WO2013051881A2 - Sewing machine and sewing method using the same - Google Patents

Sewing machine and sewing method using the same Download PDF

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Publication number
WO2013051881A2
WO2013051881A2 PCT/KR2012/008074 KR2012008074W WO2013051881A2 WO 2013051881 A2 WO2013051881 A2 WO 2013051881A2 KR 2012008074 W KR2012008074 W KR 2012008074W WO 2013051881 A2 WO2013051881 A2 WO 2013051881A2
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WO
WIPO (PCT)
Prior art keywords
sewing
sewing machine
processes
parameters
machine
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PCT/KR2012/008074
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French (fr)
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WO2013051881A3 (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 WO2013051881A2 publication Critical patent/WO2013051881A2/en
Publication of WO2013051881A3 publication Critical patent/WO2013051881A3/en

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    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05BSEWING
    • D05B19/00Programme-controlled sewing machines
    • D05B19/02Sewing machines having electronic memory or microprocessor control unit
    • D05B19/12Sewing machines having electronic memory or microprocessor control unit characterised by control of operation of machine
    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05BSEWING
    • D05B19/00Programme-controlled sewing machines

Definitions

  • the present disclosure relates to a sewing machine and a sewing method, and more particularly, to a sewing machine and a sewing method using the same, which can automatically set a sewing parameter necessary for each of a plurality of sewing processes in the sewing machine, and perform the plurality of sewing processes.
  • a sewing machine has been developed to provide various functions to stitch up fabrics, as to product an end product by sewing is increasingly diverse and the end product is required to have the significantly improved quality, and the sew machine has to enhance a productive capacity.
  • a sewing machine is proposed to receive sewing parameters such as a main shaft velocity, a stitch width, and a yarn tension in data form and to automatically set the sewing parameters in accordance with the receive data, while these parameters have been set manually by a worker.
  • Korean Patent Publication No. 10-2009-0103816 discloses a sewing machine that performs a sewing process according to sewing parameters.
  • sewing machine disclosed therein as for each sewing process, sewing data is separately inputted, and thus, there is a limitation in smoothly performing a plurality of sewing processes in a desired way.
  • a single model of sewing machine i.e., the sewing machine with Reference No.
  • KM-235 is capable of performing the sewing processes S1 to S3, a sewing parameter 30 of the sewing machine is required to be manually changed and set for each of the sewing processes S1 to S3.
  • conventional sewing machines cannot automatically change a sewing parameter at issue and perform a plurality of sewing processes accordingly.
  • the conventional sewing machines include a means for performing a plurality of sewing processes, if a sewing error occurs during a previous sewing process (for example, S1) among a plurality of sewing processes, a subsequent sewing process (for example, S2) is immediately performed. This means that there is no opportunity to correct the sewing error in the conventional sewing machines. As illustrated in FIG. 2, at the previous sewing process S1, a sewing line is produced with the number of stitches set by a corresponding sewing parameter 30.
  • a sewing error in the sewing process S1 can occur because a sewing line may not be able to reach a desired position due to the degree of skill of a worker or a material characteristic of a fabric 1 (the sewing process S1 has a start point P0 and an end point P1).
  • the sewing error cannot be compensated in due course since the conventional sewing machine is provided to immediately perform the subsequent sewing process S2 based on the sewing parameter 30 without an opportunity to correct the sewing error in the preceding sewing process S1.
  • the subsequent sewing process S2 is affected by the sewing error, and thus, the quality of a sewing product is degraded and consumers find the sewing product unreliable.
  • the present disclosure provides some embodiments of a sewing machine and a sewing method using the same, which can automatically set a sewing parameter necessary for each of a plurality of sewing processes, and perform the plurality of sewing processes.
  • the present disclosure also provides some embodiments of a sewing machine and a sewing method using the same, in which it is possible to switch a mode to correct a sewing error occurred in a certain process while the sewing machine performs a plurality of sewing processes based on a plurality of sewing parameters, which is automatically set according to a process sequence, so as to provide an opportunity to correct the sewing error before a sewing parameter corresponding to a subsequent sewing process is set in a sewing machine.
  • a sewing machine including: a sewing machine body; a driving portion including a main motor, a presser-foot pressure step motor, a presser-foot height step motor, etc.; a manipulation panel configured to receive a sewing parameter for setting a state of the sewing machine body in data form; a control block configured to control the sewing machine for a plurality of sewing processes to be sequentially performed in proper order; and a mode change switch configured to transmit a mode change signal to the control block such that in accordance with the mode change signal, the sewing machine is working in an automatic mode, in which the sewing parameter is automatically applied to the sewing machine according to the process sequence, or in a manual mode in which the sewing parameters are prevented from being automatically applied to the sewing machine according to the process sequence.
  • the sewing parameter may include at least one or more selected from a number of stitches, a main shaft velocity, a stitch width, a presser-foot pressure, and a presser-foot height.
  • the mode change switch may alternately generate a stop signal which places the driving portion in a halt state and a driving signal which places the driving portion to a driving state.
  • the control block may include: a main control module configured to generate a driving command using the sewing parameters received from the manipulation panel and the mode change signal received from the mode change switch; a motor driver module configured to receive the driving command generated by the main control module and drive the sewing driving portion; and a power source part configured to distribute an external source power to the main control module and the motor driver module.
  • a sewing method using a sewing machine which performs a plurality of sewing processes according to a process sequence, including: receiving a sewing parameter corresponding to each of the sewing processes; starting with the plurality of sewing processes based on a user's pedal input in an automatic mode in which the sewing parameter corresponding to each of the sewing processes is automatically applied to the sewing machine according to the process sequence; performing a sewing process with the number of stitches set by the sewing parameter corresponding to each of the sewing processes; and performing a yarn cutting automatically when the plurality of sewing processes are completed.
