WO2013051880A2 - Sewing machine capabale of mode conversion and sewing method using the same - Google Patents

Sewing machine capabale of mode conversion and sewing method using the same Download PDF

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Publication number
WO2013051880A2
WO2013051880A2 PCT/KR2012/008073 KR2012008073W WO2013051880A2 WO 2013051880 A2 WO2013051880 A2 WO 2013051880A2 KR 2012008073 W KR2012008073 W KR 2012008073W WO 2013051880 A2 WO2013051880 A2 WO 2013051880A2
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WO
WIPO (PCT)
Prior art keywords
sewing
mode
sewing machine
parameters
machine
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PCT/KR2012/008073
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French (fr)
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WO2013051880A3 (en
Inventor
In Chul Park
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Sunstar Co., Ltd.
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Publication date
Application filed by Sunstar Co., Ltd. filed Critical Sunstar Co., Ltd.
Publication of WO2013051880A2 publication Critical patent/WO2013051880A2/en
Publication of WO2013051880A3 publication Critical patent/WO2013051880A3/en

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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B19/00—Programme-controlled sewing machines
    • D05B19/02—Sewing machines having electronic memory or microprocessor control unit
    • D05B19/12—Sewing machines having electronic memory or microprocessor control unit characterised by control of operation of machine
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B19/00—Programme-controlled sewing machines
    • D05B19/02—Sewing machines having electronic memory or microprocessor control unit
    • D05B19/04—Sewing machines having electronic memory or microprocessor control unit characterised by memory aspects
    • D05B19/10—Arrangements for selecting combinations of stitch or pattern data from memory ; Handling data in order to control stitch format, e.g. size, direction, mirror image
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B19/00—Programme-controlled sewing machines

