JP7316420B2 - Sewing machine and sewing method - Google Patents

Description

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

In some cases, stitches are formed on a sewing object to enhance the design of the sewing object. Patent Documents 1 and 2 disclose techniques for forming stitches in upholstery materials used for vehicle seats.

JP 2013-162957 A JP 2016-141297 A

A skin material used for a vehicle seat is thick and has elasticity. If stitches are formed on a thick and elastic sewing object, the sewing object may shrink and the surface of the sewing object may be displaced. For example, when a first stitch is formed on the basis of sewing data in which a target position for forming a stitch is predetermined, and then a second stitch is formed, the object to be sewn created by forming the first stitch is It is desirable to form a second stitch at a target location on the sewing object in response to the displacement of the surface.

As a countermeasure for forming stitches at target positions on a sewing object, it is conceivable to photograph the surface of the sewing object before the sewing process and detect displacement of the surface of the sewing object. In order to improve the detection accuracy of the displacement of the surface of the sewing object, it is desired to accurately position the surface of the sewing object in the photographing area of the imaging device. In addition, in order to improve the detection accuracy of the displacement of the surface of the sewing object, it is desired to appropriately photograph the surface of the sewing object.

An object of the present invention is to improve the detection accuracy of the displacement of the surface of the sewing object.

According to a first aspect of the present invention, a holding member capable of holding and moving a sewing object within a predetermined plane including a sewing position directly below a sewing machine needle, an actuator for moving the holding member, and the sewing object. an imaging device capable of photographing an object; a sewing data acquisition unit that acquires sewing data including a sewing order referred to in sewing processing; and a plurality of characteristic patterns of the sewing object based on the sewing data. and a photographing position setting unit that outputs a control signal to the actuator so that the actuators are sequentially arranged in the photographing areas.

According to a second aspect of the present invention, a holding member capable of holding and moving a sewing object within a predetermined plane including a sewing position directly below a sewing needle, an actuator for moving the holding member, and the sewing object. an imaging device capable of photographing an object; a lighting device for illuminating the sewing object photographed by the imaging device; a lighting operation panel capable of receiving an operation related to the lighting device; and a lighting setting unit that outputs a control signal for controlling the amount of light of the lighting device according to the color of the surface of the sewing object.

According to the third aspect of the present invention, the sewing object held by the holding member movable within a predetermined plane including the sewing position immediately below the sewing needle is photographed by the imaging device, and the sewing object is referred to in the sewing process. and moving the holding member so that a plurality of characteristic patterns of the sewing object are sequentially arranged in an imaging area of the imaging device based on the sewing data. and outputting a control signal to the actuator.

According to a fourth aspect of the present invention, an imaging device photographs a sewing object held by a holding member movable within a predetermined plane including a sewing position immediately below a sewing needle, and the imaging device photographs the sewing object. receiving an operation of a lighting device for illuminating the sewing object to be sewn by a lighting operation panel; and outputting a control signal to control.

According to the aspect of the present invention, it is possible to improve the detection accuracy of displacement of the surface of the sewing object.

FIG. 1 is a perspective view showing an example of the sewing machine according to the first embodiment. FIG. 2 is a perspective view showing part of the sewing machine according to the first embodiment. FIG. 3 is a cross-sectional view showing an example of the sewing object according to the first embodiment. FIG. 4 is a plan view showing an example of the sewing object according to the first embodiment. FIG. 5 is a cross-sectional view showing an example of the sewing object according to the first embodiment. FIG. 6 is a functional block diagram showing an example of a control device according to the first embodiment; FIG. 7 is a schematic diagram showing correction points and photographing positions of a sewing object according to the first embodiment. FIG. 8 is a schematic diagram showing an example of a directory structure of sewing object data according to the first embodiment. FIG. 9 is a schematic diagram showing an example of the sewing machine according to the first embodiment. 10A and 10B are diagrams for explaining the light amount of the sewing target object and the lighting device according to the first embodiment. FIG. 11 is a schematic diagram showing an example of the sewing machine according to the first embodiment. FIG. 12 is a schematic diagram showing an example of the sewing machine according to the first embodiment. FIG. 13 is a flow chart showing an example of an initial position data generation method according to the first embodiment. FIG. 14 is a flow chart showing an example of a lighting adjustment method according to the first embodiment. FIG. 15 is a flow chart showing another example of the lighting adjustment method according to the first embodiment. FIG. 16 is a schematic diagram showing an example of the sewing machine according to the second embodiment. FIG. 17 is a flow chart showing an example of an illumination adjustment method according to the second embodiment. FIG. 18 is a plan view showing an example of a jig according to the third embodiment; FIG. 19 is a cross-sectional view showing an example of a jig according to the third embodiment. FIG. 20 is a diagram showing an example of pixel rate with respect to height. FIG. 21 is a diagram showing an example of the height of the sewing object defined for each pattern. FIG. 22 is a plan view showing an example of a jig according to the third embodiment; FIG. 23 is a cross-sectional view showing an example of a jig according to the third embodiment; FIG. 24 is a schematic diagram showing an example of how to use the jig according to the third embodiment. FIG. 25 is a schematic diagram showing an example of how to use the jig according to the third embodiment. FIG. 26 is a schematic diagram showing an example of how to use the jig according to the third embodiment.

Embodiments of the present invention will be described below with reference to the drawings, but the present invention is not limited thereto. The constituent elements of the embodiments described below can be combined as appropriate. Also, some components may not be used.

[First embodiment]
In the present embodiment, a local coordinate system (hereinafter referred to as "sewing machine coordinate system") is defined for the sewing machine 1 . The sewing machine coordinate system is defined by an XYZ Cartesian coordinate system. In this embodiment, the positional relationship of each part will be described based on the sewing machine coordinate system. The direction parallel to the X-axis within a predetermined plane is defined as the X-axis direction. A direction parallel to the Y-axis in a predetermined plane orthogonal to the X-axis is defined as the Y-axis direction. The direction parallel to the Z-axis perpendicular to the predetermined plane is defined as the Z-axis direction. Moreover, in this embodiment, a plane including the X-axis and the Y-axis is called an XY plane. A plane containing the X-axis and the Z-axis is called an XZ plane. A plane containing the Y-axis and the Z-axis is called a YZ plane. The XY plane is parallel to the predetermined plane. The XY plane, the XZ plane, and the YZ plane are orthogonal. Moreover, in this embodiment, the XY plane and the horizontal plane are parallel. The Z-axis direction is the vertical direction. The +Z direction is upward and the -Z direction is downward. Note that the XY plane may be inclined with respect to the horizontal plane.

A sewing machine 1 will be described with reference to FIGS. 1 and 2. FIG. FIG. 1 is a perspective view showing an example of a sewing machine 1 according to this embodiment. FIG. 2 is a perspective view showing part of the sewing machine 1 according to this embodiment. In this embodiment, the sewing machine 1 is an electronic cycle sewing machine. The sewing machine 1 includes a sewing machine main body 10 , an operation device 20 operated by an operator, an imaging device 30 capable of photographing a sewing object S, a display device 80 , and a control device 40 that controls the sewing machine 1 .

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

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

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

Needle plate 13 supports sewing object S. As shown in FIG. Needle plate 13 supports holding member 15 . Needle plate 13 is supported by bed 11B. Needle plate 13 is arranged below holding member 15 .

