Patent Grant
8826837
The present invention relates to a sewing machine (an embroidery sewing machine) and, more particularly, to a sewing frame actuator of a sewing machine that actuates a sewing frame, which holds processed fabric in a stretching fashion, in both a direction X (a right-left direction) and a direction Y (a front-back direction).
A sewing machine; in particular, an embroidery sewing machine, has hitherto been configured so as to actuate a sewing frame, which stretches processed fabric, in both the X direction and the Y direction.
For instance, sewing frame actuators described in connection with Patent Documents 1 and 2 each include an X actuator mechanism disposed along one side of a sewing frame to actuate the sewing frame in the right-left direction and a Y actuator mechanism disposed along one side of the sewing frame to actuate the sewing frame in the front-back direction. Each of the X actuator mechanism and the Y actuator mechanism is configured so as to include one motor and a plurality of ball screws.
Patent Document 3 describes a ball screw actuator mechanism and a belt drive mechanism that actuate a long side of a sewing frame. Another long side opposite to the long side actuated by the ball screw actuator mechanism and the belt drive mechanism is provided with a slide guide mechanism. A nut of a rear ball screw actuator mechanism or a slider of a rear belt drive mechanism and a slider of a front slide guide mechanism, which are in correspondence with each other along extensions in the longitudinal direction, are joined together by means of a coupling bar.
Patent Document 4 describes a ball screw actuator mechanism that actuates a long side of a sewing frame. Another long side opposite to the long slide actuated by the ball screw actuator mechanism is provided with a side guide mechanism. A nut of a rear ball screw actuator mechanism and a slider of a front slide guide mechanism are joined together by means of a coupling bar.
However, in Patent Documents 1 and 2, the X actuator mechanism and the Y actuator mechanism are provided on only one of the mutually-opposed sides of the sewing frame. Hence, the sewing frame becomes distorted, which raises a problem of the inability to position the sewing frame with high accuracy.
Specifically, the sewing frame is usually formed from a material that exhibits low rigidity, like aluminum. Further, the sewing frame is also formed so as to assume a substantially C-shaped cross sectional profile. For this reason, the sewing frame itself is prone to distortion. When only one of the mutually-opposed sides of the sewing frame is equipped with the X actuator mechanism and the Y actuator mechanism, the remaining side free from the X actuator mechanism and the Y actuator mechanism is liable to distortion.
In particular, the sewing frame is usually formed into a rectangular shape, wherein long sides of the sewing frame lie in the direction X and short sides of the same lie in the direction Y. As processed fabric undergoes sewing, the fabric is pulled inwardly, which in turn pulls the sewing frame to the inside. In particular, since a sewing frame of an embroidery sewing machine exhibits high sewing density, force for pulling the sewing frame toward the interior side is correspondingly strong. Moreover, since the sewing frame assumes a rectangular shape, long sides of the sewing frame get easily distorted when the sewing frame is pulled inside.
In Patent Documents 3 and 4, among mutually-opposed long sides of a sewing frame, a long side opposite to a long side to be actuated is equipped with a slide mechanism block and also a coupling bar. However, a slider of the slide mechanism block is only actuated in a following manner by way of the coupling bar as a result of the slider in the ball screw actuator mechanism and the belt drive mechanism being actuated. Hence, depending on rigidity of the coupling bar, the coupling bar becomes distorted by tensile force developing during sewing operation, which may in turn distort the sewing frame itself.
In Patent Documents 1 and 2, each of sides of the sewing frame is equipped with one motor and a plurality of ball screws. Shafts of the respective ball screws are connected to transmission shafts by way of gears, and the transmission shafts are coupled to an output shaft of the motor. In particular, the transmission shafts laid along the long sides of the sewing frame become longer. Therefore, the transmission shafts themselves become twisted, which raises a problem of the inability to accurately synchronize actuation of the respective ball screws. In this regard, the technique described in connection with Patent Document 3 also encounters a problem. Namely, a ball screw actuator shaft extending from a Y direction actuation motor becomes distorted, thereby posing difficulty in accurately synchronizing actuation of the ball screw actuator mechanism and driving operation of the belt drive mechanism that are laid along the long side. As mentioned above, when accurate synchronization between the drive mechanism and the actuator mechanism laid along one side of the sewing frame is inaccurate, distortion occurs in the sewing frame, which makes it impossible to position the sewing frame with high accuracy.
