US20070163479A1 - Sewing machine and method for detecting movements in sewing machines - Google Patents

Sewing machine and method for detecting movements in sewing machines Download PDF

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Publication number: US20070163479A1
Authority: US; United States
Prior art keywords: sewing; light; detected; sewing machine; movements
Prior art date: 2006-01-18
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.): Abandoned

Application number

US11/609,947

Other languages

English (en)

Inventor

Michael Wentkowski

Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)

Fritz Gegauf AG

Original Assignee

Fritz Gegauf AG

Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)

2006-01-18

Filing date

2006-12-13

Publication date

2007-07-19

2006-12-13 Application filed by Fritz Gegauf AG filed Critical Fritz Gegauf AG

2006-12-13 Assigned to FRITZ GEGAUF AG reassignment FRITZ GEGAUF AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WENTKOWSKI, MICHAEL

2007-07-19 Publication of US20070163479A1 publication Critical patent/US20070163479A1/en

Status Abandoned legal-status Critical Current

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Classifications

- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B19/00—Program-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
- D05B59/00—Applications of bobbin-winding or -changing devices; Indicating or control devices associated therewith
- D05B59/02—Devices for determining or indicating the length of thread still on the bobbin
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C11/00—Devices for guiding, feeding, handling, or treating the threads in embroidering machines; Machine needles; Operating or control mechanisms therefor
- D05C11/08—Thread-tensioning arrangements
- D05C11/14—Stop motions responsive to thread tension or breakage