Definitions

  • the present disclosure relates to a sewing machine, and more particularly, to a sewing machine and a sewing method using the same, in which mode conversion can be made to facilitate correction of sewing errors occurring during a sewing process performed with automatically-set sewing parameters.
  • a sewing machine is a mechanical device generally used for sewing up sewing materials, e.g., textiles, leather and paper. With an increase of necessities for diverse and high-quality sewing products and rapid improvement in productivity, various new sewing functions which could not be found in conventional sewing machines have been developed.
  • the automatic configurable sewing machines can reduce the required time for sewing processes.
  • Reference 1 Korean Laid-open Patent No. 10-2009-01038166 discloses a sewing machine performing sewing processes according to sewing data. According to Reference 1, the sewing machine controls respective motors and actuators based on the sewing data.
  • the conventional sewing machine has provided no counter means to deal with sewing errors occurring during a sewing process. That is, since sewing processes are successively performed based on automatically-set sewing parameters in the conventional sewing machines, it is very hard to correct a sewing error occurring during a sewing process because a subsequent sewing process starts immediately after the previous sewing process where the sewing error occurred.
  • the sewing process S includes separate sewing processes S1 and S2, which are alternately repeated on different positions in a sewing material 1 or on another different sewing material 1.
  • a straight lockstitch consisting of Nn number of stitches is performed, where Nn is one of the sewing parameters denoting the number of stitches.
  • Nn is one of the sewing parameters denoting the number of stitches.
  • a sewing line fails to reach a desired end point (an end point P1 of the sewing process S1 having a start point P0) due to different skill levels of the users in terms of moving or changing the sewing material 1 or different characteristics of each sewing material 1.
  • the conventional sewing machine determines that the sewing process S1 is completed when the number of stitches of the lockstitch reaches Nn and, regardless whether the sewing errors occur during the sewing process S1, Nn is set as another one of the sewing parameters for the subsequent sewing process S2. As the subsequent sewing process S2 starts, the number of lockstitch is being counted again. From the above, in the conventional sewing machine, even if sewing errors occur during the sewing process S1 (e.g., the sewing process S1 is terminated at an undesired position P1'), the sewing errors cannot be corrected without affecting the number of stitches Nn for the subsequent sewing process S2. That is, in the conventional sewing machine, no counter measure is provided to easily correct the sewing errors that occurred during successively performed sewing processes based on automatically configured parameters, thereby resulting in deteriorations in both the quality of sewing products and the productivity of sewing processes.
  • the present disclosure provides some embodiments of a sewing machine and a sewing method using the same, in which a mode conversion can be made to facilitate correction of sewing errors occurring during a sewing process performed with automatically-set sewing parameters.
  • the present disclosure provides some embodiments of a mode convertible sewing machine configured to set sewing parameters automatically to thereby perform a plurality of sewing processes and a mode convertible sewing method using the same, in which, if sewing errors occur during one of the plurality of sewing processes, the sewing machine is switched to a manual mode before starting a subsequent sewing process to facilitate correction of the sewing errors and, after the correction of the sewing errors is completed, the sewing machine is switched to an automatic mode and starts the subsequent sewing process.
  • a mode convertible sewing machine which includes: a pedal configured to receive a user command to initiate a sewing process; a manipulation panel configured to receive sewing data including sewing parameters; a control block configured to control driving of the sewing machine in accordance with the sewing parameters; and a mode change switch configured to generate a mode change signal and transmit the mode change signal to the control block to drive the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters or in a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine.
  • the sewing parameters may include at least one of a number of stitches, a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
  • the mode convertible sewing machine may further include a counter configured to measure a number of stitches by using a rotation number of a main shaft.
  • the mode convertible sewing machine may further include a correction unit configured to obtain, as correction data, the number of stitches measured by the counter in the manual mode and display the correction data.
  • a mode convertible sewing method using a sewing machine configured to receive a user command initiating a sewing process via a pedal.
  • the mode convertible sewing method includes: receiving sewing data including sewing parameters; starting the sewing process by driving the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters; checking whether sewing errors occur; performing the sewing process in the automatic mode while the sewing errors do not occur; switching the sewing machine to a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine, if the sewing errors occur; performing correction of the sewing errors in the manual mode; and switching the sewing machine to the automatic mode if the correction of the sewing errors is completed.
  • the mode convertible sewing method may further include selectively changing the sewing parameters after the switching the sewing machine to the manual mode.
  • the checking whether the sewing errors occur may include determining that the sewing errors occur if a sewing line, which is produced with the number of stitches set by a corresponding sewing parameter, has a length shorter than a target length.
  • the performing the correction of the sewing errors may include: performing additional sewing process until the length of the sewing line reaches the target length; obtaining correction data on a number of stitches measured during the additional sewing process by using a rotation number of a main shaft of the sewing machine; and selectively displaying the correction data.
  • the performing the correction of the sewing errors may further include performing a yarn cutting after the additional sewing process is completed.
  • the sewing machine is switched to a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine, thereby facilitating correction of the sewing errors.
  • the manual mode correction data on a number of stitches made in order to correct the sewing errors can be obtained and displayed, which allows a worker to easily handle the correction of the sewing errors and improve his or her sewing skill in the manual mode.