Accordingly, a drawback to be solved by the present invention is to provide a sewing machine that prevents occurrence of distortion in a sewing frame, thereby enabling highly-accurate positioning of the sewing frame.
The present invention has been conceived to solve the drawback. A first configuration of the invention is characterized by a sewing frame actuator for a sewing machine which actuates a sewing frame (50) that is a square frame for stretching processed fabric to be sewn with a sewing machine and that has a pair of long sides (52, 54) laid in parallel with each other and a pair of short sides (56, 58) laid in parallel with each other and at right angles to the respective long sides, the actuator comprising:
a sewing frame actuation block (60) for actuating the sewing frame (50) in a front-back direction and a right-left direction which includes a first front-back direction actuation block (70, 70′, 140, and 140′) which actuates the sewing frame in a front-back direction and second front-back direction actuation blocks (71, 71′, 141, and 141′) which actuate the sewing frame in a front-back direction and right-left direction actuation blocks (130, 195) which actuate the sewing frame in the right-left direction, wherein
a control circuit (200) which synchronously controls the first actuation blocks and the second actuation blocks in such a way that the first movable members and the second movable members move in an identical direction and that the third movable members and the fourth movable members move in the same direction where the first movable member moves and also synchronously controls the third actuation blocks of right-left direction actuation blocks on one short side and the third actuation blocks of the other right-left direction actuation blocks on the remaining short side in such a way that the fifth movable members move in an identical direction.
The sewing machine of the first configuration sews (embroiders) processed fabric while actuating the fabric stretched across the sewing frame in both the front-back direction and the right-left direction. Specifically, when the first actuation block in the first front-back direction actuation block operates under control of the control circuit, the first and second movable members move. When the second actuation blocks in the respective second front-back direction actuation blocks operate under control of the control circuit, the third and fourth movable members move. When the third actuation blocks of the respective right-left direction actuation blocks operate under control of the control circuit, the fifth movable members move in the right-left direction.
The engagement members of the first and second movable members engage the long sides of the sewing frame. The third and fourth movable members are connected to the short sides of the sewing frame or longitudinal ends of long sides of the sewing frame by way of the connection members. Hence, the sewing frame moves in the front-back direction as a result of movement of the first movable member and the second movable member and movement of the third movable members and the fourth movable members. Since the fifth movable members of the right-left direction actuation blocks support the supports of the respective second front-back direction actuation blocks, the sewing frame moves in the right-left direction as a result of movement of the fifth movable members.
Therefore, the movable members support the pair of long sides of the sewing frame and the pair of short sides or the longitudinal ends of the respective long sides of the sewing frame. Hence, distortion of the sewing frame can be minimized, so that the sewing frame can be positioned with high accuracy. In particular, the third movable members and the fourth movable members of the respective second front-back direction actuation blocks are connected to the sewing frame by way of the connection members. The respective second front-back direction actuation blocks are thus actuated in the right-left direction by means of the right-left direction actuation blocks. Therefore, it is possible to prevent occurrence of deflection of the longitudinal end areas of the sewing frame, which would otherwise arise in the front-back direction.
In relation to the first configuration, a second configuration of the present invention is characterized in that the first front-back direction actuation block has first space holding means (125, 86′, and 190) for maintaining constant spacing between the first movable member and the second movable member, and each of the second front-back direction actuation blocks has second space holding means (125, 86, and 190) for holding constant spacing between the third movable member and the fourth movable member.
Owing to the second configuration, the first space holding means maintains spacing between the first movable member and the second movable member. Hence, occurrence of deflection of the long sides of the sewing frame can be prevented. Moreover, the second space holding means maintains spacing between the third movable members and the fourth movable members. Hence, it is possible to prevent occurrence of deflection of the longitudinal end areas of the sewing frame in the front-back direction.
