of the computing mechanisms 108 and 25 shown in FIGS. be able to.

In this device as well, by starting the basting from the assumed embroidery position, folding back at the turn-back marker on the thread, and performing the basting in a reciprocating manner, the assumed embroidery position and the actual embroidery position are sewn back and forth. Underlay operation is performed with the length adjusted so as to absorb the amount of deviation. As a result, even if the actual amount of thread consumption deviates from the expected amount during the embroidery operation using continuous thread that changes color, the positional deviation of the embroidery color on the cloth at the current color change point can be avoided. It is possible to prevent the accumulation of deviations in yarn consumption amounts at subsequent color change points. As a result, it is possible to prevent the needle thread from being exposed to the embroidered surface when the color changes, and prevent the embroidered pattern from collapsing on the cloth.

Although 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. Also, the present invention can be variously modified or changed in light of the scope of the attached claims.

1, 1B dyeing device (printing device)
2, 2A, 2B Embroidery device 3, 3B Dyeing/embroidery system (textile printing/embroidery system)
4 Upper control device 5 Dyeing/embroidering device (textile printing/embroidering device)
21 needle 22 bobbin thread rotating body 23 stage 24 embroidery data processing section 25, 25B computing mechanism (basket stitch control section)
26 stitch counter 27 colorimetric sensor 28 driving driver 30 ejection head (dyeing head)
51 dyeing unit (printing unit)
52 Embroidery unit B Bobbin thread C Cloth N Needle thread

JP 2008-289522 A

Claims (13)