  • a mode convertible sewing machine will be described with an example lockstitch sewing machine performing a straight lockstitch.
  • the lockstitch sewing machine is presented by way of example only, and does not limit the scope of the present disclosure.
  • the mode convertible sewing machine may be embodied in various sewing machines including a chainstitch sewing machine and an embroidering machine.
  • FIGS. 2 and 3 illustrate a mode convertible sewing machine 1000 according to an embodiment of the present disclosure.
  • the sewing machine 1000 receives sewing data 2 including sewing parameters X from the outside and is automatically set to be in a sewing-ready state by the sewing parameters X before starting a sewing process S.
  • the expression "the sewing machine 1000 is automatically set by the sewing parameters X" means that the sewing data 2 including the sewing parameters X is input to the sewing machine 1000 and the sewing machine 1000 is set to be ready to perform the sewing process S based on the input sewing parameters X.
  • the sewing parameters X may include a number of stitches, a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
  • the sewing machine 1000 includes a pedal 190 configured to control when to start of the sewing process S, a manipulation panel 200 configured to receive the sewing data 2, a control block 300 configured to set the sewing machine 1000 based on the sewing parameters X to drive the sewing machine 1000, and a mode change switch 400 configured to apply a mode change signal to the control block 300 to drive the sewing machine 1000 in an automatic mode or in a manual mode.
  • the automatic mode the sewing machine 1000 is automatically set by the sewing parameters X, whereas in the manual mode, the sewing parameters X are prevented from automatically being applied to the sewing machine 1000.
  • the sewing machine 1000 is automatically set by the sewing parameters X for a sewing process S2 when a sewing process S1 that is followed by the sewing process S2 is terminated. That is, after forming a sewing line consisting of Nn number of stitches set for the sewing process S1, the sewing machine 1000 is automatically set by the number of stiches Nn for the subsequent sewing process S2 and begins to count a number of stitches when the sewing process S2 starts. On the contrary, when the sewing machine 1000 operates in the manual mode, the sewing parameters X are not automatically applied to the sewing machine 1000. To be specific, after performing the lockstitch consisting of Nn number of stitches set for the previous sewing process S1, the sewing machine 1000 is not automatically set by the number of stitches Nn for the subsequent sewing process S2.
  • sewing parameters X are not set in the sewing machine 1000 and thus, even if the sewing machine 1000 performs lockstitches for correcting sewing errors that occurred during the previous sewing process S1, these lockstitches do not affect the number of stitches Nn set for the subsequent sewing process S2.
  • the sewing machine 1000 may include a main body 100, a main motor 160 directly or indirectly (for example, via a belt) connected to a side of the main body 100, and the pedal 190 configured to receive a user instruction to drive the main motor 160.
  • a power switch 180 may be installed on a front surface of a worktable 170, on which the main body 100 is mounted, and a mode change switch 400 may be installed at a side of the power switch 180.
  • the control block 300 may be installed in a lower space of the worktable 170 and the manipulation panel 200 may be installed on a top surface of the worktable 170 or on a top surface of the main body 100.
  • a main shaft 110 may be roratably installed in the main body 100 and a needle support 130 may be vertically-movably installed at an end of the main shaft 110.
  • a sewing needle 140 may be detachably attached at a lower side of the needle support 130 and a height-controllable and pressure-controllable presser-foot 150 may be installed at a rear side of the needle support 130.
  • the presser-foot 150 may serve to press a sewing material during the sewing process.
  • a stitch width step motor 161 configured to control the stitch width
  • a presser-foot height step motor 162 configured to control the height of the presser-foot 150
  • a presser-foot pressure step motor 163 configured to control the pressure of the presser-foot 150
  • a yarn tension holding device 165 configured to keep a tension of yarn to be constant during the lockstitch.
  • the yarn tension holding device 165 may include a yarn tension measuring unit and a yarn tension solenoid.
  • a counter 500 configured to count the rotation number of the main shaft 110 may be installed at a connecting portion of the main shaft 110 and the main motor 160.
  • the main motor 160 may rotate the main shaft 110 in response to the user command received via the pedal 190 and the needle support 130 and the sewing needle 140 may make vertical movements by the rotation of the main shaft 110 to perform the lockstitch on the sewing material.
  • the sewing machine 1000 is automatically set by the sewing parameters X which are set based on, e.g., a type of the sewing material and a lockstitch pattern.
  • the respective step motors installed in the sewing machine 1000 can be controlled to set the sewing machine 1000 to be in an optimal state for performing the sewing process S.
  • the sewing parameters X are transmitted in form of the sewing data 2 from a server 10 (installed, for example, at a headquarter managing the entire sewing process) to the sewing machine 1000 via various wired or wireless communications networks.
  • the manipulation panel 200 may include a transceiver 210 configured to receive the sewing data 2 from the server 10 and transmit various data collected during the sewing process S to the server 10, and a display unit 220 configured to display an operational status of the sewing machine 1000, the input sewing data 2 and the like.
  • the manipulation panel 200 may further include a button manipulation module 230 which can be manipulated by a user to change contents displayed on the display unit 200 or change the sewing parameters X.
  • connection ports (not shown) to external devices including Personal Computers (PCs), Personal Digital Assistants (PDAs) and Universal Serial Bus (USB) memories may be provided, thereby allowing the manipulation panel 200 to receive the sewing data 2 from the external devices.
  • the sewing data 2 inputted to the manipulation panel 200 includes a number of stitches Nn for a single sewing process, and may further include a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
  • the sewing data 2 received by the transceiver 210 may be temporarily stored in a memory provided in the transceiver 210 and then transmitted to the control block 300.
  • the control block 300 may include a main controller 310 configured to generate a sewing machine setting/driving instruction signal based on the sewing data 2, motor drivers configured to receive the sewing machine setting/driving instruction signal and control respective driving units of the sewing machine 1000 based on the sewing machine setting/driving instruction signal, and a power source part 340 connected to the power switch 180 and configured to distribute an electric power supplied from outside to the main controller 310 and the motor drivers.