In relation to the second configuration, a third configuration of the present invention is characterized in that the first front-back direction actuation block (70, 70′) has a ball screw (125, 86′) for a first front-back direction actuation block as the first space holding means lying in a rotatable manner along the front-back direction; and wherein the first movable member and the second movable member are screw-engaged with the ball screw for a first front-back direction actuation block, and the first actuation block rotates the ball screw for a first front-back direction actuation block, whereby the first movable member and the second movable member move in the front-back direction. Specifically, spacing between the first movable member and the second movable member can be maintained as a result of the first movable member and the second movable member being screw-engaged with the ball screws.
In relation to the third configuration, a fourth configuration of the present invention is characterized in that, in the first front-back direction actuation block (70), the ball screw (125) for a first front-back direction actuation block has a first ball screw (86) provided in a rotatable manner along the front-back direction, a second ball screw (106) provided in a rotatable manner concentrically with the first ball screw along the front-back direction, and a joint member (124) for joining an end of the first ball screw facing the second ball screw to an end of the second ball screw facing the first ball screw; wherein the first movable member is screw-engaged with the first ball screw, and the second movable member is screw-engaged with the second ball screw; and wherein the first actuation block has a first motor (84) for rotating the first ball screw and a second motor (104) that is connected to an opposite end of the second ball screw with respect to an end thereof facing the first ball screw and that rotates the second ball screw.
Owing to the fourth configuration, when the first motor of the first front-back direction actuation block operates under control of the control circuit, the first ball screw rotates. In addition, when the second motor operates, the second ball screw rotates under control of the control circuit. The first movable member moves as the first ball screw rotates, and the second movable member moves as the second ball screw rotates. The engagement member of the first movable member and the engagement member of the second movable member engage the long sides of the sewing frame. Hence, the sewing frame moves in the front-back direction as a result of movement of the first movable member and the second movable member. As mentioned above, the long sides of the sewing frame are actively positioned by means of the first motor and the second motor. Thereby, even when processed fabric is pulled inside by tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. Moreover, since the ball screw generally exhibit high rigidity, there is a little possibility that shaft-shaped member made up of the first ball screw, the second ball screw, and the joint member will become deformed despite tensile force developing during sewing operation.
In particular, in the first front-back direction actuation block that supports the long side of the sewing frame, the first ball screw and the second ball screw are integrally formed by way of the joint member. Hence, even if movable members attempt to move against the force of the motors as a result of the sewing frame becoming deformed (in particular toward the inside), the movable members will not move against the force of the motors because the ball screws with which the respective movable members are screw-engaged are formed integrally with the other corresponding ball screws. Therefore, occurrence of distortion of the long sides of the sewing frame can be prevented.
In the fourth configuration, both ends of the first ball screw is axially supported by first bracket (82, 282), and portions of the first ball screw facing the second ball screw is formed so as to protrude from the first bracket. Further, both ends of the second ball screw is axially supported by second bracket (102, 302), and portions of the second ball screw facing the first ball screw is formed so as to protrude from the second bracket.
In relation to any one of the second through fourth configurations, a fifth configuration of the present invention is characterized in that the support (71A, 71A′) of each of the second front-back direction actuation blocks (71, 71′) has a ball screw (125, 86) for a second front-back direction actuation block lying as the second space holding means in a rotatable manner along the front-back direction; and wherein the third movable member and the fourth movable member are screw-engaged with the ball screw for a second front-back direction actuation block, and the second actuation block rotates the ball screw for a second front-back direction actuation block, whereby the third movable member and the fourth movable member move in the front-back direction. Namely, spacing between the third movable members and the fourth movable member can be maintained by means of the third movable members and the fourth movable members being screw-engaged with the respective ball screws.