Definitions

the subject matter of the invention is a sewing machine and a method for detecting movements in a sewing machine.
Sewing machines, embroidery machines, quilting devices, and the like often include sensors, with which, e.g., movements of the sewing material or the embroidery hoop can be detected. Through further processing of the signals of such sensors, e.g., control signals can be generated or displays can be driven.
a method for regulating the material transport in a sewing or embroidery machine in which a sensor is arranged for detecting advancing widths of the sewing material in the area of the needle plate.
the sensor is constructed as a CCD camera and records images of the surface of the sewing material in rapid succession.
a controller calculates the position and orientation of the sewing material or information on its movement. If deviations in the detected measurement parameters from given desired parameters are determined, the transport device for the sewing material is controlled so that such deviations are minimal.
a device for controlling or regulating the needle motion in a sewing machine comprises a detection device with an image sensor, which records a section of the sewing material surface from above at a high scanning rate. For quilting, the sewing material is shifted manually. The detection device records a section of the sewing material surface in the area of the sensor and the sewing needle in rapid succession of approximately 1500 images per second. The movements of the sewing material are determined with reference to this information and the needle drive is controlled such that successive stitches are formed at uniform intervals.
one objective of the present invention is to provide an improved detection device and a method for detecting movements in sewing machines, which allows reliable and quick detection of movements of small parts.
Another objective of the invention is to construct the detection device and the method so that object movements can be detected in a plane and/or vertical to this plane.
the method according to the invention and the sewing machine, embroidery machine, or quilting machine with the detection device according to the invention are based on the consideration that the calculation of object velocities or changes in position or orientation of objects by evaluating individual images in time succession push up against the limits of technical feasibility when the objects are small and/or the velocity or acceleration values are large or when the object movements do not take place within a given detection plane.
a laser generates a coherent light beam, which is deflected by a lens or by optical elements in the direction of the object surface to be detected. A portion of the light scattered at the object surface is reflected back in the direction of the laser.
the lens is constructed so that light scattered at the object is collected and reflected back to the laser. There, at least a portion of the scattered light enters through the semi-transparent mirror back into the resonator, where it interferes with the light generated in the resonator. In this way, fundamental properties of the laser and the light emitted by the laser are changed.
This phenomenon is also designated as the “self-mixing effect.”
another interference detector independent of the laser resonator can also be used, wherein light generated, for example, by the laser is decoupled by semi-transparent mirrors and forms interference with light scattered at the object outside of the resonator.
the frequency of the light scattered and reflected in the direction of the laser changes as a function of the velocity component in the direction of the laser beam.
This change in frequency is realistic for object movements to be recorded on the order of magnitude of approximately one kilohertz up to a few megahertz and thus can be easily evaluated without delay with conventional electronic means.
a frequency shift can still be measured even for objects with nearly unstructured, smooth, or reflective surfaces. Thus, very small inhomogeneities and scattered light portions are sufficient for creating a measurable change in frequency.
Parameters which can change based on the self-coupling effect of the laser, are, e.g., the power consumption or junction resistance, the intensity of the scattered laser light, the frequency and the diameter of the laser beam, or the threshold amplification of the laser. These parameter values change with a frequency corresponding to the frequency difference between the laser light generated by the laser and scattered back into the laser. This frequency difference is, in turn, proportional to the velocity component of the object surface in the direction of the laser light beam. It is also possible to determine the velocity component of the object surface in the respective direction by detecting and evaluating the fluctuations or one or more of these parameter values.
the velocity of the object surface in the respective direction can be calculated from the frequency difference detected directly or indirectly according to the measurement technique between the light beam emitted by the laser and the light beam scattered by the object and coupled back into the laser.
the respective positions or changes in position of the object or the object surface can be calculated practically without delay.
two or more sensors can be provided with lasers as light sources and with detectors for detecting the respective parameter fluctuations, wherein the directions of radiation and/or the positions of these laser-light sources are different.
WO2005/076116 discloses an arrangement with two laser diodes, which are arranged preferably orthogonal to each other on a common flat substrate.
the two laser beams are bundled diagonally upwards according to the alignment of the respective laser diodes by a common collecting lens, such that they are focused on the top side or just above a detection window close to each other.
Such an arrangement can be used in input devices—for example, in computer mice or in input devices for computers, mobile telephones, and the like—for detecting movements in a plane.
the lens or a different optical collecting means is constructed so that the laser beam has a focal area expanded in the direction of radiation, wherein the radiation is not focused there on the smallest possible diameter, but instead has an approximately constant beam diameter over a longer area.
moving objects can be both machine components or accessories, such as sewing needle, needle holder, pressure foot, feed dog, hook, bobbin, embroidery hoop, etc., or else objects or components to be processed, such as, the sewing material—or for several sewing layers, one sewing layer—the top thread, or the bottom thread.
the construction and arrangement of the detection device can vary. Possible applications are:
Detection of the sewing material movement especially the detection of the velocity vector or the sewing direction and the sewing material velocity, the determination of the acceleration vector or the calculation of the respective orientation and/or position of the sewing material by integrating the velocity or the velocities detected by one or more sensors.
the obtained data can be used, e.g., for controlling or regulating a transport device for the sewing material or for quality assurance in sewing or embroidery (detection of actual-value deviations in one or two dimensions of the sewing plane, slippage minimization) or for controlling or regulating the needle movement (freehand sewing or quilting).
a transport device can be regulated so that the deviations of the effective material movement from the given material movement are minimal.
the transport device can comprise, for example, transport rollers or a feed dog acting on the sewing material from below and/or from above for the material advance in the sewing direction and, if necessary, also for the transverse transport of the sewing material.
a sensor above the sewing material for example, in the sewing foot or sewing foot shaft—and below the sewing material—for example, in the needle plate—the difference between the movement signals of the two sensors can be used for determining material layer displacement.
regulation can be created, which keeps the displacement between the two material layers to a minimum.
relative movements of parts of the embroidery hoop and preferably the sewing material clamped therein can be detected. These can be used, e.g., for calibrating the embroidery hoop.
a type of barcode e.g., can be attached to the embroidery hoop or to a different machine or accessory part.
this code moves relative to the light beam of the sensor, the code can be read based on the resulting intensity fluctuations of the scattered light.
Detecting and/or monitoring a thread length or thread motion e.g., the velocity of the bottom or top thread during take-up during the sewing, quilting, or embroidering, or during a spool loading, changing, or unloading process.
the fill level of the bobbin e.g., can be determined through common processing of the rotational speed of the bottom thread bobbin and the take-up velocity of the bottom thread.
Detecting movements and/or positions or orientations of any movable machine or accessory parts such as transfer belts, main shaft, sewing foot rod, sewing foot height, transfer or deflection gears, levers, etc., especially when these are not defined or definable unambiguously through other parameters.
translation movements and/or rotational movements can be detected and processed in one, two, or three dimensions.
the measurement parameters detected by the sensor or sensors can be used for controlling or regulating these parts.
a sensor arranged suitably on the sewing machine can be used for measuring material lengths, e.g., instead of a ruler, wherein preferably switch-over means are provided, with which the desired application purpose of the sensor can be selected.
the sensor can be fixed to the machine or freely movable and connected to the machine controller via a wired or alternatively a wireless communications connection, in order to detect the relative movement between sensor and sewing material (or a different pattern).
the senor For detecting and storing movements of the sewing material or, in general, a pattern, the sensor can be integrated, e.g., in a sewing foot and connected to storage means. Then a learning mode can be activated and a pattern can be scanned by detecting means on the sewing machine. The detected movements can be stored in the memory, which is integrated, e.g., in the sewing foot or which is provided in the machine controller, or which is arranged outside of the sewing machine, and recalled later, e.g., in connection with an embroidery module.
the light sources of the sensors emit at least approximately monochromatic light. According to the object to be detected, they can be arranged spatially close to each other, preferably on a common chip, or at a greater spacing relative to each other. They can be directed onto the object to be detected such that the intersection points or areas on the object surface lie close to each other (e.g., within a few millimeters) or are spaced apart from each other. To prevent mutual interference between several sensors, they can be driven using a clocked method, e.g., in a given sequence, or several light sources with different frequencies can be used.
optical elements such as lenses, mirrors, or grating structures can be used, wherein these elements can be used separated for each of the light sources or in common for two or more of the light sources—according to the position of the individual light sources.
a detection device is allocated to each of the light sources.
these also can include common parts, e.g., one evaluation unit for alternating or parallel processing of the individual measurement parameters.
the “self-mixing” effect allows a very compact and space-saving construction of the sensors, because the detection device is coupled directly with the light source and can be integrated together with the light source on a common chip, and because the transmission beam and the detection beam are influenced by a common optical system.
the evaluation unit for processing the detected signals is preferably also integrated on the chip and freely configurable or programmable.
An external controller is not absolutely necessary and the sensors can be easily adapted to different tasks. It is also possible to arrange the optical system directly on the chip and to connect it rigidly to this chip directly or indirectly. In this way, additional optical elements and associated calibration work can be eliminated. The spatial requirements are thus extremely small.
the detectors which detect the intensity fluctuations in the laser resonator, can be constructed as photoelectric detectors, wherein preferably photodiodes are used, which are already placed on a rear resonator mirror for a laser diode and are used conventionally for maintaining the laser output.
the device according to the invention and the method according to the invention can be used for sewing machines, embroidery machines, quilting devices, and the like for detecting and controlling or regulating different movements. Alternatively or additionally, such detected movement information can also be stored and recalled at a later time. This is especially advantageous for the detection of sewing and embroidery patterns.
the detection device is arranged, at least in part, stationary in the vicinity of a movable machine part or sewing object to be detected.
the detection device or the detection optics can also be moved relative to an object to be detected, for example, when they are integrated into a stylus or other corresponding input means for detecting patterns or sewing processes.