The holding member 15 holds the sewing object S. As shown in FIG. The holding member 15 can move while holding the sewing object S within the XY plane including the sewing position Ps directly below the sewing needle 3 . The holding member 15 can move while holding the sewing object S within the XY plane including the imaging position Pf of the imaging device 30 . A stitch GP is formed on the sewing object S by moving the holding member 15, while holding the sewing object S, in the XY plane including the sewing position Ps based on sewing data, which will be described later. The holding member 15 is supported by the horizontal arm 11A via the support member 14. As shown in FIG.

The holding member 15 has a pressing member 15A and a lower plate 15B arranged facing each other. The pressing member 15A is a frame-shaped member and is movable in the Z-axis direction. The lower plate 15B is arranged below the pressing member 15A. The holding member 15 holds the sewing object S by sandwiching the sewing object S between the pressing member 15A and the lower plate 15B.

When the pressing member 15A moves in the +Z direction, the pressing member 15A and the lower plate 15B are separated. Thereby, the operator can place the sewing object S between the pressing member 15A and the lower plate 15B. When the pressing member 15A moves in the -Z direction while the sewing object S is placed between the pressing member 15A and the lower plate 15B, the sewing object S is sandwiched between the pressing member 15A and the lower plate 15B. As a result, the sewing object S is held by the holding member 15 . Further, the holding of the sewing object S by the holding member 15 is released by moving the pressing member 15A in the +Z direction. Thereby, the operator can take out the sewing object S from between the pressing member 15A and the lower plate 15B.

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

A horizontal arm shaft extending in the Y-axis direction is arranged inside the horizontal arm 11A. The actuator 16 is connected to the +Y end of the horizontal arm shaft. The -Y side end of the horizontal arm shaft is connected to the needle bar 12 via a power transmission mechanism arranged inside the head 11D. Actuation of actuator 16 rotates the horizontal arm shaft. Power generated by the actuator 16 is transmitted to the needle bar 12 via the horizontal arm shaft and the power transmission mechanism. As a result, the sewing needle 3 held by the needle bar 12 reciprocates in the Z-axis direction.

A timing belt extending in the Z-axis direction is arranged inside the vertical arm 11C. A bed shaft extending in the Y-axis direction is arranged inside the bed 11B. A pulley is arranged on each of the horizontal arm shaft and the bed shaft. A timing belt is looped over a pulley located on the horizontal arm shaft and a pulley located on the bed shaft. The horizontal arm shaft and bed shaft are connected via a power transmission mechanism including a timing belt.

A kettle is arranged inside the bed 11B. The bobbin accommodates the bobbin in the bobbin case. Actuation of actuator 16 rotates each of the horizontal arm shaft and the bed shaft. Power generated by the actuator 16 is transmitted to the hook through the horizontal arm shaft, timing belt, and bed shaft. As a result, the hook rotates in synchronization with the reciprocating movement of the needle bar 12 in the Z-axis direction.

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

Power generated by the actuator 17 is transmitted to the holding member 15 via the support member 14 . Thus, the holding member 15 can move in the X-axis direction and the Y-axis direction between the sewing needle 3 and the throat plate 13 . By operating the actuator 17 , the holding member 15 can move while holding the sewing object S within the XY plane including the sewing position Ps directly below the sewing needle 3 .

The actuator 18 generates power to move the pressing member 15A of the holding member 15 in the Z-axis direction. Actuator 18 includes a pulse motor. By moving the pressing member 15A in the +Z direction, the pressing member 15A and the lower plate 15B are separated from each other. By moving the pressing member 15A in the -Z direction, the sewing object S is sandwiched between the pressing member 15A and the lower plate 15B.

As shown in FIG. 2, the sewing machine body 10 has an intermediate presser member 19 arranged around the sewing needle 3 . The intermediate presser member 19 presses the sewing object S around the sewing needle 3 . The intermediate pressing member 19 is supported by the head 11D so as to be movable in the Z-axis direction. Inside the head 11D, an intermediate presser motor is arranged to generate power for moving the intermediate presser member 19 in the Z-axis direction. The operation of the intermediate presser motor causes the intermediate presser member 19 to move in the Z-axis direction in synchronization with the needle bar 12 . The intermediate presser member 19 prevents the sewing object S from lifting due to the movement of the sewing needle 3 .

The operating device 20 is operated by an operator. The sewing machine 1 is operated by operating the operating device 20 . In this embodiment, the operation device 20 includes an operation panel 21 and operation pedals 22 .

The operation panel 21 generates input data by being operated by a display device including a flat panel display such as a liquid crystal display (LCD) or an organic EL display (OELD). and an input device. The input device of the operation panel 21 can accept operations related to sewing processing. In this embodiment, the input device includes a touch sensor arranged on the display screen of the display device. That is, in this embodiment, the operation panel 21 includes a touch panel having the function of an input device. An operation panel 21 is mounted on the upper surface of the table 2 . The operation pedal 22 is arranged below the table 2 . The operator operates the operation pedal 22 with his/her foot. The sewing machine 1 is operated by the operator operating at least one of the operation panel 21 and the operation pedal 22 .

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

The imaging device 30 is arranged above the needle plate 13 and the holding member 15 . A shooting area FA is defined in the imaging device 30 . The imaging area FA includes the field of view area of the optical system of the imaging device 30 . A shooting area FA is defined directly below the imaging device 30 . The imaging area FA includes the position of the optical axis AX of the optical system of the imaging device 30 . The imaging device 30 acquires image data of at least a portion of the sewing object S placed in the imaging area FA. The image capturing device 30 captures, from above, at least a portion of the sewing object S placed inside the pressing member 15A.

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

Note that if there is a difference between the actual position of the imaging device 30 and the position in the design data due to an installation error of the imaging device 30, after the imaging device 30 is installed, the position of the sewing needle 3 within the XY plane is changed. The measured position of the sewing needle 3 is moved toward the imaging device 30 by the amount of known data, and the difference between the actual position of the imaging device 30 in the XY plane and the position of the sewing needle 3 after movement is measured. Accordingly, an accurate relative position between the optical axis AX of the optical system of the imaging device 30 and the sewing needle 3 can be calculated based on the measurement result of the difference.

The sewing machine 1 also has a drive amount sensor 31 that detects the drive amount of the actuator 16 and a drive amount sensor 32 that detects the drive amount of the actuator 17 .

The drive amount sensor 31 includes an encoder that detects the amount of rotation of the pulse motor that is the actuator 16 . Data detected by the driving amount sensor 31 is output to the control device 40 .

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

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

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

The sewing machine 1 also has an epi-illumination device 33 that illuminates the sewing object S. As shown in FIG. The epi-illumination device 33 is arranged near the imaging device 30 . The epi-illumination device 33 illuminates at least the imaging area FA of the imaging device 30 from above. The epi-illumination device 33 illuminates the sewing object S photographed by the imaging device 30 .

The display device 80 displays at least the image data of the sewing object S captured by the imaging device 30 . The display device 80 includes a display panel 81 that displays image data captured by the imaging device 30 and an illumination operation panel 82 that can accept operations related to the epi-illumination device 33 .

The display panel 81 is a display device including a flat panel display such as a liquid crystal display or an organic EL display.