a printing device for printing threads;
a textile printing/embroidering system comprising: an embroidery device for embroidering a cloth with a needle based on embroidery data using the thread sent from the textile printing device;
Create the initial dyeing data that realizes the thread color of the embroidery data, and create redundant data with a turn-back marker as a mark on the thread at the color change point where the dyeing color changes with the initial dyeing data as necessary. a staining data processing unit to be inserted;
Underlying data for sewing the lower side of the embroidery area of the next scheduled color at the position where the redundant data is inserted on the dyeing data, which is a color change point on the embroidery data, is added to the redundant data. an embroidery data processing unit that inserts longer than
The textile printing device
Equipped with a dyeing section that prints yarn based on dyeing data including redundant data with turn-back markers,
The embroidery device is
Regardless of the actual embroidery position on the thread, basting is started at the timing when the assumed embroidery position on the embroidery data calculated from the number of stitches sewn by the needle reaches the color change point on the embroidery data. and a basting control unit that performs the basting operation adjusting the length so as to make one reciprocation by folding back using the turn-back marker as a mark, and consumes the difference between the assumed embroidery position and the actual embroidery position. Printing and embroidery system. The embroidery data processing unit
The actual embroidery position is dyed according to the redundant data on the thread at the timing when the actual consumption of the thread is smaller than expected and the assumed embroidery position calculated from the number of stitches reaches the color change point on the embroidery data. before reaching the redundantly stained region,
Underlaying is started at that timing, and when the turn-back marker reaches the position of the needle, the forward path of underlaying is stopped, and underlaying is performed so that it is turned back and back once. The textile printing/embroidering system according to claim 1, wherein underlaying is performed over a long distance. The embroidery data processing unit
The actual consumption of the thread is larger than expected, and the timing at which the assumed embroidery position reaches the color change point on the embroidery data is the redundant dyeing area where the actual embroidery position is dyed according to the redundant data on the thread. after reaching
Underlaying is started at the timing when the assumed embroidery position reaches the color change point on the embroidery data, and when the turn-back marker reaches the position of the needle, the outward path of underlaying is stopped and turned back to perform one reciprocation. 2. The textile printing/embroidering system according to claim 1, wherein underlaying is performed over a distance shorter than the redundant dyeing area by performing underlaying in such a manner as to The embroidery device is
a forward counter that counts the number of stitches from the timing at which the assumed embroidery position reaches the color change point on the embroidery data to the timing at which the turn-back marker on the thread reaches the position of the needle as a forward basting stitch;
a return counter that counts the number of stitches after the turn-back marker on the thread reaches the position of the needle,
In the backward basting, the sewing portion is formed so as to follow the route of the forward basting, and the stitch length of each stitch in the sewing portion in the backward basting is the same as the stitch length of the forward sewing portion that is adjacently translated. is set to
When the number of stitches being counted reaches the same number of stitches as the forward basting stitches, the inward counter terminates the basting operation and performs the main embroidery for forming the embroidery pattern on the cloth in the next color.
The textile printing/embroidering system according to claim 2 or 3. The embroidery device is
5. The textile printing/embroidering system according to claim 2, further comprising thread color detection means for detecting that the turn-back marker on the thread has reached the position of the needle by detecting the color of the thread. An input unit for detecting that the turn-back marker on the thread has reached the position of the needle by the user and inputting the detection information,
The textile printing/embroidering system according to claim 2, 3 or 4. The redundant data has the same color as the color before the color change point on the staining data before the turn-back marker, and the same color as the color after the color change point after the turn-back marker. is the area of
The textile printing/embroidering system according to any one of claims 1 to 6, wherein the turn-back marker is set to a color different from two colors adjacent to each other at a color change point on the dyeing data. The staining data processing unit
8. The textile printing/embroidering system according to any one of claims 1 to 7, wherein at a color change point on said dyeing data, it is determined whether to insert redundant data based on a color difference between two adjacent colors. The staining data processing unit
9. The textile printing/embroidering system according to any one of claims 1 to 8, wherein at a color change point on said dyeing data, it is determined whether or not to insert redundant data based on the duration of each of two adjacent colors. The staining data processing unit
10. The textile printing/embroidering system according to claim 9, wherein the length of redundant data to be inserted is set based on the continuation length of each of two colors adjacent at a color change point on said dyeing data. 11. The dyeing data processing unit and the embroidery data processing unit are mounted in a host controller connectable to the textile printing apparatus, the embroidery apparatus, or the textile printing/embroidery system. Printing and embroidery system described in . a printing unit for printing threads;
a textile printing/embroidering apparatus comprising: an embroidery unit for embroidering a cloth with a needle based on embroidery data using the thread sent from the textile printing unit;
Create the initial dyeing data that realizes the thread color of the embroidery data, and create redundant data with a turn-back marker as a mark on the thread at the color change point where the dyeing color changes with the initial dyeing data as necessary. a staining data processing unit to be inserted;
Underlying data for sewing the lower side of the embroidery area of the next scheduled color at the position where the redundant data is inserted on the dyeing data, which is a color change point on the embroidery data, is added to the redundant data. an embroidery data processing unit that inserts longer than
A dyeing unit that prints yarn based on dyeing data including redundant data with turn-back markers;
Regardless of the actual embroidery position on the thread, basting is started at the timing when the assumed embroidery position on the embroidery data calculated from the number of stitches sewn by the needle reaches the color change point on the embroidery data. and a basting control unit that performs the basting operation adjusting the length so as to make one reciprocation by folding back using the turn-back marker as a mark, and consumes the difference between the assumed embroidery position and the actual embroidery position. Printing and embroidery equipment. An embroidery adjustment method for a textile printing/embroidery system comprising a textile printing device and an embroidery device, comprising:
Create the initial dyeing data that realizes the thread color of the embroidery data, and create redundant data with a turn-back marker as a mark on the thread at the color change point where the dyeing color changes with the initial dyeing data as necessary. a staining data processing step to insert;
Underlying data for sewing the lower side of the embroidery area of the next scheduled color at the position where the redundant data is inserted on the dyeing data, which is a color change point on the embroidery data, is added to the redundant data. an embroidery data processing step that inserts longer than
a dyeing step of printing a yarn based on dyeing data including redundant data with turn-back markers;
Regardless of the actual embroidery position on the thread, basting is started at the timing when the assumed embroidery position on the embroidery data calculated from the number of stitches sewn by the needle reaches the color change point on the embroidery data. a basting control step of performing a basting operation whose length is adjusted so as to make one reciprocation by folding back using the turn-back marker as a mark, thereby consuming the difference between the assumed embroidery position and the actual embroidery position; Having an embroidery adjustment method.

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