  • the sewing method may further include: determining whether a sewing error occurs in each of the sewing processes; driving the sewing machine in a manual mode in which the sewing parameter is prevented from automatically being applied according to the process sequence, when it is determined that the sewing error occurs; performing an operation of correcting the sewing error; and switching the mode of the sewing machine to the automatic mode when the operation of correcting the sewing error is completed.
  • the sewing error may include a case in which a sewing line, which is formed with the number of stitches set by the sewing parameter, is shorter than a originally desired length of the sewing line.
  • the sewing method may further include selectively changing the sewing parameter, after switching the sewing machine mode into a manual mode.
  • a lockstitch sewing machine performing liner lockstitch will be provided as an example of a sewing machine, but the present disclosure is not limited thereto. Alternatively, the present disclosure may be applied to various types of sewing machines which determine to end a certain sewing process based on the number of stitches set by a sewing parameter.
  • the sewing machine 1000 may include: a sewing machine body 100; a sewing machine driver 120 that includes a main motor 115, a stitch width step motor 121, a presser-foot height step motor 122, a presser-foot pressure step motor 123, and a yarn cutting step motor 124; a manipulation panel 200 that receives a sewing parameter 300 for setting the state of the sewing machine 1000 and sewing data 20 including a sewing process sequence S; a control block 300 that controls the sewing machine driver 120 in order for a plurality of sewing processes to be sequentially performed according to the process sequence S; and a mode change switch 400 that transmits a mode change signal to the control block 300 such that the sewing machine driver 120 is driven in an automatic mode (in which corresponding sewing parameters 30 are automatically applied to the sewing machine 1000 in order of the process sequence S), or a manual mode (in which the sewing parameters are prevented from being applied in order of the process sequence S).
  • a sewing machine driver 120 that includes a main motor 115, a stitch width step motor 121, a presser-foot height
  • the sewing machine 1000 performs a plurality of sewing processes in which the corresponding sewing parameters 30 are set differently for each sewing process.
  • the sewing machine 1000 moves forward performing a subsequent sewing process without any interruption in accordance with a command received from a worker through a pedal 118.
  • the command determines whether or not to initiate the subsequent sewing process.
  • the sewing parameters 30 include a number of stitches N, a stitch width W, a main shaft velocity V, a yarn tension T, and parameters associated with a presser-foot height and a presser-foot pressure. Further, the sewing parameter 30 may be included in the sewing data 20 for each of a plurality of sewing processes that are sequentially performed according to a process sequence S (for example, S1 to S3). Especially, a parameter corresponding to a number of stitches N in the sewing parameter 30 may be used to determine whether or not to end a corresponding sewing process.
  • a plurality of sewing processes are sequentially performed according to the process sequence S included in the sewing data 20. in the automatic mode.
  • the sewing parameters 30 corresponding to a corresponding process are automatically applied to the sewing machine 1000.
  • a sewing operation may be performed by the number of stitches (i.e., 100 stitch number) that is set by one of corresponding sewing parameters 30.
  • a subsequent sewing operation according to the process sequence S2 may then be performed by the number of stitches (i.e., 120 stitch number) that is set by another of the sewing parameters 30.
  • a sewing operation according to the process sequence S3 is performed by the number of stitches (i.e., 80 stitch number) that is set by another different one of the sewing parameters 30.
  • each sewing process may be determined to be completed based on the number of stitches N set by one of the sewing parameters 30.
  • a plurality of sewing processes may be continually performed without stopping the sewing machine 100.
  • the sewing machine body 100 may include a sewing machine main body 110, a main motor 115 that is directly connected to one end portion of the sewing machine main body 110 or indirectly connected thereto through a means such as a belt, and a pedal 118 that receives a command from a worker which controls driving of the main motor 115.
  • the sewing machine main body 110 may be disposed at a top of a work table 116, and an on/off type of power switch 117 may be disposed at a front one side of the work table 116.
  • a main shaft 111 may be rotatably disposed in the sewing machine main body 110.
  • a needle bar 112 may be disposed at one end of the main shaft 111 to move upward and downward, and a sewing needle 113 attached/detached to/from a bottom of the sewing needle 113 may move upward and downward.
  • a presser-foot 114 that presses the fabric 1 in performing a sewing process may be disposed in the rear of the needle bar 112 to allow adjusting of the height and pressure.
  • the stitch width step motor 121 for setting a stitch width, the presser-foot height step motor 122 for setting the height of the presser-foot 114, and the presser-foot pressure step motor 123 for setting the pressure of the presser-foot 114 may be mounted on the sewing machine body 100.
  • the yarn cutting step motor 124 that automatically cuts a yarn after a sewing process is completed may be disposed at the work table 117 under the needle bar 112.
  • a yarn tension holder 130 that includes a yarn tension measurement means and a yarn tension solenoid for maintaining a constant yarn tension may be disposed at a front one side of the sewing machine main body 110, and a counter 500 that counts the number of rotations of the main shaft 111 may be disposed at a connection portion between the main shaft 111 and the main motor 115.
  • the manipulation panel 200 is mounted on a top of the sewing machine main body 110, thereby making the top space of the work table 116 easier to use. Further, the manipulation panel 200 may be detached from the sewing machine main body 110 and movably disposed at the top of the work table 116.
  • the mode change switch 400 may be disposed at one side of the power switch 117 in the front of the work table 116 such that a worker can quickly push the switch during a sewing process.
  • the control block 300 may be disposed at one side in a lower space of the work table 116 such that a worker can operate the pedal 118 without any discomfort.
  • the sewing data 20 which may be transmitted from a server 10 (which is placed at a headquarter managing an overall manufacturing process) over a wireless network or a wired network using a copper line or an optical fiber (such as the Internet or a local area network (LAN)), is inputted to the manipulation panel 200.
  • the sewing data 20 may be used to place the sewing machine body 100 into a preparation state (i.e., a state in which a sewing process can be started immediately). Further, the sewing data 20 may be used to set the state of the sewing machine driver 120 in order to perform the sewing process in accordance with the sewing parameters 30 including the number of stitches N, the stitch width W, the main shaft velocity V, and the yarn tension T.