The lighting operation panel 82 functions as an input device that generates input data by being operated by an operator. In the present embodiment, the input device is a touch panel placed over the display screen of the display panel 81 .

The sewing object S will be described with reference to FIGS. 3 and 4. FIG. FIG. 3 is a cross-sectional view showing an example of the sewing object S according to this embodiment. FIG. 4 is a plan view showing an example of the sewing object S according to this embodiment. 3 and 4 show the sewing object S before the sewing process is performed. In this embodiment, the sewing object S is a skin material used for a vehicle seat.

As shown in FIG. 3 , the sewing object S has a front material 4 , a pad material 5 and a back material 6 . A hole 7 is formed in the surface member 4 .

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

As shown in FIG. 4 , a plurality of holes 7 are arranged in the surface member 4 . The holes 7 are arranged in a defined pattern DP. In this embodiment, the defined pattern DP includes a plurality of reference patterns DPh. A single reference pattern DPh is formed by a plurality of holes 7 . In this embodiment, the plurality of holes 7 form the reference pattern DPh. In this embodiment, one reference pattern DPh is formed with 17 holes 7 .

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

Also, a plurality of characteristic patterns UP (UP1, UP2, UP3, UP4, UP5, UP6, UP7) are arranged on the sewing object S. As shown in FIG. In this embodiment, the characteristic pattern UP is part of the defined pattern DP. In this embodiment, the feature pattern UP is part of the reference pattern DPh. As shown in FIG. 4, in the present embodiment, the feature patterns UP (UP1, UP2, UP3, UP4, UP5, UP6, UP7) are patterns including one acute corner of the reference pattern DPh. The characteristic pattern UP is a pattern that can be specified by a pattern matching method, which is a type of image processing method.

Displacement that occurs on the surface of the sewing object S when the stitch GP is formed on the sewing object S that is thick and elastic will be described with reference to FIG. FIG. 5 is a cross-sectional view showing an example of the sewing object S according to this embodiment. FIG. 5 shows the sewing object S after the sewing process has been carried out. The sewing object S is thick and has elasticity. Forming the stitches GP on the sewing object S that is thick and elastic is highly likely to cause the sewing object S to shrink, as shown in FIG. When the sewing object S shrinks, the surface of the sewing object S may be displaced. If the surface of the sewing object S is displaced, there is a high possibility that the target positions of the stitches GP defined on the surface of the sewing object S will be displaced within the XY plane. When the target position of the stitch GP is displaced within the XY plane, it becomes difficult to form the stitch GP at the target position if the holding member 15 is moved according to the target pattern RP. Therefore, even if the sewing object S shrinks due to the formation of the stitch GP and the surface of the sewing object S is displaced, the holding member 15 moves according to the amount of displacement so that the next stitch GP is formed at the target position. be done.

In the following description, the target position of the stitch GP defined on the surface of the sewing object S will be referred to as a stitch formation target position. The target stitch formation positions are defined in the machine coordinate system.

The control device 40 will be described with reference to FIG. FIG. 6 is a functional block diagram showing an example of the control device 40 according to this embodiment. Control device 40 outputs control signals for controlling sewing machine 1 . Controller 40 includes a computer system. The control device 40 includes an input/output interface device 50, a storage device 60 including non-volatile memory such as ROM (Read Only Memory) or storage and volatile memory such as RAM (Random Access Memory), and a CPU (Central Processing Unit) and an arithmetic processing unit 70 including a processor.

The control device 40 includes an actuator 16 that moves the sewing needle 3 in the Z-axis direction, an actuator 17 that moves the holding member 15 in the XY plane, and an actuator 18 that moves the pressing member 15A of the holding member 15 in the Z-axis direction. , the operating device 20 , the imaging device 30 , the epi-illumination device 33 , and the display device 80 are connected via the input/output interface device 50 .

A driving amount sensor 31 for detecting the driving amount of the actuator 16 and a driving amount sensor 32 for detecting the driving amount of the actuator 17 are connected to the control device 40 .

The control device 40 controls the actuator 16 based on the data detected by the driving amount sensor 31 . The control device 40 determines, for example, the actuation timing of the actuator 16 based on the detection data of the driving amount sensor 31 .

The control device 40 controls the actuator 17 based on the detection data of the driving amount sensor 32 . Based on the data detected by the driving amount sensor 32, the control device 40 feedback-controls the actuator 17 so that the holding member 15 moves to the target position.

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

The storage device 60 has a sewing data storage section 61 and a program storage section 62 .

The sewing data storage unit 61 stores sewing data. The sewing data is known data that can be derived from the design data of the sewing object S, such as CAD (Computer Aided Design) data.

Sewing data will be described with reference to FIG. The sewing data is referenced in the sewing process. The sewing data includes the target pattern RP of the stitches GP to be formed on the sewing object S and the movement conditions of the holding member 15 .

The target pattern RP includes the target shape or target pattern of the stitches GP to be formed on the sewing object S. The target pattern RP is defined in the machine coordinate system.

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

The sewing data includes stitch forming target positions defined on the surface of the sewing object S. As shown in FIG. A target stitch formation position is defined in the stitch formation area MA. The sewing machine 1 performs sewing processing based on the sewing data so that the stitch GP is formed at the target stitch formation position.

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

The target patterns RP include a first target pattern RP1, a second target pattern RP2, and similarly a third target pattern RP3 to a tenth target pattern RP10. In this embodiment, a plurality of target patterns RP (RP1, RP2, RP3, RP4, RP5, RP6, RP7, RP8, RP9, RP10) are defined in the Y-axis direction. In the sewing machine coordinate system, the plurality of target patterns RP are separated from each other. One target pattern RP is defined linearly. In this embodiment, one target pattern RP extends in the X-axis direction and is defined in a zigzag shape in the Y-axis direction. The target stitch formation positions are defined in a zigzag shape in the Y-axis direction and extending in the X-axis direction in the stitch formation area MA corresponding to the target pattern RP.

The first sewing data includes a first target pattern RP1 of a first stitch GP1 to be formed on the sewing object S in the first sewing process. Further, the first sewing data includes conditions for moving the holding member 15 within the XY plane in the first sewing process.

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

The second sewing data includes a second target pattern RP2 of a second stitch GP2 to be formed on the sewing object S in the second sewing process. Further, the second sewing data includes conditions for moving the holding member 15 within the XY plane in the second sewing process.

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

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

Similarly, the third sewing process to the tenth sewing process form the third stitch GP3 to the tenth stitch GP10 on the sewing object S based on the third target pattern RP3 to the tenth target pattern RP10, respectively. Including processing. The third sewing process to the tenth sewing process are sequentially performed.

The first sewing data is referred to in the first sewing process. The second sewing data is referred to in the second sewing process. Similarly, the third sewing data to the tenth sewing data are referred to in the third sewing process to the tenth sewing process, respectively.

The sewing data includes the sewing order for forming the first stitch GP1 to the tenth step GP10. As described above, the sewing data is defined such that the second sewing process for forming the second stitch GP2 is performed after the first sewing process for forming the first stitch GP1 is performed. . Similarly, the sewing data is defined such that the third sewing process for forming the third stitch GP3 to the tenth sewing process for forming the tenth stitch GP10 are sequentially performed.