In relation to the fifth configuration, a sixth configuration of the present invention is characterized in that, in each of the second front-back direction actuation blocks (71), the ball screw (125) for a second front-back direction actuation block has a third ball screw (86) provided in a rotatable manner along the front-back direction, a fourth screw (106) provided concentrically with the third ball screw in a rotatable manner along the front-back direction; and a joint member (124) for joining an end of the third ball screw facing the fourth ball screw to an end of the fourth ball screw facing the third ball screw; wherein the third movable member is screw-engaged with the third ball screw, and the fourth movable member is screw-engaged with the fourth ball screw; and wherein the second actuation block has a third motor (84) for rotating the third ball screw and a fourth motor (104) that is connected to an opposite end of the fourth ball screw with respect to an end thereof facing the third ball screw and that rotates the fourth ball screw.
Owing to the sixth configuration, when the third motors of the respective second front-back direction actuation blocks operate under control of the control circuit, the third ball screws rotate. In addition, when the respective fourth motors operate under control of the control circuit, the fourth ball screws rotate. The third movable members move as the third ball screws rotate, and the fourth movable members move as the fourth ball screws rotate. Since the third movable members and the fourth movable members are connected to the respective short sides of the sewing frame or longitudinal ends of the respective long sides of the sewing frame. Hence, the sewing frame moves in the front-back direction as a result of movement of the third and fourth movable members. As above, predetermined positions on the short sides of the sewing frame or positions of the longitudinal ends of the long sides of the sewing frame are actively set. As a result, even if processed fabric is pulled inside by tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. Since the ball screws generally exhibit high rigidity, there is a little possibility that shaft-shaped members made up of the third ball screws, the fourth ball screws, and the joint members will become deformed despite tensile force developing during sewing operation.
In particular, in the second front-back direction actuation blocks that support the short sides of the sewing frame, the third ball screws and the fourth ball screws are integrally formed by way of the joint members. Hence, even if movable members attempt to move against the force of the motors as a result of the sewing frame becoming deformed (in particular toward the inside), the movable members will not move against the force of the motors because the ball screws with which the respective movable members are screw-engaged are formed integrally with the other corresponding ball screws. Therefore, occurrence of distortion of the longitudinal end areas of the sewing frame in the front-back direction can be prevented.
In relation to any one of the first through sixth configurations, a seventh configuration of the present invention is characterized in that the fifth movable member of each of the right-left direction actuation blocks (130, 195) is moved by means of a ball screw mechanism or a timing belt mechanism that is actuated by the third actuation block. Therefore, as a result of the short sides of the sewing frame being actively positioned, it is possible to prevent occurrence of distortion of the sewing frame even when processed fabric is pulled inside by means of tensile force developing during sewing operation.
In relation to any one of the first through seventh configurations, an eighth configuration of the present invention is characterized in that the respective right-left direction actuation blocks (130) are provided in correspondence with one short side and a remaining short side; wherein
each of first right-left direction actuation blocks provided in correspondence with one short side has a fifth ball screw (136) provided in a rotatable manner along the right-left direction; wherein each of the fifth ball screws is rotated by a fifth motor (134) that is provided in each of the first right-left direction actuation blocks and that serves as the third actuation block; and the fifth movable member provided in each of the first right-left direction actuation blocks is screw-engaged with the fifth ball screw and moves in the right-left direction as a result of rotation of the fifth ball screw; and
each of second right-left direction actuation blocks provided in correspondence with a remaining short side includes a sixth ball screw (136) provided in a rotatable manner along the right-left direction; the sixth ball screw is rotated by a sixth motor (134) that is provided in each of the second right-left direction actuation blocks and that serves as the third actuation block; the fifth movable member provided in each of the second right-left direction actuation blocks is screw-engaged with the sixth ball screw and moves in the right-left direction as a result of rotation of the sixth ball screw.
In relation to the second configuration, a ninth configuration of the present invention is characterized in that the first front-back direction actuation block (140) has a first timing belt (162) provided so as to be revolvable in the front-back direction and a second timing belt (182) that is provided so as to be revolvable in the front-back direction and that has a path of revolution in an extension of a path of revolution of the first timing belt; the first movable member is fixed to the corresponding first timing belt; the second movable member is fixed to the corresponding second timing belt; a rod-shaped joint member (190) serving as the first space holding means is interposed between the first movable member and the second movable member; and the first actuation block has a first motor for revolving the first timing belt and a second motor for revolving the second timing belt.