  • the motor drivers may include a main motor driver 320 configured to control driving of the main motor 160 and a step motor driver 330 configured to control driving of the respective step motors including the stitch width step motor 161, the presser-foot height step motor 162 and the presser-foot pressure step motor 163. Further, a yarn cutting step motor 164 may be configured to automatically cut yarn when the sewing process S is completed, and be connected to the step motor driver 330. Driving status of the main motor 160 and the respective step motors 161 to 164 connected to the motor drivers 320 and 330 can be monitored by the main controller 310 and displayed on the display unit 220 of the manipulation panel 200, thereby allowing a user to easily check the status of the respective driving units.
  • the main controller 310 is connected to the pedal 190 configured to receive a user command to initiate the sewing process S (including restart of the sewing process S after the sewing process S is suspended), the yarn tension holding unit 165 configured to keep the tension of yarn to be constant during the lockstitch, and the mode change switch 400 configured to control the sewing machine 1000 to operate in the automatic mode or in the manual mode. Further, the main controller 310 is connected to the counter 500 configured to count the number of stitches by measuring the rotation number of the main shaft 110, and a correction unit 510 configured to receive from the counter 500 information on a number of stitches used in a lockstitch performed to correct sewing errors and generate correction data based on the information.
  • the sewing machine 1000 can be switched to operate in the manual mode based on a user command inputted via the mode change switch 400.
  • the mode change signal is generated and transmitted to the main controller 310 of the control block 300.
  • the main controller 310 transmits a stop signal to the motor drivers.
  • the sewing parameters X for the sewing process S1 during which the sewing errors occur are kept as the setting of the sewing machine 1000. Accordingly, a procedure for correcting the sewing errors can be performed by using the same sewing parameters X as those used in the sewing process S1 during which the sewing errors occur. Alternatively, the user can change the sewing parameters X to correct the sewing errors when the sewing machine 1000 operates in the manual mode.
  • a yarn cutting may be performed, and the sewing machine 1000 can be switched to operate in the automatic mode according to a user instruction input via the mode change switch 400.
  • a sewing method using the above-described mode convertible sewing machine (hereinafter, referred to as "a mode convertible sewing method") will now be described with reference to accompanying drawings. In the following, the same explanation on the sewing machine as that described above will be omitted or briefly referred.
  • the mode convertible sewing method may include: receiving sewing data including sewing parameters by a sewing machine (step S110); receiving a user command to initiate a sewing process via a pedal (step S120); starting the sewing process in an automatic mode where the sewing machine is automatically set by the sewing parameters (step S130); checking whether sewing errors occur during the sewing process (step S140); performing, if sewing errors do not occur, the sewing process in the automatic mode until a number of stitches reaches a number set in the sewing parameters (step S150); and performing an automatic yarn cutting after the number of stitches reaches the number set in the sewing parameters (step S160).
  • the method further includes: switching the sewing machine to a manual mode if sewing errors occur (step S210); receiving a user command to drive the sewing machine via the pedal (step S240); and performing correction of the sewing errors (step S250); and switching the sewing machine to the automatic mode via a mode change switch after the correction of the sewing errors is completed (step S270).
  • whether or not sewing errors occur due to different skill levels of the users and/or different characteristics of the sewing materials can be determined by the length of a sewing line. In other words, it can be determined that sewing errors occur if a sewing line formed by a sewing process has a length shorter than a target length.
  • the method may further include determining whether or not to change the sewing parameters in order to correct the sewing errors (step S220) and setting the sewing machine based on the changed sewing parameters (step S230).
  • the steps S220 and S230 may be performed after the sewing errors are detected and the sewing machine is switched to the manual mode.
  • the correction of the sewing errors is performed under the same sewing parameter set for the sewing process during which the sewing errors occur.
  • the user can selectively change the stitch width, the presser-foot pressure, the presser-foot height and the main shaft velocity to perform the correction of the sewing errors.
  • the number of stitches for correcting the sewing errors may be measured by detecting the rotation number of the main shaft of the sewing machine and correction data on the measured number of stitches can be selectively displayed. That is, the user can check the number of stitches for correcting the sewing errors and be more cautious in the subsequent sewing process, thereby improving his or her level of work skill.
  • step S260 After the correction of the sewing errors is completed, the automatic yarn cutting is performed to terminate the sewing process (step S260). In the step S270, the sewing machine is switched from the manual mode to the automatic mode to perform the subsequent sewing process.
  • the user can appropriately perform the correction of the sewing errors by preventing the input sewing parameters from automatically being applied to the sewing machine and by selectively applying the input sewing parameters to the sewing machine. Accordingly, an error rate during the sewing process can be reduced and the productivity can be increased, thereby improving the quality of sewing products and consumer trust in the sewing products.
  • the present disclosure can reduce both an error rate while sewing a product and a processing time of sewing processes, and as a result, save manufacturing costs of sewing products and improve sewing process productivity. Further, the present disclosure can improve uniformity of sewing products and consumer trust in the sewing products.
  • FIG. 1 illustrates an example of a sewing error occurring during a sewing process.
  • FIG. 2 illustrates a front view of a mode convertible sewing machine according to an embodiment of the present disclosure.
  • FIG. 3 illustrates a configuration of the mode convertible sewing machine according to the embodiment of the present disclosure.
  • FIG. 4 illustrates a flowchart of a sewing method using a mode convertible sewing machine according to an embodiment of the present disclosure.