  • the manipulation panel 200 includes: a transmission/reception module 210 that receives the sewing data 20 from the server 10 of the headquarter and transmits sewing process performance information to enable the server 10 of the headquarter to check various states of the sewing machine body 100; and a display module 220 that displays visible information to enable a worker to check the received sewing data 20 and the driving state of the sewing machine body 100.
  • the manipulation panel 200 includes a button manipulation module 230 that allows a worker to manually change information displayed by the display module 200 or change the sewing parameter 30.
  • the sewing data 20 transmitted from the transmission/reception module 210 is stored together with information such as a transmitted date and a transmitted time, in a memory means of the transmission/reception module 210, and then transmitted to the control block 300.
  • the transmission/reception module 210 may include a port (not shown) for connecting to a PC, a PDA, or a USB memory device, and receive sewing data through a device such as a PC, a PDA, or a USB.
  • the control block 300 controls driving the sewing machine driver 120 such that a plurality of sewing processes are sequentially performed according to the process sequence S included in the sewing data 20.
  • the control block 300 may include a main control module 310 that generates a driving command based on the transmitted sewing data 20 and the mode change signal received from the mode change switch 400, a motor driver module 320 that receives the driving command to drive the sewing machine driver 120, and a power source part 330 that distributes a source voltage applied from the outside to the main control module 310 and the motor driver module 320.
  • the motor driver module 320 may control the sewing machine driver 120, namely, the main motor 115, the stitch width step motor 121, the presser-foot height step motor 122, the presser-foot pressure step motor 123, and the yarn cutting step motor 124, according to the driving command. Further, the mobile driver module 320 may include a main motor driver 322 that controls the main motor 115, and a step motor driver 324 that controls the step motors 121 to 124.
  • the driving command generated by the main control module 310 includes a driving control command that allows the sewing machine driver 120 to perform a sewing process, and a setting control command that enables the sewing machine body 100 to be set to a preparation state according to the sewing parameter 30 before performing the sewing process.
  • the pedal 118 and the yarn tension holder 130 are connected to the main control module 310, which is connected to the mode change switch 400 for placing the sewing machine body 100 into one of the automatic mode and the manual mode, switchably.
  • the main control module 310 is connected to the counter 500 that counts the number of stitches based on the number of rotations of the main shaft 111.
  • the counter 500 includes a correction processing module 510 that receives information regarding the number of stitches N from the counter 500 to generate correction data, which will be used in a sewing process performed for correcting a sewing error.
  • the correction data generated by the correction processing module 510 may be displayed by the display module 220 of the manipulation part 200 via the main control module 310, and thus, a worker can easily determine the frequency of any defective sewing and improve the degree of work skill.
  • the main control module 310 may place the sewing machine 1000 from the automatic mode into the manual mode according to a user command inputted through the mode change switch 400.
  • the mode change switch 400 When a worker pushes the mode change switch 400, the mode change switch 400 generates the mode change signal and transmits the mode change signal to the main control module 310 of the control block 300.
  • the mode change switch 400 alternately generates a stop signal for placing the sewing machine driver 120 (i.e., the main motor 115 and the step motors 121 to 124) in a stop state and a driving signal for setting the sewing machine driver 120 to a driving state.
  • the sewing machine driver 120 When the stop signal as the mode change signal is generated as the worker pushes the mode change switch 400, the sewing machine driver 120 is set to be in the manual mode where the sewing machine driver 120 is stopped. Thereafter, when the worker pushes the mode change switch 400 again, the driving signal as the mode change signal is generated and the sewing machine driver 120 is set to be in the automatic mode where the sewing parameter 30 is automatically applied according to the process sequence S.
  • the sewing parameters 30 that were used during the sewing process where a sewing error occurred are applied to the sewing machine body 100.
  • an operation of correcting the sewing error can be performed under the same conditions as that of the sewing process where the sewing error occurred. That is, a worker can immediately perform a correction operation to correct the sewing error without applying the sewing parameters 30 one by one, thereby preventing the quality of a sewing product from being degraded due to the correction operation.
  • the sewing parameters 30 necessarily have to be changed to correct a sewing error, but an operation for correcting the sewing error may be performed by changing the sewing parameters 30 through the manual manipulation of a worker if the thickness of a fabric 1 portion having the sewing error is expected to change.
  • the sewing parameters 30 may be manually changed by pressing the button manipulation module 230 of the manipulation panel 200.
  • the worker may push the mode change switch 400 to place the sewing machine 1000 in the automatic mode from the manual mode in order to move forward performing a subsequent sewing process.
  • an operation of correcting the sewing error may be performed again through the above-described operation (through switching to the manual mode).
  • the automatic yarn cutting may be performed by driving the yarn cutting step motor 124, and thus, the sewing process may be ended.
  • a sewing method sequentially performs a plurality of sewing processes according to a process sequence.
  • the sewing method includes: operation S110 that receives sewing data including a sewing process sequence and sewing parameters related to each of the sewing processes; operation S120 that starts the plurality of sewing processes based on a user command inputted through the pedal in the automatic mode where sewing parameters corresponding to a corresponding process are automatically applied to the sewing machine in accordance with the process sequence; operation S130 that performs a sewing task until the number of stitches, which is set as a sewing parameter corresponding to each of the sewing processes, is completed; and operation S140 that performs automatic yarn cutting when the plurality of sewing processes have been all performed.
  • each sewing process is made by performing lockstitches by the number of stitches set by a sewing parameter in response to a start command inputted through the pedal.
  • a sewing error may accidentally occur due to a different skill level of a worker or different characteristics of a fabric material, while performing the plurality of sewing processes.
  • the sewing error may also occur if a sewing line is shorter than a target length of the sewing line, which is proportional to the number of stitches set as a sewing parameter. For example, a start point and an end point for each sewing process may be marked on a fabric, and thus, whether or not a sewing error occurs may be checked using an image processing apparatus or the like.