the detection device can be connected to a sewing machine controller or a data recording device, e.g., via radio or a communications line.
FIG. 1 is a block diagram for illustrating the movement recording in a sewing machine using a self-coupling laser Doppler interferometer
FIG. 2 is a side view of a partially cut-away hook with bottom thread bobbin set therein
FIG. 3 is a detail view of a sewing machine in the area of the stitch forming device with sensors integrated into the needle plate,
FIG. 4 is a view of a sewing foot with integrated detection device.
FIG. 1 the principle function of detecting movement using a self-coupling laser Doppler interferometer is shown.
a laser preferably a semiconductor laser
the decoupled coherent light is bundled by one or more optical elements, for example, by a collection lens 9 , into a light beam or a transmission beam 11 .
This beam intersects an object 13 to be detected and is scattered there at least partially. A portion of the scattered light is reflected back in the direction of the laser as reception beam 15 .
the light coupled in this way back into the resonator 3 interferes with the light amplified in the resonator 3 , as is known, e.g., from WO-A1-02/37410.
This interference phenomenon affects the amplification of the laser and the intensity of the light or transmission beam 11 generated by the laser.
the intensity of the transmission beam 11 has minimum and maximum values as a function of the range.
the frequency of the reception beam 15 changes a little due to the Doppler effect.
the intensity fluctuations for example, by means of a photodiode 17 arranged behind the rear, only slightly semi-transparent laser mirror 7 , the component of the object velocity in the direction of the transmission beam 11 can be determined.
Such photodiodes 17 are used conventionally for maintaining the intensity of the laser light.
the direction of movement can be determined based on the asymmetry of the functions f(L) or g(L), where f is the frequency of the laser, g is the amplification in the laser resonator 3 , and L is the object range from the front resonator mirror 5 .
the surface of the machine or accessory parts to be detected can be roughened or coated, e.g., whereby the diffusely scattered portion of the laser light is increased.
the object 13 to be detected is a bottom thread bobbin that can rotate about a bobbin axis 19 .
the transmission beam 11 intersects the flange surface at the edge area of the front bobbin flange 21 at an angle of incidence a.
the transmission beam 11 has at least one directional component corresponding to the surface velocity v A of the flange surface at the intersection position A.
the transmission beam 11 is preferably oriented so that its directional component is relatively large in the direction of the surface velocity v A at the intersection position A.
the bottom thread bobbin can be detected from different directions according to the visibility of the respective hook arrangement.
the front flange 21 or the rear flange 21 ′ of the bobbin can be detected from the front or from the back or radially from the outside.
the sensor or sensors can be integrated into the drive shaft 31 of the hook 24 (not shown) and the rotational movement of the bobbin relative to this shaft can be detected, in that the sleeve-like bobbin spindle or core 33 ( FIG. 1 ) is scanned from the inside out.
the sensor or sensors can be arranged, e.g., on the bobbin cartridge 23 or within the hook housing 29 .
the power supply and communication to the sensor can be guaranteed, e.g., via sliding contacts (not shown) on the drive shaft 31 .
the bobbin cartridge 23 there can be openings 26 , through which the bobbin can be scanned.
the sensor electronics or the controller evaluates the different sensor signals and takes into account only those signals detecting the bobbin movement at the respective time.
the bottom thread bobbin has only a single degree of freedom, namely the rotational movement about the bobbin shaft 19 . Therefore, in a suitable arrangement, a single sensor is sufficient with only one transmission beam 11 , in order to detect this movement unambiguously.
the electronics or controller necessary for evaluating the sensor signals can be integrated partially or completely in the sensor or can be included partially or completely in the machine controller.
a non-volatile storage medium is provided (not shown), in which, if necessary, information on the object 13 to be detected, its position, orientation in space, and its possible movements, as well as the arrangement of the sensor or sensors, can be stored. In connection with such stored information, the controller can determine the associated movements, positions, etc., of the detected object 13 from the sensor signals.
the direction of the object movement at the intersection position A can be broken down into several components, of which one has the direction of the transmission beam 11 . Then, e.g., the ratio of these movement components to the total object movement, as well as the distance r A of the intersection position A from the bobbin shaft 19 can be stored in the memory ( FIG. 1 ).
any movements in objects 13 with several degrees of freedom can also be detected by several sensors or by sensors with several transmission beams 11 , wherein the transmission beams 11 intersect the object 13 in various directions.
the number of degrees of freedom of movement determines the number of transmission beams 11 necessary for an unambiguous detection of the object motion.
two or more light sources 1 can be arranged close to each other on a common chip or substrate, wherein the respective transmission beams 11 are preferably emitted from different sides through a common optical system 9 in the direction of the respective object 13 to be detected.
several transmission beams 11 can also be emitted independent from each other from different directions onto the object 13 .
object movements can also be detected from a greater range (e.g., 10 cm to 15 cm).
the optical elements 9 can be constructed, so that the transmission beams 11 are not sharply focused onto a point, but instead have a slight lack of focus over a greater area.
such transmission beams 11 have a uniform or only slightly varying beam diameter within the usable measurement area. In this way, object movements in the direction of the transmission beam 11 can also be detected reliably, because the intensity of the scattered light component, which is coupled back into the resonator 3 , varies only slightly for such movements.
other objects 13 are detected by one or more sensors, e.g., sewing machine parts, such as sewing needles, needle holders, material presser foot, feed dog, hook, bottom thread bobbin, embroidery hoop, etc., or objects 13 or components to be processed, e.g., the sewing material or—for several sewing material layers—the top-most and/or the bottom-most sewing material layer, the top thread or the bottom thread.