Abstract

Provided are a sewing machine and a sewing method using the same, in which a mode conversion can be made to facilitate correction of sewing errors occurring during a sewing process performed with automatically-set sewing parameters. The mode convertible sewing machine includes: a pedal configured to receive a user command initiating a sewing process; a manipulation panel configured to receive sewing data including sewing parameters; a control block configured to control driving of the sewing machine based on the sewing parameters; and a mode change switch configured to generate a mode change signal and transmit the mode change signal to the control block to drive the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters or in a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine.

Description

SEWING MACHINE CAPABALE OF MODE CONVERSION AND SEWING METHOD USING THE SAME
The present disclosure relates to a sewing machine, and more particularly, to a sewing machine and a sewing method using the same, in which mode conversion can be made to facilitate correction of sewing errors occurring during a sewing process performed with automatically-set sewing parameters.
A sewing machine is a mechanical device generally used for sewing up sewing materials, e.g., textiles, leather and paper. With an increase of necessities for diverse and high-quality sewing products and rapid improvement in productivity, various new sewing functions which could not be found in conventional sewing machines have been developed.
Recently, there have been proposed automatic configurable sewing machines to which sewing parameters are automatically applied, whereas in conventional sewing machines, the sewing parameters are manually input by a user. The sewing parameters include, e.g., the number of stitches, a presser-foot pressure, a presser-foot height and a yarn tension. The automatic configurable sewing machines can reduce the required time for sewing processes.
As an example of the automatic configurable sewing machines, Reference 1 (Korean Laid-open Patent No. 10-2009-0103816) discloses a sewing machine performing sewing processes according to sewing data. According to Reference 1, the sewing machine controls respective motors and actuators based on the sewing data. However, the conventional sewing machine has provided no counter means to deal with sewing errors occurring during a sewing process. That is, since sewing processes are successively performed based on automatically-set sewing parameters in the conventional sewing machines, it is very hard to correct a sewing error occurring during a sewing process because a subsequent sewing process starts immediately after the previous sewing process where the sewing error occurred.
The above-described problem in the conventional sewing machines will be described in detail with reference to a sewing process S shown in FIG. 1. The sewing process S includes separate sewing processes S1 and S2, which are alternately repeated on different positions in a sewing material 1 or on another different sewing material 1. In each of the sewing processes S1 and S2, a straight lockstitch consisting of Nn number of stitches is performed, where Nn is one of the sewing parameters denoting the number of stitches. Even though the straight lockstitch consisting of the Nn number of stitches is made in the sewing process S1, a sewing line fails to reach a desired end point (an end point P1 of the sewing process S1 having a start point P0) due to different skill levels of the users in terms of moving or changing the sewing material 1 or different characteristics of each sewing material 1. In this case, sewing errors can occur. However, the conventional sewing machine determines that the sewing process S1 is completed when the number of stitches of the lockstitch reaches Nn and, regardless whether the sewing errors occur during the sewing process S1, Nn is set as another one of the sewing parameters for the subsequent sewing process S2. As the subsequent sewing process S2 starts, the number of lockstitch is being counted again. From the above, in the conventional sewing machine, even if sewing errors occur during the sewing process S1 (e.g., the sewing process S1 is terminated at an undesired position P1'), the sewing errors cannot be corrected without affecting the number of stitches Nn for the subsequent sewing process S2. That is, in the conventional sewing machine, no counter measure is provided to easily correct the sewing errors that occurred during successively performed sewing processes based on automatically configured parameters, thereby resulting in deteriorations in both the quality of sewing products and the productivity of sewing processes.
The present disclosure provides some embodiments of a sewing machine and a sewing method using the same, in which a mode conversion can be made to facilitate correction of sewing errors occurring during a sewing process performed with automatically-set sewing parameters.
The present disclosure provides some embodiments of a mode convertible sewing machine configured to set sewing parameters automatically to thereby perform a plurality of sewing processes and a mode convertible sewing method using the same, in which, if sewing errors occur during one of the plurality of sewing processes, the sewing machine is switched to a manual mode before starting a subsequent sewing process to facilitate correction of the sewing errors and, after the correction of the sewing errors is completed, the sewing machine is switched to an automatic mode and starts the subsequent sewing process.
According to an aspect of the present disclosure, disclosed is a mode convertible sewing machine which includes: a pedal configured to receive a user command to initiate a sewing process; a manipulation panel configured to receive sewing data including sewing parameters; a control block configured to control driving of the sewing machine in accordance with the sewing parameters; and a mode change switch configured to generate a mode change signal and transmit the mode change signal to the control block to drive the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters or in a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine.
The sewing parameters may include at least one of a number of stitches, a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
The mode convertible sewing machine may further include a counter configured to measure a number of stitches by using a rotation number of a main shaft.
The mode convertible sewing machine may further include a correction unit configured to obtain, as correction data, the number of stitches measured by the counter in the manual mode and display the correction data.
According to another aspect of the present disclosure, disclosed is a mode convertible sewing method using a sewing machine configured to receive a user command initiating a sewing process via a pedal. The mode convertible sewing method includes: receiving sewing data including sewing parameters; starting the sewing process by driving the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters; checking whether sewing errors occur; performing the sewing process in the automatic mode while the sewing errors do not occur; switching the sewing machine to a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine, if the sewing errors occur; performing correction of the sewing errors in the manual mode; and switching the sewing machine to the automatic mode if the correction of the sewing errors is completed.
The mode convertible sewing method may further include selectively changing the sewing parameters after the switching the sewing machine to the manual mode.
The checking whether the sewing errors occur may include determining that the sewing errors occur if a sewing line, which is produced with the number of stitches set by a corresponding sewing parameter, has a length shorter than a target length.
The performing the correction of the sewing errors may include: performing additional sewing process until the length of the sewing line reaches the target length; obtaining correction data on a number of stitches measured during the additional sewing process by using a rotation number of a main shaft of the sewing machine; and selectively displaying the correction data.
The performing the correction of the sewing errors may further include performing a yarn cutting after the additional sewing process is completed.