  • the sewing error is corrected at operation S220 before performing a subsequent sewing process, namely, before changing any sewing parameters.
  • Operation S220 of correcting the sewing error may include: operation S221 for switching a mode to enable the sewing machine to operate in the manual mode according to a user command inputted through the mode change switch; operation S224 for receiving a command to start a correction operation from a user through the pedal; operation S225 for performing a sewing error correction operation, such as forming an additional sewing line from an already generated sewing line (which is shorter than a target length of the sewing line) to reach the target length; operation S226 for determining whether the operation of correcting the sewing error is completed; and operation S227 for switching a swing machine mode into the automatic mode according to a user command inputted through the mode change switch, when it is determined that the correction operation is completed.
  • a sewing error is corrected under the same sewing parameters as those for the sewing process in which the sewing error occurred.
  • the operation of correcting the sewing error may be performed by changing a sewing parameter according to a worker's determination.
  • operation S220 for correcting the sewing error may further include operation S222 for determining whether to change the sewing parameter after operation S221 for switching the sewing machine mode to the manual mode, and operation S223 for changing the sewing parameter and setting the changed sewing parameter in the sewing machine according to the worker's determination.
  • Operation S225 for correcting the sewing error may detect the number of rotations of the main shaft of the sewing machine to measure the number of stitches necessary for correcting the error while performing the correction work, and store the measured number of stitches as correction data, or display the measured number of stitches outwardly. Accordingly, by checking the correction data, a worker can easily enhance the skill level for sewing works that are repeatedly required.
  • an automatic yarn cutting operation may be performed in operation S140, and thus, the whole sewing process may be ended.
  • sewing parameters in association with each of a plurality of sewing processes are automatically applied to the sewing machine sequentially in the order to the process sequence.
  • a single sewing machine can perform a plurality of sewing processes, thereby minimizing the number of sewing machines and workers involved in sewing processes.
  • the sewing error can be easily corrected by placing the sewing machine from the automatic mode into the manual mode before sewing parameters in association with a subsequent sewing process are automatically applied to the sewing machine. Then, after the correction of the sewing error is completed, by switching back from the manual mode to the automatic mode, the subsequent sewing process can be continuously performed in the automatic mode in which sewing parameters are automatically applied to the sewing machine according to the sewing process sequence. Accordingly, an error rate while sewing a product is reduced and thus product quality can be enhanced. Moreover, production cost is saved and thus the productivity of a sewing process can be enhanced.
  • FIG. 1 is a sewing process table indicating that a plurality of sewing parameters is applied to each corresponding process in a plurality of sewing processes.
  • FIG. 2 is a diagram for describing a sewing error occurred while performing a plurality of sewing processes.
  • FIG. 3 is a front view illustrating a sewing machine according to an embodiment of the present disclosure.
  • FIG. 4 is a block diagram illustrating a configuration of the sewing machine according to an embodiment of the present disclosure.
  • FIG. 5 is a flowchart illustrating a sewing method according to an embodiment of the present disclosure.
  • FIG. 6 is a flowchart illustrating a sewing method according to another embodiment of the present disclosure.
  • FIG. 7 is a flowchart illustrating in detail an operation to correct a sewing error, as depicted in FIG. 6 .

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  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Sewing Machines And Sewing (AREA)

Abstract

Provided are a sewing machine and a sewing method using the same, which can perform a plurality of sewing processes by automatically applying sewing parameters according to a process sequence. The sewing machine includes a sewing machine body; a manipulation panel configured to receive sewing data that includes sewing parameters for setting a state of the sewing machine body and a sequence of a plurality of sewing processes; a control block configured to control a sewing machine driver to perform the plurality of sewing processes according to the sequence; and a mode change switch configured to transmit a mode change signal to the control block. During the automatic mode, the sewing parameters are automatically applied to the sewing machine according to the process sequence, and during the manual mode, the sewing parameters are not automatically applied according to the process sequence.

Description

SEWING MACHINE AND SEWING METHOD USING THE SAME
The present disclosure relates to a sewing machine and a sewing method, and more particularly, to a sewing machine and a sewing method using the same, which can automatically set a sewing parameter necessary for each of a plurality of sewing processes in the sewing machine, and perform the plurality of sewing processes.
A sewing machine has been developed to provide various functions to stitch up fabrics, as to product an end product by sewing is increasingly diverse and the end product is required to have the significantly improved quality, and the sew machine has to enhance a productive capacity. Recently, a sewing machine is proposed to receive sewing parameters such as a main shaft velocity, a stitch width, and a yarn tension in data form and to automatically set the sewing parameters in accordance with the receive data, while these parameters have been set manually by a worker.
As an example of a sewing machine in which sewing parameters are automatically set as described above, Korean Patent Publication No. 10-2009-0103816 discloses a sewing machine that performs a sewing process according to sewing parameters. However, in the sewing machine disclosed therein, as for each sewing process, sewing data is separately inputted, and thus, there is a limitation in smoothly performing a plurality of sewing processes in a desired way. For example, as illustrated in FIG. 1, when performing a process S including a plurality of sewing processes S1 to Sn with a conventional sewing machine, a single model of sewing machine (i.e., the sewing machine with Reference No. KM-235) is capable of performing the sewing processes S1 to S3, a sewing parameter 30 of the sewing machine is required to be manually changed and set for each of the sewing processes S1 to S3. However, it is difficult to perform a plurality of sewing processes with the same model of single sewing machine. Therefore, the conventional art requires more sewing machines and workers in order to perform a plurality of sewing processes, and the production cost and working hours increase, thereby causing a decrease in productivity.