Owing to the ninth configuration, when the first motor of the first front-back direction actuation block operates under control of the control circuit, the first timing belt revolves. When the second motor operates under control of the control circuit, the second timing belt revolves. The first movable member moves as the first timing belt revolves, and the second movable member moves as the second timing belt revolves. Since the engagement member of the first movable member and the engagement member of the second movable member engage the respective long sides of the sewing frame, the sewing frame moves in the front-back direction as a result of movement of the first and second movable members. As above, the first movable member is secured to the first timing belt, and the second movable member is secured to the second timing belt. Moreover, the rod-like joint member serving as the first space holding means is interposed between the first and second movable members. Hence, spacing between the first movable member and the second movable member can be maintained. Therefore, the first motor and the second motor actively position the long sides of the sewing frame. Even if processed fabric is pulled inside by tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. In particular, in the first front-back direction actuation block that supports the long side of the sewing frame, the first movable member and the second movable member are integrally formed by way of each of the joint member. Hence, even if the movable members attempt to move against the force of the motors as a result of the sewing frame becoming deformed (in particular toward the inside), movement of the movable members will be restricted by the joint member, so that the movable members will not move against the force of the motors. Specifically, if processed fabric to be sewn is pulled inside as the fabric is sewn, the long sides of the sewing frame will also be pulled inside. Both the first and second movable members are thus pulled inside. However, since both the first and second movable members are secured to the respective joint members, the movable members will not move inside. Consequently, a possibility of deformation of the sewing frame; in particular, a possibility of deformation of the long sides, can be minimized, and the sewing frame can be positioned with high accuracy.
In relation to the second configuration, a tenth configuration of the present invention is characterized in that the first front-back direction actuation block (140′) has a timing belt (162) for a first front-back direction actuation block provided so as to be revolvable in the front-back direction; the first movable member and the second movable member are secured to the timing belt for a first front-back direction actuation block; and a rod-shaped joint member (190) serving as the first space holding means is interposed between the first movable member and the second movable member; and the first actuation block revolves the timing belt for a first front-back direction actuation block.
Owing to the tenth configuration, when the first actuation block of the first front-back direction actuation block operates under control of the control circuit, the timing belt for a first front-back direction actuation block revolve, whereupon the first movable member and the second movable member move. Since the engagement member of the first movable member and the engagement members of the second movable member engage the respective long sides of the sewing frame, the sewing frame moves in the front-back direction as a result of movement of the first and second movable members. As above, the first movable member and the second movable member are secured to the timing belt for a first front-back direction actuation block. Moreover, the rod-like joint members serving as the first space holding means are interposed between the first and second movable member. Hence, spacing between the first movable member and the second movable member can be maintained. Therefore, the first actuation block actively position the long sides of the sewing frame. Even if processed fabric is pulled inside by tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. In particular, in the first front-back direction actuation block that supports the long sides of the sewing frame, the first movable member and the second movable member are integrally formed by way of the joint member. Hence, even if the movable member attempt to move against the force of the first actuation block as a result of the sewing frame becoming deformed (in particular toward the inside), movement of the movable members will be restricted by the joint member, so that the movable members will not move against the force of the first actuation block. Specifically, if processed fabric to be sewn is pulled inside as the fabric is sewn, the long sides of the sewing frame will also be pulled inside. Both the first and second movable members are thus pulled inside. However, since both the first and second movable members are secured to the joint member, the movable members will not move inside. Consequently, a possibility of deformation of the sewing frame; in particular, a possibility of deformation of the long sides, can be minimized, and the sewing frame can be positioned with high accuracy.