According to the mode convertible sewing machine and the mode convertible sewing method using the same of the present disclosure, if sewing errors occur due to a different skill level of a worker or different characteristics of sewing materials while performing a sewing process performed with automatically-set sewing parameters, the sewing machine is switched to a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine, thereby facilitating correction of the sewing errors. In the manual mode, correction data on a number of stitches made in order to correct the sewing errors can be obtained and displayed, which allows a worker to easily handle the correction of the sewing errors and improve his or her sewing skill in the manual mode.
A mode convertible sewing machine according to the present disclosure will be described with an example lockstitch sewing machine performing a straight lockstitch. However, the lockstitch sewing machine is presented by way of example only, and does not limit the scope of the present disclosure. Indeed, the mode convertible sewing machine may be embodied in various sewing machines including a chainstitch sewing machine and an embroidering machine.
Hereinafter, embodiments of the present disclosure will be described with reference to accompanying drawings.
FIGS. 2 and 3 illustrate a mode convertible sewing machine 1000 according to an embodiment of the present disclosure. As shown in FIG. 2, the sewing machine 1000 receives sewing data 2 including sewing parameters X from the outside and is automatically set to be in a sewing-ready state by the sewing parameters X before starting a sewing process S. Here, the expression "the sewing machine 1000 is automatically set by the sewing parameters X" means that the sewing data 2 including the sewing parameters X is input to the sewing machine 1000 and the sewing machine 1000 is set to be ready to perform the sewing process S based on the input sewing parameters X. The sewing parameters X may include a number of stitches, a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity. The sewing machine 1000 includes a pedal 190 configured to control when to start of the sewing process S, a manipulation panel 200 configured to receive the sewing data 2, a control block 300 configured to set the sewing machine 1000 based on the sewing parameters X to drive the sewing machine 1000, and a mode change switch 400 configured to apply a mode change signal to the control block 300 to drive the sewing machine 1000 in an automatic mode or in a manual mode. In the automatic mode, the sewing machine 1000 is automatically set by the sewing parameters X, whereas in the manual mode, the sewing parameters X are prevented from automatically being applied to the sewing machine 1000.
Specifically, in the automatic mode, the sewing machine 1000 is automatically set by the sewing parameters X for a sewing process S2 when a sewing process S1 that is followed by the sewing process S2 is terminated. That is, after forming a sewing line consisting of Nn number of stitches set for the sewing process S1, the sewing machine 1000 is automatically set by the number of stiches Nn for the subsequent sewing process S2 and begins to count a number of stitches when the sewing process S2 starts. On the contrary, when the sewing machine 1000 operates in the manual mode, the sewing parameters X are not automatically applied to the sewing machine 1000. To be specific, after performing the lockstitch consisting of Nn number of stitches set for the previous sewing process S1, the sewing machine 1000 is not automatically set by the number of stitches Nn for the subsequent sewing process S2. Instead, sewing parameters X are not set in the sewing machine 1000 and thus, even if the sewing machine 1000 performs lockstitches for correcting sewing errors that occurred during the previous sewing process S1, these lockstitches do not affect the number of stitches Nn set for the subsequent sewing process S2.
The sewing machine 1000 may include a main body 100, a main motor 160 directly or indirectly (for example, via a belt) connected to a side of the main body 100, and the pedal 190 configured to receive a user instruction to drive the main motor 160. In addition, a power switch 180 may be installed on a front surface of a worktable 170, on which the main body 100 is mounted, and a mode change switch 400 may be installed at a side of the power switch 180. Further, the control block 300 may be installed in a lower space of the worktable 170 and the manipulation panel 200 may be installed on a top surface of the worktable 170 or on a top surface of the main body 100.
A main shaft 110 may be roratably installed in the main body 100 and a needle support 130 may be vertically-movably installed at an end of the main shaft 110. A sewing needle 140 may be detachably attached at a lower side of the needle support 130 and a height-controllable and pressure-controllable presser-foot 150 may be installed at a rear side of the needle support 130. The presser-foot 150 may serve to press a sewing material during the sewing process. In the main body 100, there may be provided a stitch width step motor 161 configured to control the stitch width, a presser-foot height step motor 162 configured to control the height of the presser-foot 150, a presser-foot pressure step motor 163 configured to control the pressure of the presser-foot 150, and a yarn tension holding device 165 configured to keep a tension of yarn to be constant during the lockstitch. The yarn tension holding device 165 may include a yarn tension measuring unit and a yarn tension solenoid. Further, a counter 500 configured to count the rotation number of the main shaft 110 may be installed at a connecting portion of the main shaft 110 and the main motor 160. With the sewing machine 1000 having the above-described configuration, when the power switch 180 is turned on, the main motor 160 may rotate the main shaft 110 in response to the user command received via the pedal 190 and the needle support 130 and the sewing needle 140 may make vertical movements by the rotation of the main shaft 110 to perform the lockstitch on the sewing material.
Before starting the sewing process S, the sewing machine 1000 is automatically set by the sewing parameters X which are set based on, e.g., a type of the sewing material and a lockstitch pattern. For example, the respective step motors installed in the sewing machine 1000 can be controlled to set the sewing machine 1000 to be in an optimal state for performing the sewing process S. In this embodiment, the sewing parameters X are transmitted in form of the sewing data 2 from a server 10 (installed, for example, at a headquarter managing the entire sewing process) to the sewing machine 1000 via various wired or wireless communications networks.
As shown in FIG. 3, the manipulation panel 200 may include a transceiver 210 configured to receive the sewing data 2 from the server 10 and transmit various data collected during the sewing process S to the server 10, and a display unit 220 configured to display an operational status of the sewing machine 1000, the input sewing data 2 and the like. The manipulation panel 200 may further include a button manipulation module 230 which can be manipulated by a user to change contents displayed on the display unit 200 or change the sewing parameters X. At the transceiver 210, connection ports (not shown) to external devices including Personal Computers (PCs), Personal Digital Assistants (PDAs) and Universal Serial Bus (USB) memories may be provided, thereby allowing the manipulation panel 200 to receive the sewing data 2 from the external devices. The sewing data 2 inputted to the manipulation panel 200 includes a number of stitches Nn for a single sewing process, and may further include a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