Also, conventional sewing machines cannot automatically change a sewing parameter at issue and perform a plurality of sewing processes accordingly. Moreover, even when it is assumed that the conventional sewing machines include a means for performing a plurality of sewing processes, if a sewing error occurs during a previous sewing process (for example, S1) among a plurality of sewing processes, a subsequent sewing process (for example, S2) is immediately performed. This means that there is no opportunity to correct the sewing error in the conventional sewing machines. As illustrated in FIG. 2, at the previous sewing process S1, a sewing line is produced with the number of stitches set by a corresponding sewing parameter 30. Nonetheless, a sewing error in the sewing process S1 can occur because a sewing line may not be able to reach a desired position due to the degree of skill of a worker or a material characteristic of a fabric 1 (the sewing process S1 has a start point P0 and an end point P1). However, in the conventional art, even if the sewing error occurs, the sewing error cannot be compensated in due course since the conventional sewing machine is provided to immediately perform the subsequent sewing process S2 based on the sewing parameter 30 without an opportunity to correct the sewing error in the preceding sewing process S1. As a result, the subsequent sewing process S2 is affected by the sewing error, and thus, the quality of a sewing product is degraded and consumers find the sewing product unreliable.
The present disclosure provides some embodiments of a sewing machine and a sewing method using the same, which can automatically set a sewing parameter necessary for each of a plurality of sewing processes, and perform the plurality of sewing processes.
The present disclosure also provides some embodiments of a sewing machine and a sewing method using the same, in which it is possible to switch a mode to correct a sewing error occurred in a certain process while the sewing machine performs a plurality of sewing processes based on a plurality of sewing parameters, which is automatically set according to a process sequence, so as to provide an opportunity to correct the sewing error before a sewing parameter corresponding to a subsequent sewing process is set in a sewing machine.
According to an aspect of the present disclosure, disclosed is a sewing machine including: a sewing machine body; a driving portion including a main motor, a presser-foot pressure step motor, a presser-foot height step motor, etc.; a manipulation panel configured to receive a sewing parameter for setting a state of the sewing machine body in data form; a control block configured to control the sewing machine for a plurality of sewing processes to be sequentially performed in proper order; and a mode change switch configured to transmit a mode change signal to the control block such that in accordance with the mode change signal, the sewing machine is working in an automatic mode, in which the sewing parameter is automatically applied to the sewing machine according to the process sequence, or in a manual mode in which the sewing parameters are prevented from being automatically applied to the sewing machine according to the process sequence.
The sewing parameter may include at least one or more selected from a number of stitches, a main shaft velocity, a stitch width, a presser-foot pressure, and a presser-foot height.
The mode change switch may alternately generate a stop signal which places the driving portion in a halt state and a driving signal which places the driving portion to a driving state.
The control block may include: a main control module configured to generate a driving command using the sewing parameters received from the manipulation panel and the mode change signal received from the mode change switch; a motor driver module configured to receive the driving command generated by the main control module and drive the sewing driving portion; and a power source part configured to distribute an external source power to the main control module and the motor driver module.
According to another aspect of the present disclosure, disclosed is a sewing method using a sewing machine, which performs a plurality of sewing processes according to a process sequence, including: receiving a sewing parameter corresponding to each of the sewing processes; starting with the plurality of sewing processes based on a user's pedal input in an automatic mode in which the sewing parameter corresponding to each of the sewing processes is automatically applied to the sewing machine according to the process sequence; performing a sewing process with the number of stitches set by the sewing parameter corresponding to each of the sewing processes; and performing a yarn cutting automatically when the plurality of sewing processes are completed.
The sewing method may further include: determining whether a sewing error occurs in each of the sewing processes; driving the sewing machine in a manual mode in which the sewing parameter is prevented from automatically being applied according to the process sequence, when it is determined that the sewing error occurs; performing an operation of correcting the sewing error; and switching the mode of the sewing machine to the automatic mode when the operation of correcting the sewing error is completed.
The sewing error may include a case in which a sewing line, which is formed with the number of stitches set by the sewing parameter, is shorter than a originally desired length of the sewing line.
The sewing method may further include selectively changing the sewing parameter, after switching the sewing machine mode into a manual mode.
The following detailed description includes various embodiments that can implement the present disclosure. The disclosed embodiments merely facilitate the understanding of the content of the present disclosure, and do not limit the present disclosure at all. Also, elements or operations that are separately described in one embodiment of the present disclosure may be integrated as one element or one operation in another embodiment.
In one embodiment, a lockstitch sewing machine performing liner lockstitch will be provided as an example of a sewing machine, but the present disclosure is not limited thereto. Alternatively, the present disclosure may be applied to various types of sewing machines which determine to end a certain sewing process based on the number of stitches set by a sewing parameter.
Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings.
A sewing machine 1000 according to an embodiment of the present disclosure will now be described with reference to FIGS. 3 and 4. As illustrated in FIG. 3, the sewing machine 1000 may include: a sewing machine body 100; a sewing machine driver 120 that includes a main motor 115, a stitch width step motor 121, a presser-foot height step motor 122, a presser-foot pressure step motor 123, and a yarn cutting step motor 124; a manipulation panel 200 that receives a sewing parameter 300 for setting the state of the sewing machine 1000 and sewing data 20 including a sewing process sequence S; a control block 300 that controls the sewing machine driver 120 in order for a plurality of sewing processes to be sequentially performed according to the process sequence S; and a mode change switch 400 that transmits a mode change signal to the control block 300 such that the sewing machine driver 120 is driven in an automatic mode (in which corresponding sewing parameters 30 are automatically applied to the sewing machine 1000 in order of the process sequence S), or a manual mode (in which the sewing parameters are prevented from being applied in order of the process sequence S).
The sewing machine 1000 according to an embodiment of the present disclosure performs a plurality of sewing processes in which the corresponding sewing parameters 30 are set differently for each sewing process. When a previous sewing process is completed, the sewing machine 1000 moves forward performing a subsequent sewing process without any interruption in accordance with a command received from a worker through a pedal 118. The command determines whether or not to initiate the subsequent sewing process.