As shown in FIG. 7, the sewing data includes correction points Pc (Pc1, Pc2, Pc3), which are reference points for correcting displacement of the surface of the sewing object S, for each of the plurality of target patterns RP. Position data, position data of photographing positions Pf (Pf1, Pf2, Pf3) of a plurality of characteristic patterns UP of the sewing object S photographed by the imaging device 30 for calculating the displacement amount of the correction point Pc, and correction points. and an idle feed amount of the holding member 15 for moving Pc to the imaging area FA of the imaging device 30 . The position data of the correction point Pc can be obtained from the design data of the sewing object S. The position data of the photographing position Pf can be obtained from the design data of the sewing object S and the position data of the correction points Pc. The position data of the shooting position Pf may be set by operating an operation unit displayed by the characteristic pattern setting unit 74, which will be described later. The idle feed amount can be obtained based on the design data of the sewing object S and the distance between the correction points Pc adjacent in the sewing direction. FIG. 7 is a schematic diagram showing the correction point Pc and the imaging position Pf of the sewing object S according to this embodiment.

An example of a sewing data directory structure will be described with reference to FIG. FIG. 8 is a schematic diagram showing an example of the directory structure of sewing object data according to the present embodiment. The sewing data is stored in the sewing data storage section 61 of the storage device 60 in the directory structure shown in FIG. Sewing data includes a definition file and a data file. The definition file includes data on the thickness of the fabric of the sewing object S. As shown in FIG. The data file contains position data of the correction point Pc corresponding to the characteristic pattern UP, position data of the photographing position Pf of the characteristic pattern UP, and idle feed of the holding member 15 to the next photographing position Pf or sewing processing start position SP. including quantity and

More specifically, a definition file storing setting values and a file containing an identification number identifying the feature pattern UP included in the nth sewing data are stored in a folder with a folder name including an identification number identifying the nth sewing data. A plurality of data files named are stored for each n-th sewing data.

Returning to FIG. 6, program storage unit 62 stores computer programs for controlling sewing machine 1 . The sewing data stored in the sewing data storage section 61 is input to the computer program stored in the program storage section 62 . A computer program is loaded into the arithmetic processing unit 70 . Arithmetic processing unit 70 controls sewing machine 1 according to a computer program stored in program storage unit 62 .

Arithmetic processing device 70 includes sewing data acquisition section 71 , photographing position setting section 72 , illumination setting section 73 , characteristic pattern setting section 74 , initial position data generation section 75 , and sewing processing section 76 .

Sewing data acquisition portion 71 acquires sewing data from sewing data storage portion 61 . In the present embodiment, the sewing data acquisition unit 71 obtains the first sewing data referred to in the first sewing process and the second sewing data referred to in the second sewing process performed subsequent to the first sewing process as sewing data. Acquired from the storage unit 61 . Similarly, the sewing data obtaining portion 71 obtains from the sewing data storage portion 61 each of the third sewing data to the tenth sewing data referred to in each of the third sewing process to the tenth sewing process.

Based on the sewing data acquired by the sewing data acquiring unit 71, the photographing position setting unit 72 sequentially arranges the plurality of characteristic patterns UP arranged on the sewing object S in the photographing area FA of the image pickup device 30. Then, a control signal is output to the actuator 17 that moves the holding member 15 .

Further, the photographing position setting unit 72 enables the photographing position Pf to be set by the operator's operation when the initial position data is created. More specifically, when the initial position data is generated, the shooting position setting unit 72 performs control to move the shooting positions Pf before and after the current shooting position Pf to the shooting area FA of the imaging device 30 based on the sewing data. The shooting position setting section 72 includes a display control section 721 and a movement control section 722 .

When the initial position data is generated, the display control unit 721 causes the operation unit 21A capable of receiving an operation to move the shooting positions Pf before and after the current shooting position Pf to the shooting area FA of the imaging device 30 on the operation panel of the operation device 20. 21.

The operation section 21A displayed on the operation panel 21 by the display control section 721 will be described with reference to FIG. FIG. 9 is a schematic diagram showing an example of the sewing machine 1 according to this embodiment. The operation unit 21A has a front key 21B for moving the photographing position Pf before (next to) the current photographing position Pf to the photographing area FA of the image pickup device 30, and a front key 21B for moving the photographing area FA of the image pickup device 30 to the photographing area FA after the current photographing position Pf. and a rear key 21C for moving the photographing position Pf. The previous (next) photographing position Pf is the photographing position Pf to be photographed next when the holding member 15 is moved in order corresponding to the sewing order. The subsequent photographing position Pf is the photographing position Pf that has already been photographed when the holding member 15 is moved in the reverse order corresponding to the sewing order.

The movement control unit 722 controls the sewing data so that the plurality of characteristic patterns UP arranged on the sewing object S are sequentially arranged in the photographing area FA of the imaging device 30 in order or in reverse order corresponding to the sewing order. , a control signal is output to the actuator 17 .

In the present embodiment, the movement control unit 722 moves the holding member 15 according to the operation of the operation unit 21A based on the sewing data, and moves the holding member 15 to the photographing area FA of the imaging device 30 before and after the current photographing position Pf. A control signal for moving the photographing position Pf is output. More specifically, when the operation of the front key 21B is detected, the movement control section 722 drives the X-axis motor 17X of the actuator 17 to move the holding member 15 in the X-axis direction by the amount of idle feed. The imaging position Pf before the current imaging position Pf is moved to the imaging area FA of the imaging device 30 . When the operation of the rear key 21C is detected, the movement control section 722 drives the X-axis motor 17X of the actuator 17 to move the holding member 15 in the X-axis direction by the amount corresponding to the idle feed amount. A photographing position Pf behind the current photographing position Pf is moved to the photographing area FA. Further, when the current imaging position Pf is at the end in the X-axis direction, the movement control unit 722 drives the Y-axis motor 17Y of the actuator 17 to move the holding member 15 in the Y-axis direction by the amount corresponding to the idle feed amount. Let

The lighting setting unit 73 outputs a control signal for controlling the light amount of the epi-illumination device 33 according to the color of the surface of the sewing object S (the color of the material of the front material 4) based on the operation of the lighting operation panel 82. do. Note that the illumination setting unit 73 may automatically control the amount of light without being operated by the operator. Illumination setting portion 73 includes a display control portion 732 , an adjustment portion 733 , and a light amount data storage portion 731 .

The relationship between the color of the front material 4 and the amount of light will be described with reference to FIG. FIG. 10 is a diagram for explaining the sewing object S and the amount of illumination light according to this embodiment. When the color and amount of light of the surface material 4 are appropriate, the contrast between the surface material 4 and the holes 7 is increased as shown on the left. For example, if the color of the surface material 4 shown on the left differs from that of the material, the amount of light will not be appropriate, and the contrast between the surface material 4 and the hole 7 will be reduced as shown in the upper right. In addition, for example, when the recognition parameters are inconsistent, such as when the amount of light is insufficient or the binarization threshold is inappropriate, the entire photographed image is dark as shown in the lower right of FIG. or the boundary between the surface material 4 and the hole 7 becomes unclear or unclear.

The display control unit 732 causes the operation panel 82 of the display device 80 to display an operation unit 82A capable of receiving an operation for adjusting the light amount of the epi-illumination device 33 .