In relation to the second, ninth, or tenth configuration, an eleventh configuration of the present invention is characterized in that the support (141A) of each of the second front-back direction actuation blocks (141) has a third timing belt (162) provided so as to be revolvable in the front-back direction and a fourth timing belt (182) that is provided so as to be revolvable in the front-back direction and that has a path of revolution in an extension of a path of revolution of the third timing belt; the third movable member is secured to the third timing belt; the fourth movable member is secured to the fourth timing belt; a rod-shaped joint member (190) to serve as second space holding means is interposed between the third movable member and the fourth movable member; and each of the second actuation blocks includes a third motor for revolving the third timing belt and a fourth motor for revolving the fourth timing belt.
Owing to the eleventh configuration, when the third motors of the second front-back direction actuation blocks operate under control of the control circuit, the third timing belts revolve. When the fourth motors operate under control of the control circuit, the fourth timing belts revolve. The third movable members move as the third timing belts revolve, and the fourth movable members move as the fourth timing belts revolve. Since the respective third movable members and the respective fourth movable members engage the respective short sides of the sewing frame or longitudinal ends of the respective long sides of the sewing frame, the sewing frame moves in the front-back direction as a result of movement of the third and fourth movable members. As above, the third movable members are secured to the third timing belts, and the fourth movable members are secured to the fourth timing belts. Moreover, the rod-like joint members serving as the second space holding means are interposed between the respective third and fourth movable members. Hence, spacing between the third movable members and the fourth movable members can be maintained. As mentioned above, the predetermined positions on the short sides of the sewing frame or the positions of the longitudinal ends of the long sides of the sewing frame are actively positioned. As a result, even if processed fabric is pulled inside by means of tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. In particular, in the second front-back direction actuation blocks that are provided along the respective short sides of the sewing frame, the third movable members and the fourth movable members are integrally formed by way of the joint members. Hence, even if the movable members attempt to move against the force of the motors as a result of the sewing frame becoming deformed (in particular toward the inside), movement of the movable members will be restricted by the joint members, so that the movable members will not move against the force of the motors. Specifically, if processed fabric to be sewn is pulled inside as the fabric is sewn, the long sides of the sewing frame will also be pulled inside. Both the third and fourth movable members are thus pulled inside. However, since both the third and fourth movable members are secured to the respective joint members, the movable members will not move inside. Consequently, a possibility of deformation of the sewing frame; in particular, a possibility of deformation of the long sides, can be minimized, thereby preventing occurrence of distortion in the longitudinal end areas of the sewing frame in the front-back direction.
In relation to the second, ninth, or tenth configuration, a twelfth configuration of the present invention is characterized in that the support (141A′) of each of the second front-back direction actuation blocks (141′) has a timing belt for a second front-back direction actuation block provided so as to be revolvable in the front-back direction; the third movable member and the fourth movable member are secured to the timing belt for a second front-back direction actuation block; a rod-shaped joint member to serve as the second space holding means is interposed between the third movable member and the fourth movable member; and each of the second actuation blocks revolves the timing belt for a second front-back direction actuation block.
Owing to the twelfth configuration, when the second actuation blocks of the second front-back direction actuation blocks operate under control of the control circuit, the timing belts for a second front-back direction actuation block revolve. The third movable members and the fourth movable members thereupon move. Since the respective third movable members and the respective fourth movable members are connected to the respective short sides of the sewing frame or longitudinal ends of the respective long sides of the sewing frame, the sewing frame moves in the front-back direction as a result of movement of the third and fourth movable members. As above, the third movable members and the fourth movable members are secured to the timing belts for a second front-back direction actuation block. Moreover, the rod-like joint members serving as the second space holding means are interposed between the respective third and fourth movable members. Hence, spacing between the third movable members and the fourth movable members can be maintained. As mentioned above, the predetermined positions on the short sides of the sewing frame or the positions of the longitudinal ends of the long sides of the sewing frame are actively positioned. As a result, even if processed fabric is pulled inside by means of tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented. In particular, in the second front-back direction actuation blocks that are provide along the respective short sides of the sewing frame, the third movable members and the fourth movable members are integrally formed by way of the joint members. Hence, even if the movable members attempt to move against the force of the motors as a result of the sewing frame becoming deformed (in particular toward the inside), movement of the movable members will be restricted by the joint members, so that the movable members will not move against the force of the motors. Specifically, if processed fabric to be sewn is pulled inside as the fabric is sewn, the long sides of the sewing frame will also be pulled inside. Both the third and fourth movable members are thus pulled inside. However, since both the third and fourth movable members are secured to the respective joint members, the movable members will not move inside. Consequently, a possibility of deformation of the sewing frame; in particular, a possibility of deformation of the long sides, can be minimized, thereby preventing occurrence of distortion in the longitudinal end areas of the sewing frame in the front-back direction.