Moreover, the sewing parameters 30 include a number of stitches N, a stitch width W, a main shaft velocity V, a yarn tension T, and parameters associated with a presser-foot height and a presser-foot pressure. Further, the sewing parameter 30 may be included in the sewing data 20 for each of a plurality of sewing processes that are sequentially performed according to a process sequence S (for example, S1 to S3). Especially, a parameter corresponding to a number of stitches N in the sewing parameter 30 may be used to determine whether or not to end a corresponding sewing process.
When the sewing data 20 is inputted to the manipulation panel 200, a plurality of sewing processes are sequentially performed according to the process sequence S included in the sewing data 20. in the automatic mode. During the automatic mode, the sewing parameters 30 corresponding to a corresponding process are automatically applied to the sewing machine 1000. For example, when a sewing process according to the process sequence S1 is initiated, a sewing operation may be performed by the number of stitches (i.e., 100 stitch number) that is set by one of corresponding sewing parameters 30. A subsequent sewing operation according to the process sequence S2 may then be performed by the number of stitches (i.e., 120 stitch number) that is set by another of the sewing parameters 30. Lastly, a sewing operation according to the process sequence S3 is performed by the number of stitches (i.e., 80 stitch number) that is set by another different one of the sewing parameters 30. In this way, each sewing process may be determined to be completed based on the number of stitches N set by one of the sewing parameters 30. Further, unless a sewing error is occurred while performing a sewing process, a plurality of sewing processes may be continually performed without stopping the sewing machine 100.
The sewing machine body 100 may include a sewing machine main body 110, a main motor 115 that is directly connected to one end portion of the sewing machine main body 110 or indirectly connected thereto through a means such as a belt, and a pedal 118 that receives a command from a worker which controls driving of the main motor 115. The sewing machine main body 110 may be disposed at a top of a work table 116, and an on/off type of power switch 117 may be disposed at a front one side of the work table 116. A main shaft 111 may be rotatably disposed in the sewing machine main body 110. A needle bar 112 may be disposed at one end of the main shaft 111 to move upward and downward, and a sewing needle 113 attached/detached to/from a bottom of the sewing needle 113 may move upward and downward. Also, a presser-foot 114 that presses the fabric 1 in performing a sewing process may be disposed in the rear of the needle bar 112 to allow adjusting of the height and pressure. The stitch width step motor 121 for setting a stitch width, the presser-foot height step motor 122 for setting the height of the presser-foot 114, and the presser-foot pressure step motor 123 for setting the pressure of the presser-foot 114 may be mounted on the sewing machine body 100. The yarn cutting step motor 124 that automatically cuts a yarn after a sewing process is completed may be disposed at the work table 117 under the needle bar 112. In addition, a yarn tension holder 130 that includes a yarn tension measurement means and a yarn tension solenoid for maintaining a constant yarn tension may be disposed at a front one side of the sewing machine main body 110, and a counter 500 that counts the number of rotations of the main shaft 111 may be disposed at a connection portion between the main shaft 111 and the main motor 115.
According to an embodiment of the present disclosure, the manipulation panel 200 is mounted on a top of the sewing machine main body 110, thereby making the top space of the work table 116 easier to use. Further, the manipulation panel 200 may be detached from the sewing machine main body 110 and movably disposed at the top of the work table 116. The mode change switch 400 may be disposed at one side of the power switch 117 in the front of the work table 116 such that a worker can quickly push the switch during a sewing process. The control block 300 may be disposed at one side in a lower space of the work table 116 such that a worker can operate the pedal 118 without any discomfort. With such configuration of the sewing machine 1000, when the power switch 117 is turned on, the main motor 115 is driven according to a user command inputted through the pedal 118. Further, the main shaft 111 rotates and the needle bar 112 and the sewing needle 113 move upward and downward. As a result, a sewing stitch is operationally produced in combination with a bottom yarn means (not shown).
The sewing data 20, which may be transmitted from a server 10 (which is placed at a headquarter managing an overall manufacturing process) over a wireless network or a wired network using a copper line or an optical fiber (such as the Internet or a local area network (LAN)), is inputted to the manipulation panel 200. The sewing data 20 may be used to place the sewing machine body 100 into a preparation state (i.e., a state in which a sewing process can be started immediately). Further, the sewing data 20 may be used to set the state of the sewing machine driver 120 in order to perform the sewing process in accordance with the sewing parameters 30 including the number of stitches N, the stitch width W, the main shaft velocity V, and the yarn tension T.
As illustrated in FIG. 4, the manipulation panel 200 includes: a transmission/reception module 210 that receives the sewing data 20 from the server 10 of the headquarter and transmits sewing process performance information to enable the server 10 of the headquarter to check various states of the sewing machine body 100; and a display module 220 that displays visible information to enable a worker to check the received sewing data 20 and the driving state of the sewing machine body 100. Also, the manipulation panel 200 includes a button manipulation module 230 that allows a worker to manually change information displayed by the display module 200 or change the sewing parameter 30. The sewing data 20 transmitted from the transmission/reception module 210 is stored together with information such as a transmitted date and a transmitted time, in a memory means of the transmission/reception module 210, and then transmitted to the control block 300. The transmission/reception module 210 may include a port (not shown) for connecting to a PC, a PDA, or a USB memory device, and receive sewing data through a device such as a PC, a PDA, or a USB.
The control block 300 controls driving the sewing machine driver 120 such that a plurality of sewing processes are sequentially performed according to the process sequence S included in the sewing data 20. The control block 300 may include a main control module 310 that generates a driving command based on the transmitted sewing data 20 and the mode change signal received from the mode change switch 400, a motor driver module 320 that receives the driving command to drive the sewing machine driver 120, and a power source part 330 that distributes a source voltage applied from the outside to the main control module 310 and the motor driver module 320.