The operation section 82A displayed on the operation panel 82 by the display control section 732 will be described with reference to FIG. FIG. 11 is a schematic diagram showing an example of the sewing machine 1 according to this embodiment. The operation unit 82A includes an upper key 82B for increasing the amount of light, a lower key 82C for decreasing the amount of light, and an automatic key 82D for automatically setting the amount of light. A light amount display section 82E is arranged near the operation section 82A. The light amount display section 82E displays the light amount.

The adjuster 733 adjusts the amount of light from the epi-illumination device 33 when an operation on the operation unit 82A is detected. The adjuster 733 increases the amount of light from the epi-illumination device 33 when an operation on the up key 82B is detected. The adjuster 733 reduces the amount of light from the epi-illumination device 33 when an operation on the down key 82C is detected. The adjustment unit 733 automatically adjusts the light amount of the epi-illumination device 33 when an operation on the automatic key 82D is detected.

The light amount data storage unit 731 stores the light amount and the binarization threshold adjusted as described above as light amount data in association with the generated initial position data. Further, the light amount data storage unit 731 stores the average density and allowable range of the surface material 4 and the holes 7 when the appropriate light amount is obtained.

The characteristic pattern setting unit 74 sets the position of the template frame of the characteristic pattern UP and the imaging position Pf on the image data captured by the imaging device 30 displayed on the display panel 81 of the display device 80 .

When the initial position data is generated, the characteristic pattern setting unit 74 sets the position of the template frame of the characteristic pattern UP in the image of the surface of the sewing object S photographed by the imaging device 30 and the imaging position by the operation of the display device 80 by the operator. Set Pf. In this embodiment, the shooting position Pf is the center of the template frame. The characteristic pattern setting portion 74 includes a display control portion 741 and a setting portion 742 .

The operation section 82A displayed on the operation panel 82 by the display control section 741 will be described with reference to FIG. FIG. 12 is a schematic diagram showing an example of the sewing machine 1 according to this embodiment. The display control unit 741 superimposes the image of the cross key indicating the photographing position Pf and the image of the template frame indicating the characteristic pattern UP on the image of the surface of the sewing object S photographed by the imaging device 30 on the display panel 81 . to display. In this embodiment, the template frame is half the area of the captured image. The display control unit 741 causes the display panel 81 to display a registration button image 82F capable of accepting an operation of registering the area surrounded by the template frame as the feature pattern UP. Further, the display control unit 741 causes the operation panel 21 of the operation device 20 to display a registration button image 21D capable of accepting an operation for setting a template frame. The operator can set the feature pattern using the registration button image 21D of the operation device 20 or the registration button image 82F of the display device 80. FIG.

When the registration button image 82F or the registration button image 21D is pressed, the setting unit 742 performs image processing on the captured image using the feature pattern UP, which is the area surrounded by the template frame on the display panel 81. FIG. The setting unit 742 determines the position of the characteristic pattern UP, which is the area surrounded by the template frame on the display panel 81, based on the drive amount of the actuator 17 detected by the drive amount sensor 32 when the image is correctly recognized as a result of the image processing. , and the photographing position Pf, which is the central position. If the image is not recognized correctly, the setting unit 742 enlarges the template frame and performs image processing again. The setting unit 742 makes an error when the size of the template frame is increased to a predetermined upper limit and is not correctly recognized.

The initial position data generator 75 generates initial position data indicating the initial positions of the plurality of characteristic patterns UP arranged on the sewing object S based on the image data captured by the imaging device 30 . The initial position data of the characteristic pattern UP indicates the initial position of the characteristic pattern UP in the sewing machine coordinate system. The initial position data generator 75 automatically acquires the initial position of the characteristic pattern UP based on the image data of the characteristic pattern UP of the sewing object S before the sewing process is started. Note that the initial position data of the characteristic pattern UP may be obtained by operating the operation section 21A displayed on the operation panel 21 . The initial position data of the feature pattern UP is known data that can be derived from the design data of the sewing object S, such as CAD data. Initial position data of the characteristic pattern UP is stored in the sewing data storage unit 61 .

The initial position data of the characteristic pattern UP defines the light amount data of the epi-illumination device 33 for each sewing object S. As shown in FIG.

The initial position data may be generated automatically or manually from the CAD data, or the initial position data may be generated by operating the operation section 21A displayed on the operation panel 21 as shown in FIG. You may

A method of generating initial position data by operating the operation unit 21A displayed on the operation panel 21 will be described. First, the control device 40 controls the actuator 17 to move the characteristic pattern UP of the sewing object S held by the holding member 15 to the imaging area FA of the imaging device 30 . In this embodiment, the center position C of the characteristic pattern UP is moved to the optical axis position, which is the center position of the imaging area FA of the imaging device 30 . The shooting position Pf includes the optical axis position. The imaging device 30 photographs the characteristic pattern UP arranged in the imaging area FA. The initial position data generator 75 acquires image data of the characteristic pattern UP. The initial position data generator 75 performs image processing on the image data of the feature pattern UP by pattern matching to specify the specific pattern UP. A driving amount sensor 32 detects the position of the holding member 15 in the sewing machine coordinate system when the characteristic pattern UP is arranged in the imaging area FA of the imaging device 30 . As described above, the drive amount sensor 32 functions as a position sensor that detects the position of the holding member 15 within the XY plane. The initial position data generator 75 acquires detection data of the driving amount sensor 32 . In this manner, the initial position data generation unit 75 determines the position of the characteristic pattern UP arranged in the photographing area FA based on the detection data of the driving amount sensor 32 when the characteristic pattern UP is arranged in the photographing area FA. Initial position data indicating an initial position within the XY plane is acquired. When moving the next characteristic pattern UP to the imaging area FA of the imaging device 30, it may be moved automatically, or may be moved by operating the operation unit 21A. These processes are repeated to generate initial position data.

The sewing processing unit 76 forms predetermined stitches on the sewing object S based on the sewing data generated as described above, the initial position data, and the correction data generated based on the displacement amount of the correction point Pc. Further, the sewing processing section 76 may automatically adjust the light amount based on the light amount data set when the initial position data is generated when the sewing object S is sewn.

Next, the initial position data generation method according to this embodiment will be described with reference to FIG. FIG. 13 is a flow chart showing an example of an initial position data generation method according to the first embodiment.

The sewing object S is held by the holding member 15 (step S101).

The control device 40 controls the actuator 17 to move the sewing process start position SP1, which is the sewing start position, to the photographing area FA immediately below the imaging device 30 (step S102).

The control device 40 controls the actuator 17 based on the dummy feed amount of the first sewing data to move the first characteristic pattern UP1 to the photographing area FA immediately below the imaging device 30 (step S103). The control device 40 moves the holding member 15 so that the center position C1 of the first characteristic pattern UP1 is arranged at the imaging position Pf of the imaging area FA of the imaging device 30 .

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

The first characteristic pattern UP1 is arranged near the vertex of the first target pattern RP1 defined in a zigzag shape. In this embodiment, the first characteristic pattern UP1 is arranged near the end of the sewing object S on the -X side.

The control device 40 adjusts the epi-illumination device 33 by the illumination setting unit 73 (step S104). A method for adjusting illumination of the epi-illumination device 33 will be described later.