In relation to any of the ninth to twelfth configurations, a thirteenth configuration of the present invention is characterized in that each of the fifth movable members of the respective right-left direction actuation blocks (130, 195) is moved by means of a ball screw mechanism or a timing belt mechanism that is actuated by the third actuation block. Consequently, the short sides of the sewing frame are actively positioned. Therefore, even if processed fabric is pulled inside by means of tensile force developing during sewing operation, occurrence of distortion of the sewing frame can be prevented.
In relation to the first, second, ninth, tenth, eleventh, twelfth, or thirteenth configuration, a fourteenth configuration of the present invention is characterized in that the respective right-left direction actuation blocks (195) are provided in correspondence with one short side and a remaining short side; each of first right-left direction actuation blocks provided in correspondence with one short side has a fifth timing belt (195-12) provided so as to be revolvable in the right-left direction; the fifth timing belt is rotated by a fifth motor (195-8) that is provided in the corresponding right-left direction actuation block and that serves as the third actuation block; each of the fifth movable members provided in the respective first right-left direction actuation blocks is fastened to the fifth timing belt and moves in the right-left direction as a result of revolution of the fifth timing belt; and
each of second right-left direction actuation blocks provided in correspondence with a remaining short side has a sixth timing belt (195-12) provided so as to be revolvable in the right-left direction; the sixth timing belt is rotated by a sixth motor (195-8) that is provided in the corresponding second right-left direction actuation block and that serves as the third actuation block; and each of the fifth movable member provided in the respective second right-left direction actuation blocks is fastened to the sixth timing belt and moves in the right-left direction as a result of revolution of the sixth timing belt.
The following can also be adopted as a fifteenth configuration of the present invention. The fifteenth configuration of the invention is characterized by a sewing frame actuator for a sewing machine that actuates a sewing frame (50) which is a square frame for stretching processed fabric to be sewn with a sewing machine and which has a pair of long sides (52, 54) laid in parallel with each other and a pair of short sides (56, 58) laid in parallel with each other and at right angles to the respective long sides, the actuator comprising:
a control circuit (200) for controlling operation of the respective motors that synchronously controls the first motor, the second motor, the third motor, and the fourth motor in such a way that the first ball screws and the second ball screws rotate in an identical direction, that the first movable members and the second movable members move in an identical direction, that the third ball screws and the fourth ball screws rotate in the same direction where the first ball screw rotates, and that the third movable members and the fourth movable members move in the same direction where the first movable member moves and also synchronously controls the fifth motors of the right-left direction actuation blocks on one short side and the fifth motors of the right-left direction actuation blocks on the other short side such that the fifth movable members move in a same direction.