the sensors are arranged at suitable positions of the sewing or embroidery machine accordingly.
FIG. 3 shows a section of a sewing machine in the region of the stitch-forming unit.
three openings 35 are formed in the needle plate 27 with optical elements arranged in these openings.
These optical elements can include, e.g., windows that are transparent for the light of the light sources 1 and that are set flush with the top side of the needle plate 27 in the openings 35 .
the optical elements could also include collection lenses 9 ( FIG. 1 ).
the curvature can project slightly past the plane of the needle plate 27 .
the sensors are arranged with the light sources 1 . Under each of the lenses 9 , one or more sensors can be arranged.
each of the openings 35 there are two sensors each with a light source 1 ( FIG. 1 ), so that the transmission beams 11 generated by the light sources 1 intersect the sewing plane in different directions, preferably in the sewing direction y and in the transverse direction x, from below at an angle of incidence ⁇ ( FIG. 1 ) on the order of magnitude from approximately 15° to approximately 75° to the sewing material.
the two transmission beams 11 can also intersect the sewing material at different angles of incidence ⁇ .
a third sensor can be provided, wherein its transmission beam 11 preferably intersects the sewing material at an angle of incidence ⁇ of 0°—that is, vertical.
the transmission beam 11 of the third light source 1 can also intersect the sewing material at a different angle of incidence ⁇ . This should differ as much as possible, however, from the angles of incidence ⁇ of the other transmission beams 11 .
the sewing material surface can be detected by several sensors at different positions, e.g., in the region of two openings 35 .
the openings 25 with the sensors can be arranged, for example, on one side or on two sides of the needle piercing opening 37 in the needle plate 27 and/or in front of or behind the needle piercing opening 37 viewed in the sewing direction y. Its mutual distance is large enough with a few centimeters that rotational movements can be distinguished from linear displacements and small enough that errors due to possible draping of the sewing material are minimal.
FIG. 3 additional elements are visible at the bottom on the sewing machine head 39 , especially a sewing foot 41 held on a material presser rod 43 with articulated sewing foot sole 42 and a needle bar 45 with sewing needle 47 set therein, and also a section of the top thread 49 , which is suspended in a thread guide 51 on the needle bar 45 .
the detection of movements or changes in position of the sewing material in the region of the needle piercing position can be used, e.g., for recognizing deviations in the actual sewing material movement from a given sewing material movement and for regulating the transport device (e.g., feed dog or embroidery hoop).
the transport device e.g., feed dog or embroidery hoop
the transport device is not active.
the sewing material is guided by hand.
the stitch-forming unit can be driven, so that needle stitches are set in the sewing material at uniform intervals of the piercing positions—independent of the sewing material velocity.
the detection device can be used to detect and to store a sewing pattern.
this sewing pattern can be reconstructed at a later time (for example, under the use of an embroidery hoop) as many times as needed.
the sensor device can also be integrated alternatively in a stylus or an equivalent scanning device. For scanning the pattern, the pattern remains at rest and the stylus is moved relative to the pattern.
sensors are installed in the sewing foot 41 or in a sewing foot sole 42 , as shown schematically in FIG. 4 .
the electronics for detecting and evaluating the sensor signals are integrated in common with the light source 1 on a chip 53 .
the electronics of the sewing foot 41 can be connected, e.g., by a cable plug 55 to the controller of the sewing machine (not shown).
the connection between the sewing foot and machine controller can also be realized in other ways, for example, by spring contacts between the sewing foot 41 and material presser bar 43 or by a wireless communications connection.
sensors For detecting the sewing material movement from above or for detecting movements of sewing machine parts in the region of the machine head 39 , sensors—with correspondingly adapted optics—can also be arranged directly next to or underneath the machine head 39 .
At least one sensor is arranged on the sewing machine so that it can detect the take-off velocity of the bottom thread or the top thread, that is, in the region of the thread guide 51 , it is connected rigidly, for example, to the moving needle bar 45 or at the upper arm of the sewing machine in the region of a spring-like or elastic thread tensioning device (not shown) or in the region of the bobbin carrier for the top thread bobbin (not shown). Because both the top thread and also the bottom thread are taken off in jerk-like motions during the sewing, in the respective evaluation electronics, there can be a processing step for smoothing these signals or for continuous average value calculation. Integrating the detected velocity measurement parameters gives the amount of thread. If the amount of thread located on the thread bobbin is stored, then this value can be updated continuously. In particular, the sewing process can be stopped before reaching the end of the thread.
a minimum relative velocity between the sensor and the object 13 to be detected is necessary.
a conventional device for detecting changes in position can optionally be provided, which evaluates, for example, changes in orientation of features of the object surface by means of image processing.
stitching machine is to be interpreted broadly and also includes quilting devices, embroidery machines, or other stitch-forming devices or devices suitable for joining flat textiles.

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Engineering & Computer Science (AREA)
Textile Engineering (AREA)
Computer Hardware Design (AREA)
Microelectronics & Electronic Packaging (AREA)
Sewing Machines And Sewing (AREA)

US11/609,947 2006-01-18 2006-12-13 Sewing machine and method for detecting movements in sewing machines Abandoned US20070163479A1 (en)

Applications Claiming Priority (2)

Application Number	Priority Date	Filing Date	Title
CH1032006		2006-01-18
CH00103/06		2006-01-18

Publications (1)

Publication Number	Publication Date
US20070163479A1 true US20070163479A1 (en)	2007-07-19

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ID=37890548

Family Applications (1)

Application Number	Title	Priority Date	Filing Date
US11/609,947 Abandoned US20070163479A1 (en)	2006-01-18	2006-12-13	Sewing machine and method for detecting movements in sewing machines

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US (1)	US20070163479A1 (fr)
EP (1)	EP1811073A2 (fr)

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