The control device 40 registers the first characteristic pattern UP1 by the characteristic pattern setting unit 74 (step S105). In the present embodiment, the control device 40 causes the display control unit 741 to display the image of the surface of the sewing object S captured by the imaging device 30, the image of the cross key indicating the imaging position Pf, and the first An image of a template frame showing the characteristic pattern UP1 is superimposed and displayed. The display control unit 741 causes the display panel 81 to display the registration button image 82F and the operation panel 21 to display the registration button image 21D. The operator sets the first characteristic pattern UP1 using the registration button image 21D of the operation device 20 or the registration button image 82F of the display device 80. FIG.

After the first characteristic pattern UP1 is set, the control device 40 takes an image with the imaging device 30 (step S106). The control device 40 acquires the captured image data of the first characteristic pattern UP1.

The control device 40 uses the initial position data generation unit 75 to generate data of the first characteristic pattern UP1 and stores it as initial position data (step S107). Control device 40 stores the position of first characteristic pattern UP1 and shooting position Pf when registration button image 82F or registration button image 21D is pressed as initial position data in association with the shot image data.

The controller 40 uses the light amount data storage unit 731 to store the illumination data when the first characteristic pattern UP1 was captured in the initial position data of the first characteristic pattern UP1 (step S108). The illumination data includes the amount of light, the binarization threshold, the average density and allowable range of the surface material 4 as the background, and the average density and allowable range of the holes 7 .

The control device 40 sets the counter n to "2" (step S109).

The control device 40 controls the actuator 17 based on the dummy feed amount of the (n-1)th sewing data to move the nth characteristic pattern UPn directly below the imaging device 30 (step S110).

The control device 40 registers the n-th characteristic pattern UPn by the characteristic pattern setting unit 74 (step S111).

After the n-th characteristic pattern UPn is set, the control device 40 takes an image with the imaging device 30 (step S112).

The control device 40 uses the initial position data generator 75 to generate data of the n-th characteristic pattern UPn and stores it as initial position data (step S113).

The control device 40 stores the illumination data when the n-th characteristic pattern UPn was photographed in the initial position data of the n-th characteristic pattern UPn by the light amount data storage unit 731 (step S114).

Control device 40 determines whether generation of initial position data for the first sewing data has been completed (step S115). When the generation of the initial position data for all characteristic patterns UP of the first sewing data is completed (Yes in step S115), control device 40 ends the process. If control device 40 has not finished generating initial position data for all characteristic patterns UP of the first sewing data (No in step S115), control device 40 proceeds to step S116.

If initial position data generation for all characteristic patterns UP of the first sewing data has not been completed (No in step S115), control device 40 increments counter n by "1" (step S116).

Next, the illumination adjustment method according to this embodiment will be described with reference to FIGS. 14 and 15. FIG. FIG. 14 is a flow chart showing an example of an illumination adjustment method according to this embodiment. FIG. 15 is a flowchart showing another example of the lighting adjustment method according to this embodiment. It is assumed that the sewing object S is held by the holding member 15 and the first characteristic pattern UP1 is arranged in the imaging area FA of the imaging device 30 .

First, with reference to FIG. 14, a case where the initial position data does not store the amount of light of the epi-illumination device 33 will be described. The illumination setting unit 73 increases the amount of light of the epi-illumination device 33 (step S201). The illumination setting unit 73 gradually increases the amount of light from a preset minimum value.

The illumination setting unit 73 photographs the sewing object S held by the holding member 15 by the imaging device 30 (step S202).

The illumination setting unit 73 executes discriminant analysis (step S203). In the discriminant analysis method, image processing is performed on image data of the surface of the sewing object S to determine the surface material 4, which is the background portion of the sewing object S. FIG. In the present embodiment, the surface material 4 can be identified as a white area (high-brightness area) by performing the binarization process.

The illumination setting unit 73 calculates the average density of the area of the sewing object S determined as the surface material 4 by the discriminant analysis method (step S204).

The illumination setting unit 73 determines whether the average density of the front material 4 is greater than the upper threshold (step S205). If the average density of the surface material 4 is greater than the upper threshold value (Yes in step S205), the illumination setting unit 73 proceeds to step S206. If the average density of the surface material 4 is not greater than the upper threshold value (No in step S205), the illumination setting unit 73 returns to step S201 and executes the process again.

When the average density of the surface material 4 exceeds the upper limit threshold, the illumination setting unit 73 determines the current light amount as the maximum light amount (step S206).

The illumination setting unit 73 reduces the light intensity below the maximum light intensity (step S207). The illumination setting unit 73 gradually reduces the light intensity from the maximum light intensity.

The illumination setting unit 73 photographs the sewing object S held by the holding member 15 by the imaging device 30 (step S208).

The illumination setting unit 73 executes discriminant analysis (step S209). The discriminant analysis method performs image processing on image data of the surface of the sewing object S to determine the holes 7 of the sewing object S. As shown in FIG. In the present embodiment, the hole 7 can be identified as a black area (low luminance area) by binarization processing.

The illumination setting unit 73 calculates the average density of the area determined as the hole 7 by the discriminant analysis method (step S210).

The illumination setting unit 73 determines whether the average density of the holes 7 is smaller than the lower limit threshold (step S211). If the average density of the holes 7 is smaller than the lower limit threshold (Yes in step S211), the illumination setting unit 73 proceeds to step S212. If the average density of the holes 7 is not smaller than the lower limit threshold (No in step S211), the illumination setting unit 73 returns to step S207 and executes the process again.

The illumination setting unit 73 determines the optimum light amount (step S212). The illumination setting unit 73 determines an optimum light amount equal to or greater than the current light amount and equal to or less than the maximum light amount.

Next, with reference to FIG. 15, the case where the initial position data stores light amount data (recognition parameters) including the light amount of the epi-illumination device 33 will be described. The illumination setting unit 73 sets the light intensity of the epi-illumination device 33 to the light intensity stored in the initial position data (step S301).

The illumination setting unit 73 takes an image with the imaging device 30 (step S302).

The illumination setting unit 73 determines whether the average density of the surface material 4 and the average density of the holes 7 are within the range of reference density values stored in advance (step S303). The illumination setting unit 73 calculates the average density of the surface material 4 and the average density of the holes 7 . If the average density of the surface material 4 and the average density of the holes 7 are within the range of the reference density values (Yes in step S303), the illumination setting unit 73 proceeds to step S308. If the average density of the surface material 4 and the average density of the holes 7 are not within the range of the reference density values (No in step S303), the illumination setting unit 73 determines that the current recognition parameters are data inconsistent. proceed to The recognition parameters include light amount data and binarization threshold data.

The illumination setting unit 73 displays a warning that the recognition parameters are data inconsistent (step S304). In addition to the warning display, the lighting setting unit 73 also displays a screen for selecting whether or not to readjust the light amount on the display panel 81 .

The illumination setting unit 73 determines whether a selection operation for readjusting the light amount has been performed (step S305). If readjustment of the light amount is selected (Yes in step S305), the illumination setting unit 73 proceeds to step S306. If it is selected not to readjust the light amount (No in step S305), the illumination setting unit 73 proceeds to step S307.

The illumination setting unit 73 resets the illumination (step S306). As shown in FIG. 11, the display controller 732 causes the operation panel 82 to display an operation section 82A. The operator operates the operation unit 82A so that the light amount of the lighting device is appropriate. Alternatively, if there is data inconsistency even after adjusting the amount of light, the binarization threshold may be changed.