The sewing data 2 received by the transceiver 210 may be temporarily stored in a memory provided in the transceiver 210 and then transmitted to the control block 300. The control block 300 may include a main controller 310 configured to generate a sewing machine setting/driving instruction signal based on the sewing data 2, motor drivers configured to receive the sewing machine setting/driving instruction signal and control respective driving units of the sewing machine 1000 based on the sewing machine setting/driving instruction signal, and a power source part 340 connected to the power switch 180 and configured to distribute an electric power supplied from outside to the main controller 310 and the motor drivers. The motor drivers may include a main motor driver 320 configured to control driving of the main motor 160 and a step motor driver 330 configured to control driving of the respective step motors including the stitch width step motor 161, the presser-foot height step motor 162 and the presser-foot pressure step motor 163. Further, a yarn cutting step motor 164 may be configured to automatically cut yarn when the sewing process S is completed, and be connected to the step motor driver 330. Driving status of the main motor 160 and the respective step motors 161 to 164 connected to the motor drivers 320 and 330 can be monitored by the main controller 310 and displayed on the display unit 220 of the manipulation panel 200, thereby allowing a user to easily check the status of the respective driving units.
The main controller 310 is connected to the pedal 190 configured to receive a user command to initiate the sewing process S (including restart of the sewing process S after the sewing process S is suspended), the yarn tension holding unit 165 configured to keep the tension of yarn to be constant during the lockstitch, and the mode change switch 400 configured to control the sewing machine 1000 to operate in the automatic mode or in the manual mode. Further, the main controller 310 is connected to the counter 500 configured to count the number of stitches by measuring the rotation number of the main shaft 110, and a correction unit 510 configured to receive from the counter 500 information on a number of stitches used in a lockstitch performed to correct sewing errors and generate correction data based on the information.
If sewing errors occur due to different skill levels of the users and/or different characteristics of sewing materials during the sewing process S, the sewing machine 1000 can be switched to operate in the manual mode based on a user command inputted via the mode change switch 400. When the user pushes the mode change switch 400, the mode change signal is generated and transmitted to the main controller 310 of the control block 300. In response to the mode change signal, the main controller 310 transmits a stop signal to the motor drivers.
If the sewing machine 1000 is switched to operate in the manual mode, the sewing parameters X for the sewing process S1 during which the sewing errors occur are kept as the setting of the sewing machine 1000. Accordingly, a procedure for correcting the sewing errors can be performed by using the same sewing parameters X as those used in the sewing process S1 during which the sewing errors occur. Alternatively, the user can change the sewing parameters X to correct the sewing errors when the sewing machine 1000 operates in the manual mode.
After the correction procedure for the sewing errors is completed in the manual mode, a yarn cutting may be performed, and the sewing machine 1000 can be switched to operate in the automatic mode according to a user instruction input via the mode change switch 400.
A sewing method using the above-described mode convertible sewing machine (hereinafter, referred to as "a mode convertible sewing method") will now be described with reference to accompanying drawings. In the following, the same explanation on the sewing machine as that described above will be omitted or briefly referred.
Referring to FIG. 4, the mode convertible sewing method according to an embodiment of the present disclosure may include: receiving sewing data including sewing parameters by a sewing machine (step S110); receiving a user command to initiate a sewing process via a pedal (step S120); starting the sewing process in an automatic mode where the sewing machine is automatically set by the sewing parameters (step S130); checking whether sewing errors occur during the sewing process (step S140); performing, if sewing errors do not occur, the sewing process in the automatic mode until a number of stitches reaches a number set in the sewing parameters (step S150); and performing an automatic yarn cutting after the number of stitches reaches the number set in the sewing parameters (step S160). The method further includes: switching the sewing machine to a manual mode if sewing errors occur (step S210); receiving a user command to drive the sewing machine via the pedal (step S240); and performing correction of the sewing errors (step S250); and switching the sewing machine to the automatic mode via a mode change switch after the correction of the sewing errors is completed (step S270).
For the sewing process in which the sewing parameters are automatically set, whether or not sewing errors occur due to different skill levels of the users and/or different characteristics of the sewing materials can be determined by the length of a sewing line. In other words, it can be determined that sewing errors occur if a sewing line formed by a sewing process has a length shorter than a target length.
The method may further include determining whether or not to change the sewing parameters in order to correct the sewing errors (step S220) and setting the sewing machine based on the changed sewing parameters (step S230). The steps S220 and S230 may be performed after the sewing errors are detected and the sewing machine is switched to the manual mode. In general, the correction of the sewing errors is performed under the same sewing parameter set for the sewing process during which the sewing errors occur. Alternatively, the user can selectively change the stitch width, the presser-foot pressure, the presser-foot height and the main shaft velocity to perform the correction of the sewing errors.
During the step S250 to correct the sewing errors, the number of stitches for correcting the sewing errors may be measured by detecting the rotation number of the main shaft of the sewing machine and correction data on the measured number of stitches can be selectively displayed. That is, the user can check the number of stitches for correcting the sewing errors and be more cautious in the subsequent sewing process, thereby improving his or her level of work skill.
After the correction of the sewing errors is completed, the automatic yarn cutting is performed to terminate the sewing process (step S260). In the step S270, the sewing machine is switched from the manual mode to the automatic mode to perform the subsequent sewing process.
As described above, according to the mode convertible sewing machine and the sewing method using the same of the present disclosure, if the sewing errors occur due to different skill levels of users or different characteristics of the sewing materials, the user can appropriately perform the correction of the sewing errors by preventing the input sewing parameters from automatically being applied to the sewing machine and by selectively applying the input sewing parameters to the sewing machine. Accordingly, an error rate during the sewing process can be reduced and the productivity can be increased, thereby improving the quality of sewing products and consumer trust in the sewing products.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosures. Indeed, the novel methods and apparatuses described herein may be embodied in a variety of other forms; furthermore, various changes, modifications, corrections, and substitutions with regard to the embodiments described herein may be made without departing from the spirit of the disclosures.
Accordingly, the present disclosure can reduce both an error rate while sewing a product and a processing time of sewing processes, and as a result, save manufacturing costs of sewing products and improve sewing process productivity. Further, the present disclosure can improve uniformity of sewing products and consumer trust in the sewing products.
FIG. 1 illustrates an example of a sewing error occurring during a sewing process.
FIG. 2 illustrates a front view of a mode convertible sewing machine according to an embodiment of the present disclosure.
FIG. 3 illustrates a configuration of the mode convertible sewing machine according to the embodiment of the present disclosure.
FIG. 4 illustrates a flowchart of a sewing method using a mode convertible sewing machine according to an embodiment of the present disclosure.