The motor driver module 320 may control the sewing machine driver 120, namely, the main motor 115, the stitch width step motor 121, the presser-foot height step motor 122, the presser-foot pressure step motor 123, and the yarn cutting step motor 124, according to the driving command. Further, the mobile driver module 320 may include a main motor driver 322 that controls the main motor 115, and a step motor driver 324 that controls the step motors 121 to 124.
The driving command generated by the main control module 310 includes a driving control command that allows the sewing machine driver 120 to perform a sewing process, and a setting control command that enables the sewing machine body 100 to be set to a preparation state according to the sewing parameter 30 before performing the sewing process. The pedal 118 and the yarn tension holder 130 are connected to the main control module 310, which is connected to the mode change switch 400 for placing the sewing machine body 100 into one of the automatic mode and the manual mode, switchably. Also, the main control module 310 is connected to the counter 500 that counts the number of stitches based on the number of rotations of the main shaft 111. The counter 500 includes a correction processing module 510 that receives information regarding the number of stitches N from the counter 500 to generate correction data, which will be used in a sewing process performed for correcting a sewing error. The correction data generated by the correction processing module 510 may be displayed by the display module 220 of the manipulation part 200 via the main control module 310, and thus, a worker can easily determine the frequency of any defective sewing and improve the degree of work skill.
When a sewing error occurs in a certain sewing process due to a different skill level of a worker and a different characteristic of a fabric material, the main control module 310 may place the sewing machine 1000 from the automatic mode into the manual mode according to a user command inputted through the mode change switch 400. When a worker pushes the mode change switch 400, the mode change switch 400 generates the mode change signal and transmits the mode change signal to the main control module 310 of the control block 300. At this point, the mode change switch 400 alternately generates a stop signal for placing the sewing machine driver 120 (i.e., the main motor 115 and the step motors 121 to 124) in a stop state and a driving signal for setting the sewing machine driver 120 to a driving state. When the stop signal as the mode change signal is generated as the worker pushes the mode change switch 400, the sewing machine driver 120 is set to be in the manual mode where the sewing machine driver 120 is stopped. Thereafter, when the worker pushes the mode change switch 400 again, the driving signal as the mode change signal is generated and the sewing machine driver 120 is set to be in the automatic mode where the sewing parameter 30 is automatically applied according to the process sequence S.
When the sewing machine 1000 is switched to operate in the manual mode, the sewing parameters 30 that were used during the sewing process where a sewing error occurred are applied to the sewing machine body 100. Thus, an operation of correcting the sewing error can be performed under the same conditions as that of the sewing process where the sewing error occurred. That is, a worker can immediately perform a correction operation to correct the sewing error without applying the sewing parameters 30 one by one, thereby preventing the quality of a sewing product from being degraded due to the correction operation. The sewing parameters 30 necessarily have to be changed to correct a sewing error, but an operation for correcting the sewing error may be performed by changing the sewing parameters 30 through the manual manipulation of a worker if the thickness of a fabric 1 portion having the sewing error is expected to change. Here, the sewing parameters 30 may be manually changed by pressing the button manipulation module 230 of the manipulation panel 200. When the operation of correcting the sewing error is completed, the worker may push the mode change switch 400 to place the sewing machine 1000 in the automatic mode from the manual mode in order to move forward performing a subsequent sewing process. In the subsequent sewing process, when a sewing error is detected, an operation of correcting the sewing error may be performed again through the above-described operation (through switching to the manual mode). When a plurality of sewing processes according to the process sequence S are all performed, the automatic yarn cutting may be performed by driving the yarn cutting step motor 124, and thus, the sewing process may be ended.
Hereinafter, a sewing method using the above-described sewing machine will be described with reference to the accompanying drawings. In the below description, the configuration and operation that are already disclosed in association with the sewing machine will not be repeated and/or will be simply described.
Referring to FIG. 5, a sewing method according to an embodiment of the present disclosure sequentially performs a plurality of sewing processes according to a process sequence. The sewing method includes: operation S110 that receives sewing data including a sewing process sequence and sewing parameters related to each of the sewing processes; operation S120 that starts the plurality of sewing processes based on a user command inputted through the pedal in the automatic mode where sewing parameters corresponding to a corresponding process are automatically applied to the sewing machine in accordance with the process sequence; operation S130 that performs a sewing task until the number of stitches, which is set as a sewing parameter corresponding to each of the sewing processes, is completed; and operation S140 that performs automatic yarn cutting when the plurality of sewing processes have been all performed.
As described above, if no sewing error occurs when performing the plurality of sewing processes according to the process sequence, each sewing process is made by performing lockstitches by the number of stitches set by a sewing parameter in response to a start command inputted through the pedal.
However, a sewing error may accidentally occur due to a different skill level of a worker or different characteristics of a fabric material, while performing the plurality of sewing processes. The sewing error may also occur if a sewing line is shorter than a target length of the sewing line, which is proportional to the number of stitches set as a sewing parameter. For example, a start point and an end point for each sewing process may be marked on a fabric, and thus, whether or not a sewing error occurs may be checked using an image processing apparatus or the like. As illustrated in FIG. 6, when a sewing error is detected at operation S210 for checking the occurrence of the sewing error, the sewing error is corrected at operation S220 before performing a subsequent sewing process, namely, before changing any sewing parameters.
Operation S220 of correcting the sewing error, as illustrated in FIG. 7, may include: operation S221 for switching a mode to enable the sewing machine to operate in the manual mode according to a user command inputted through the mode change switch; operation S224 for receiving a command to start a correction operation from a user through the pedal; operation S225 for performing a sewing error correction operation, such as forming an additional sewing line from an already generated sewing line (which is shorter than a target length of the sewing line) to reach the target length; operation S226 for determining whether the operation of correcting the sewing error is completed; and operation S227 for switching a swing machine mode into the automatic mode according to a user command inputted through the mode change switch, when it is determined that the correction operation is completed.