The lighting setting unit 73 interrupts the subsequent processing (step S307). In this case, no subsequent processing is performed.

After setting the light amount, the illumination setting unit 73 executes subsequent processing (step S308). In this case, subsequent processing is executed with the set light intensity.

As described above, in the present embodiment, based on the sewing data including the sewing order, the plurality of characteristic patterns UP of the sewing object S are sequentially arranged in the photographing area FA immediately below the imaging device 30. An actuator 17 that moves the holding member 15 is controlled. Since the feature patterns UP on the sewing object S are accurately moved to the photographing area FA immediately below the imaging device 30 in accordance with the sewing order, the initial position data can be easily generated.

In this embodiment, the sewing data includes the correction point Pc on the line, which is the reference point for correction, the photographing position Pf in the feature pattern UP, and the next photographing position Pf or sewing processing start position SP. and the idle feed amount of the holding member 15. In this embodiment, based on such sewing data, the feature patterns UP on the sewing object S are picked up automatically or by operating the operation section 21A displayed on the operation panel 21, corresponding to the sewing order. It is possible to accurately move to the imaging area FA directly below the device 30 . In this manner, the present embodiment can easily generate initial position data.

On the other hand, when the characteristic pattern UP of the sewing object S is manually moved to the photographing area FA directly below the imaging device 30, the position of the holding member 15 must be accurately aligned and the posture of the sewing object S must be adjusted. is difficult to match accurately. As a result, it takes time and effort to generate the initial position data. In addition, when executing manually, it may be difficult to reproduce repeated movement to the same position.

In this embodiment, the position of the holding member 15 can be accurately adjusted and the posture of the sewing object S can be easily and accurately adjusted based on the sewing data.

Further, in this embodiment, when the initial position data is generated, the operator sets the position of the template frame of the feature pattern UP and the photographing position Pf in the image of the surface of the sewing object S photographed by the imaging device 30 . can do. According to this embodiment, it is possible to set the characteristic pattern UP with higher detection accuracy, so that more appropriate initial position data can be generated.

Further, according to the present embodiment, the amount of light of the lighting device can be automatically set for the sewing object S set on the holding member 15 . Further, in this embodiment, the adjusted light amount and the binarization threshold value are stored as light amount data in association with the generated initial position data. As a result, according to the present embodiment, it is possible to easily reproduce an appropriate amount of light during the sewing process.

On the other hand, if the lighting is manually set for each sewing object S, the work efficiency and accuracy may vary depending on the skill level of the operator. Similarly setting the lighting can be difficult to reproduce when performed manually.

Furthermore, in this embodiment, when the illumination is set for generating the initial position data for the sewing data for the first time, the consistency of the recognition parameters of the stored illumination data is checked and a warning is displayed. The risk of occurrence can be reduced. In addition, the present embodiment can perform readjustment when a recognition parameter mismatch occurs. According to this embodiment, the recognition parameters can be appropriately set according to the material of the surface material 4 of the sewing object S. FIG.

[Second embodiment]
A sewing machine 1 according to the present embodiment will be described with reference to FIGS. 16 and 17. FIG. FIG. 16 is a schematic diagram showing an example of the sewing machine 1 according to this embodiment. FIG. 17 is a flow chart showing an example of an illumination adjustment method according to this embodiment. The basic configuration of the sewing machine 1 is similar to that of the sewing machine 1 of the first embodiment described above. In the following description, components similar to those of the sewing machine 1 are denoted by the same reference numerals or corresponding reference numerals, and detailed description thereof will be omitted. The sewing machine 1 differs from the first embodiment in that it includes a transmissive illumination device 34 .

The transmitted illumination device 34 is arranged on the table 2 below the imaging device 30 and below the holding member 15 . The transmission illumination device 34 illuminates at least the imaging area FA of the imaging device 30 from below. The transmissive illumination device 34 is a panel-type illumination device. In the transmissive illumination device 34, when the sewing object S is viewed from the surface, the hole 7 becomes a high luminance area and the surface material 4 becomes a low luminance area.

When using the transmissive illumination device 34, it is preferable to cover the imaging area FA of the imaging device 30 with a cylindrical cover (not shown) in order to suppress the influence of ambient light.

Next, the lighting adjustment method according to this embodiment will be described with reference to FIG. 16 . The illumination setting unit 73 sets the epi-illumination device 33 (step S401). The amount of light of the epi-illumination device 33 is set based on the amount of light data included in the initial position data.

The illumination setting unit 73 photographs the sewing object S held by the holding member 15 by the imaging device 30 (step S402).

The illumination setting unit 73 executes discriminant analysis (step S403). In the discriminant analysis method, image processing is performed on image data obtained by photographing the surface of the sewing object S, and the surface material 4 and the holes 7 of the sewing object S are discriminated. In this embodiment, the surface material 4 can be discriminated as a low-brightness region, and the holes 7 can be discriminated as a high-brightness region. If the hole 7 cannot be properly recognized by the discriminant analysis method, the illumination setting section 73 may determine the hole 7 based on the sewing data generated from the CAD data.

The illumination setting unit 73 calculates the average density of the area of the sewing object S that has been determined as the hole 7 by the discriminant analysis method (step S404).

The illumination setting unit 73 acquires and stores the calculated average density of the holes 7 when the epi-illumination device 33 is used as the first hole information (step S405).

The illumination setting unit 73 sets the transmissive illumination device 34 (step S406). The amount of light of the transmission illumination device 34 is set based on the amount of light data included in the initial position data.

The illumination setting unit 73 photographs the sewing object S held by the holding member 15 by the imaging device 30 (step S407).

The illumination setting unit 73 executes discriminant analysis (step S408).

The illumination setting unit 73 calculates the average density of the area determined as the hole 7 of the sewing object S by the discriminant analysis method (step S409).

The illumination setting unit 73 acquires and stores the calculated average density of the holes 7 when the transmission illumination device 34 is used as second hole information (step S410).

The illumination setting unit 73 collates the first hole information and the second hole information (step S411). If the first hole information and the second hole information match (Yes in step S411), the illumination setting unit 73 proceeds to step S414. If the first hole information and the second hole information do not match (No in step S411), the illumination setting unit 73 proceeds to step S413.

The lighting setting unit 73 sets lighting using the epi-illumination device 33 (step S413).

The illumination setting unit 73 sets illumination using the transmissive illumination device 34 (step S414).

As described above, in this embodiment, it is possible to appropriately set whether to use the epi-illumination device 33 or the transmissive illumination device 34 . In this embodiment, when the transmitted illumination device 34 is used, it is possible to prevent the image from changing depending on the color of the surface material 4 of the sewing object S, the presence or absence of wrinkles on the surface, and the thread color, which affects the recognition result. can be done. In other words, in this embodiment, by using the transmissive illumination device 34, proper recognition can be achieved regardless of the color of the surface material 4, the presence or absence of wrinkles on the surface, and the thread color.