Claims (9)

  1. A mode convertible sewing machine, comprising:
    a pedal configured to receive a user command initiating a sewing process via a pedal;
    a manipulation panel configured to receive sewing data including sewing parameters;
    a control block configured to control driving of the mode convertible sewing machine based on the sewing parameters; and
    a mode change switch configured to generate a mode change signal, and transmit the mode change signal to the control block to drive the mode convertible sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters or in a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine.
  2. The mode convertible sewing machine of Claim 1, wherein the sewing parameters include at least one of a number of stitches, a stitch width, a presser-foot pressure, a presser-foot height, a yarn tension and a main shaft velocity.
  3. The mode convertible sewing machine of Claim 1, further comprising:
    a counter configured to measure a number of stitches by counting a rotation number of a main shaft.
  4. The mode convertible sewing machine of Claim 3, further comprising:
    a correction unit configured to obtain and display the number of stitches measured by the counter in the manual mode.
  5. A mode convertible sewing method using a sewing machine configured to receive a user command initiating a sewing process via a pedal, the method comprising:
    receiving sewing data including sewing parameters;
    starting the sewing process by driving the sewing machine in an automatic mode where the sewing machine is automatically set by the sewing parameters;
    checking whether sewing errors occur;
    performing the sewing process in the automatic mode while the sewing errors do not occur;
    switching the sewing machine to a manual mode where the sewing parameters are prevented from automatically being applied to the sewing machine, if the sewing errors occur;
    performing correction of the sewing errors in the manual mode; and
    switching the sewing machine to the automatic mode if the correction of the sewing errors is completed.
  6. The mode convertible sewing method of Claim 5, further comprising:
    selectively changing the sewing parameters after the switching the sewing machine to the manual mode.
  7. The mode convertible sewing method of Claim 5 or 6, wherein the checking whether the sewing errors occur includes:
    determining that the sewing errors occur if a sewing line produced with the number of stitches set by the respective sewing parameters has a length shorter than a target length.
  8. The mode convertible sewing method of Claim 7, wherein the performing the correction of the sewing errors includes:
    performing additional sewing process until the length of the sewing line reaches the target length;
    obtaining correction data regarding a number of stitches measured during the additional sewing process by measuring a rotation number of a main shaft of the sewing machine; and
    displaying the correction data.
  9. The mode convertible sewing method of Claim 8, wherein the performing the correction of the sewing errors further includes:
    performing a yarn cutting after the additional sewing process is completed.
PCT/KR2012/008073 2011-10-05 2012-10-05 Sewing machine capabale of mode conversion and sewing method using the same WO2013051880A2 (en)

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KR10-2011-0101250 2011-10-05
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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4160424A (en) * 1978-02-13 1979-07-10 Dan River Incorporated Stitch counter for a sewing machine
EP0036404A1 (en) * 1980-03-19 1981-09-23 Husqvarna Aktiebolag Sewing guide of a seam pattern sewing machine
KR940005364B1 (en) * 1992-02-11 1994-06-17 이덕문 Controller system for sewing machine
US6681707B2 (en) * 2002-01-25 2004-01-27 Juki Corporation Sewing machine having a means for setting a sewing working device to a predetermined optimum set value
US20050115481A1 (en) * 2002-06-12 2005-06-02 Philip Shad Sewing machine having a wireless switch and independant controller
JP2007252598A (en) * 2006-03-23 2007-10-04 Brother Ind Ltd Holing machine

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4160424A (en) * 1978-02-13 1979-07-10 Dan River Incorporated Stitch counter for a sewing machine
EP0036404A1 (en) * 1980-03-19 1981-09-23 Husqvarna Aktiebolag Sewing guide of a seam pattern sewing machine
KR940005364B1 (en) * 1992-02-11 1994-06-17 이덕문 Controller system for sewing machine
US6681707B2 (en) * 2002-01-25 2004-01-27 Juki Corporation Sewing machine having a means for setting a sewing working device to a predetermined optimum set value
US20050115481A1 (en) * 2002-06-12 2005-06-02 Philip Shad Sewing machine having a wireless switch and independant controller
JP2007252598A (en) * 2006-03-23 2007-10-04 Brother Ind Ltd Holing machine

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TW201315855A (en) 2013-04-16
WO2013051880A3 (en) 2013-06-13

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