Generally, a sewing error is corrected under the same sewing parameters as those for the sewing process in which the sewing error occurred. However, since the thickness of a fabric may change at a certain portion where the sewing error has occurred, the operation of correcting the sewing error may be performed by changing a sewing parameter according to a worker's determination. To this end, operation S220 for correcting the sewing error may further include operation S222 for determining whether to change the sewing parameter after operation S221 for switching the sewing machine mode to the manual mode, and operation S223 for changing the sewing parameter and setting the changed sewing parameter in the sewing machine according to the worker's determination.
Operation S225 for correcting the sewing error may detect the number of rotations of the main shaft of the sewing machine to measure the number of stitches necessary for correcting the error while performing the correction work, and store the measured number of stitches as correction data, or display the measured number of stitches outwardly. Accordingly, by checking the correction data, a worker can easily enhance the skill level for sewing works that are repeatedly required. When a plurality of sewing processes according to a process sequence is all completed, an automatic yarn cutting operation may be performed in operation S140, and thus, the whole sewing process may be ended.
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. Also, the elements and operations of the sewing design manufacturing management apparatus and method of the present disclosure may be implemented as a plurality of distributed hardware modules or software modules.
Therefore, the accompanying claims and their equivalents including the foregoing modifications are intended to cover the scope and spirit of the disclosures, and are not limited by the present disclosures.
According to the sewing machine and the sewing method using the same of the present disclosure, sewing parameters in association with each of a plurality of sewing processes are automatically applied to the sewing machine sequentially in the order to the process sequence. Thus, a single sewing machine can perform a plurality of sewing processes, thereby minimizing the number of sewing machines and workers involved in sewing processes.
Moreover, even though a sewing error occurs while performing a plurality of sewing processes due to a worker's different skill level or a fabric material's different characteristic, the sewing error can be easily corrected by placing the sewing machine from the automatic mode into the manual mode before sewing parameters in association with a subsequent sewing process are automatically applied to the sewing machine. Then, after the correction of the sewing error is completed, by switching back from the manual mode to the automatic mode, the subsequent sewing process can be continuously performed in the automatic mode in which sewing parameters are automatically applied to the sewing machine according to the sewing process sequence. Accordingly, an error rate while sewing a product is reduced and thus product quality can be enhanced. Moreover, production cost is saved and thus the productivity of a sewing process can be enhanced.
FIG. 1 is a sewing process table indicating that a plurality of sewing parameters is applied to each corresponding process in a plurality of sewing processes.
FIG. 2 is a diagram for describing a sewing error occurred while performing a plurality of sewing processes.
FIG. 3 is a front view illustrating a sewing machine according to an embodiment of the present disclosure.
FIG. 4 is a block diagram illustrating a configuration of the sewing machine according to an embodiment of the present disclosure.
FIG. 5 is a flowchart illustrating a sewing method according to an embodiment of the present disclosure.
FIG. 6 is a flowchart illustrating a sewing method according to another embodiment of the present disclosure.
FIG. 7 is a flowchart illustrating in detail an operation to correct a sewing error, as depicted in FIG. 6.

Claims (9)

  1. A sewing machine, comprising:
    a sewing machine body;
    a manipulation panel configured to receive sewing data that comprises sewing parameters for setting a state of the sewing machine body and a sequence of a plurality of sewing processes;
    a control block configured to control a sewing machine driver to perform the plurality of sewing processes according to the sequence; and
    a mode change switch configured to transmit a mode change signal to the control block,
    wherein the sewing machine operates in one of an automatic mode and a manual mode according to the mode change signal,
    wherein during the automatic mode, the sewing parameters are automatically applied to the sewing machine according to the sequence, and
    wherein during the manual mode, the sewing parameters are not automatically applied according to the sequence.
  2. The sewing machine of Claim 1, wherein the sewing parameters include at least one or more selected from the number of stitches, a main shaft velocity, a stitch width, a presser-foot pressure, and a presser-foot height.
  3. The sewing machine of Claim 1 or 2, wherein the mode change switch is further configured to alternately generate a stop signal for configuring the sewing machine driver into a stop state and a driving signal for configuring the sewing machine driver into a driving state.
  4. The sewing machine of Claim 1 or 2, wherein the control block comprises:
    a main control module configured to generate a driving command based on the sewing data received from the manipulation panel and the mode change signal received from the mode change switch;
    a motor driver module configured to receive the driving command generated by the main control module, and drive the sewing machine driver; and
    a power source part configured to distribute an external electric power to the main control module and the motor driver module.
  5. The sewing machine of Claim 4, wherein the sewing machine driver comprises at least one of a main motor, a stitch width step motor, a presser-foot pressure step motor, and a presser-foot height step motor.
  6. A sewing method of using a sewing machine that performs a plurality of sewing processes according to a process sequence, the sewing method comprising:
    receiving sewing data that comprises respective sewing parameters in association with each of the sewing processes;
    starting the plurality of sewing processes in an automatic mode in which the respective sewing parameters in association with each of the sewing processes are automatically applied to the sewing machine according to the process sequence;
    performing each of the sewing processes by a number of stitches that is set by the respective sewing parameters in association with each of the sewing processes; and
    performing automatic yarn cutting when the plurality of sewing processes are completed.
  7. The sewing method of Claim 6, further comprising:
    determining whether a sewing error occurs in each of the sewing processes;
    when it is determined that the sewing error occurred, switching the sewing machine to operate in a manual mode in which the sewing parameters are not automatically applied according to the process sequence;
    performing an operation of correcting the sewing error; and
    switching the sewing machine to operate in the automatic mode when the operation of correcting the sewing error is completed.
  8. The sewing method of Claim 7, wherein the sewing error comprises a case in which a length of a sewing line formed by the number of stitches according to the respective sewing parameters, is shorter than a target length of the sewing line.
  9. The sewing method of Claim 7, further comprising selectively changing the respective sewing parameters, after the switching the sewing machine to operate in a manual mode.
PCT/KR2012/008074 2011-10-05 2012-10-05 Sewing machine and sewing method using the same WO2013051881A2 (en)

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