[Third Embodiment]
A jig 100 and a jig 110 used for calibrating the imaging device 30 of the sewing machine 1 according to the present embodiment will be described with reference to FIGS. 18 to 26. FIG. FIG. 18 is a plan view showing an example of the jig 100 according to this embodiment. FIG. 19 is a cross-sectional view showing an example of the jig 100 according to this embodiment. FIG. 20 is a diagram showing an example of pixel rate with respect to height. FIG. 21 is a diagram showing an example of the height of the sewing object defined for each pattern. FIG. 22 is a plan view showing an example of the jig 110 according to this embodiment. FIG. 23 is a cross-sectional view showing an example of the jig 110 according to this embodiment. FIG. 24 is a schematic diagram showing an example of how to use the jig 110 according to this embodiment. FIG. 25 is a schematic diagram showing an example of how to use the jig 110 according to this embodiment. FIG. 26 is a schematic diagram showing an example of how to use the jig 110 according to this embodiment.

The jig 100 will be described with reference to FIGS. 18 and 19. FIG. The jig 100 is a jig for calculating an accurate pixel rate for each thickness of the sewing object S. As shown in FIG. The jig 100 has three stages of thickness. The jig 100 has a first thickness portion 101 with a thickness h1, a second thickness portion 102 with a thickness h2 that is thicker than the thickness h1, and a third thickness portion 103 with a thickness h3 that is thicker than the thickness h2. have The first thickness portion 101 has circles 101a and circles 101b arranged on its surface. The second thickness portion 102 has circles 102a and circles 102b arranged on its surface. The third thickness portion 103 has circles 103a and circles 103b arranged on its surface. Circle 101a, circle 101b, circle 102a, circle 102b, circle 103a, and circle 103b have the same size. The centers of the circle 101a, the circle 102a, and the circle 103a are located on the same straight line. The centers of the circle 101b, the circle 102b, and the circle 103b are located on the same straight line. The actual center-to-center distances on the surfaces of the circles 101a and 101b, the circles 102a and 102b, and the circles 103a and 103b are the same.

Image processing is performed on the image data captured by the imaging device 30, and the center-to-center distances between the circles 101a and 101b, the circles 102a and 102b, and the circles 103a and 103b on the image are calculated. is calculated.

The pixel rate will be described with reference to FIGS. 20 and 21. FIG. As shown in FIG. 20, a regression line is obtained based on three stages of pixel rates obtained using the jig 100 described above. Based on the regression line, it is possible to calculate an appropriate pixel rate for a sewing object S of arbitrary thickness, as shown in FIG. As shown in FIG. 21, the thickness of the sewing object S is defined for each pattern. Alternatively, based on three levels of pixel rates, intermediate values between two points may be used to simplify the calculation process.

The jig 110 will be described with reference to FIGS. 22 and 23. FIG. The jig 110 is a jig for correcting the correspondence between the sewing machine coordinate system and the camera coordinate system when the holding member 15 is used. The jig 110 is a square plate. The jig 110 has a circular portion 111 arranged in the center and a hole 112 formed in the center of the circular portion 111 . The circular portion 111 is colored in a different color than the rest of the jig 110 . Hole 112 is the center of gravity of jig 110 . The position of the jig 110 can be accurately detected by calculating the center of gravity.

A method of using the jig 110 will be described with reference to FIGS. 24 to 26. FIG. First, as shown in the upper part of FIG. 24, the jig 110 is fixed at an arbitrary position on the holding member 15 . Then, as shown in the center of FIG. 24, the holding member 15 is moved to the sewing machine origin, which is directly below the sewing needle 3, and the sewing machine coordinate values are stored. Then, as shown in the lower part of FIG. 24, the holding member 15 is moved directly below the imaging device 30, and the coordinate values of the center of gravity of the jig 110 are detected based on the photographed image. Then, as shown in FIG. 25, based on the amount of movement in the X-axis direction and the amount of movement in the Y-axis direction obtained from the drive amount of the actuator 17, and the coordinate values of the center of gravity of the jig 110, the imaging device 30 in the sewing machine coordinate system. Get the coordinates of the center of the . As shown in FIG. 26, the table 2 is moved in the horizontal plane by known amounts in the X-axis direction and the Y-axis direction, and the coordinate values of the center of gravity of the jig 110 are detected again. Based on the detected coordinate values of the two centers of gravity and the amount of movement of the table 2, the camera coordinate system, the sewing machine coordinate system, and the inclination θ can be calculated. In this way, it is possible to correct the correspondence between the machine coordinate system and the camera coordinate system.

As described above, the present embodiment can appropriately calculate the pixel rate according to the thickness of the sewing object S. Further, in this embodiment, when the holding member 15 is used, the positional relationship between the imaging device 30 and the sewing object S in the sewing machine coordinate system can be accurately obtained. In this embodiment, the displacement occurring on the surface of the sewing object S can be detected with high accuracy regardless of the thickness of the sewing object S.

DESCRIPTION OF SYMBOLS 1... Sewing machine, 2... Table, 3... Sewing needle, 4... Surface material, 5... Pad material, 6... Backing material, 7... Hole, 10... Sewing machine body, 11... Sewing machine frame, 11A... Horizontal arm, 11B... Bed , 11C... vertical arm, 11D... head, 12... needle bar, 13... needle plate, 14... support member, 15... holding member, 15A... pressing member, 15B... lower plate, 16... actuator, 17... actuator, 17X... X-axis motor 17Y Y-axis motor 18 Actuator 19 Intermediate pressing member 20 Operation device 21 Operation panel 22 Operation pedal 30 Imaging device 31 Drive amount sensor 32 Drive amount Sensor 32X...X-axis sensor 32Y...Y-axis sensor 33...Epi-illumination device 40...Control device 50...Input/output interface device 60...Storage device 61...Sewing data storage unit 62...Program storage unit 70...Arithmetic processing unit 71...Sewing data acquisition unit 72...Photographing position setting unit 75...Initial position data generation unit 76...Sewing processing unit 77...Control unit 80...Display device 81...Display panel 82 Illumination operation panel 721 Display control unit 722 Movement control unit 73 Illumination setting unit 731 Light amount data storage unit 732 Display control unit 733 Adjustment unit 74 Characteristic pattern setting unit 741 Display control unit 742 Setting unit AX Optical axis DP Prescribed pattern DPh Reference pattern FA Shooting area GP Stitch GP1 First stitch GP2 Second stitch MA Stitch forming area , Pf .

Claims (2)

a holding member capable of holding and moving the sewing object within a predetermined plane including the sewing position directly below the sewing needle;
an actuator that moves the holding member;
an imaging device capable of imaging the sewing object;
an illumination device that illuminates the sewing object photographed by the imaging device;
a lighting operation panel capable of accepting operations related to the lighting device;
an illumination setting unit that outputs a control signal for controlling the amount of light of the illumination device according to the color of the surface of the sewing object based on the operation of the illumination operation panel;
an initial position data generation unit that generates initial position data indicating initial positions of the plurality of characteristic patterns of the sewing object based on the image data captured by the imaging device ;
wherein the initial position data defines light amount data of the lighting device for each of the sewing objects;
sewing machine. photographing, with an imaging device, a sewing object held by a holding member movable within a predetermined plane including a sewing position directly below a sewing needle;
receiving an operation of a lighting device that illuminates the sewing object photographed by the imaging device on a lighting operation panel;
outputting a control signal for controlling the amount of light of the lighting device according to the color of the surface of the sewing object based on the operation of the lighting operation panel;
generating initial position data indicating initial positions of the plurality of characteristic patterns of the sewing object based on the image data captured by the imaging device ;
wherein the initial position data defines light amount data of the lighting device for each of the sewing objects;
Sewing method.

Images