The following can also be adopted as a sixteenth configuration of the present invention. The sixteenth configuration of the invention is characterized by a sewing frame actuator for a sewing machine which actuates a sewing frame (50) that is a square frame for stretching processed fabric to be sewn with a sewing machine and that has a pair of long sides (52, 54) laid in parallel with each other and a pair of short sides (56, 58) laid in parallel with each other and at right angles to the respective long sides, the actuator comprising:
a sewing frame actuation block (60) that actuates the sewing frame in a front-back direction and a right-left direction which includes a first front-back direction actuation block (140) which actuates the sewing frame in the front-back direction and second front-back direction actuation blocks (141) which actuate the sewing frame in the front-back direction and right-left direction actuation blocks (195) which actuate the sewing frame in the right-left direction, wherein
the first front-back direction actuation block (140) includes
the second front-back direction actuation blocks (141) each include
the right-left direction actuation blocks (195) each are laid along the pair of respective short sides, and each include
a control circuit (200) for controlling operation of the respective motors that synchronously controls the first motor, the second motor, the third motor, and the fourth motor in such a way that the first timing belts and the second timing belts revolve in a same direction, that the first movable member and the second movable member move in an identical direction, that the third timing belt and the fourth timing belt revolve in a direction identical to a direction of revolution of the first timing belt, and that the third movable members and the fourth movable members move in the same direction where the first movable member moves and also synchronously controls the fifth motors of the right-left direction actuation blocks on one short side and the fifth motors of the right-left direction actuation blocks on the other short side such that the fifth movable members move in an identical direction.
In the sewing frame actuator for a sewing machine of the present invention, the movable members support the pair of long sides of the sewing frame and the pair of short sides or the longitudinal ends of the respective long sides of the sewing frame. Hence, distortion of the sewing frame can be minimized, so that the sewing frame can be positioned with high accuracy. In particular, the third movable members and the fourth movable members of the respective second front-back direction actuation blocks are connected to the sewing frame by way of the connection members. The respective second front-back direction actuation blocks are thus actuated in the right-left direction by means of the right-left direction actuation blocks. Therefore, it is possible to prevent occurrence of deflection of the longitudinal end areas of the sewing frame, which would otherwise arise in the front-back direction. Furthermore, when the first space holding means and the second space holding means are provided, the first space holding means maintains spacing between the first movable members and the second movable members. Hence, occurrence of deflection of the long sides of the sewing frame can be prevented. Moreover, the second space holding means maintains spacing between the third movable members and the fourth movable members. Hence, it is possible to prevent occurrence of deflection of the longitudinal end areas of the sewing frame in the front-back direction.
The present invention accomplishes an objective for providing a sewing machine that can position a sewing frame with a high degree of accuracy by preventing occurrence of distortion in the sewing frame; in particular, an objective for providing a sewing machine that can position a sewing frame with high accuracy by preventing occurrence of distortion in long sides of the sewing frame.
An embroidery sewing machine of a sewing machine 5 of an embodiment of the present invention is built as shown in
The frame block 10 makes up a machine casing of the sewing machine 5. The frame block 10 has bases 11 that are formed along the front-back direction (the direction Y1-Y2) and that are disposed on both sides of the right-left direction (the X1-X2 direction); vertical frame blocks 12 and 14 that stand on the respective bases 11, to thus serve as pillars; horizontal frame blocks 16 and 18 that are horizontally laid between the pair consisting of the vertical frame blocks 12 and 14; and beds 20. The horizontal frame block 16 is horizontally laid at an arbitrary position along a heightwise direction of the pair consisting of the vertical frame blocks 12 and 14, and both sides of the horizontal frame block 16 are secured to the vertical frame block 12 and the vertical frame block 14. The horizontal frame block 18 is horizontally laid at a position higher than the horizontal frame block 16 and parallel to the horizontal frame block 16, and both sides of the horizontal frame block 18 are secured to the vertical frame block 12 and the vertical frame block 14. Each of the beds 20 assumes the shape of a plate and is horizontally supported by an upper surface of the horizontal frame block 16. The beds 20 are provided for installing front-back direction actuation blocks 70 and right-left direction actuation blocks 130. Hence, the beds 20 are disposed at a position beneath the front-back direction actuation blocks 70 and the right-left direction actuation blocks 130. For instance, plate-like members each of which has a width enabling installation of the corresponding front-back direction actuation block 70 are laid in correspondence with the respective front-back direction actuation blocks 70 along the front-back direction. Moreover, in relation to the right-left direction actuation blocks 130, three right-left direction actuation blocks 130 are put on an upper surface of one of the beds 20. The beds 20 are not placed in an area of openings 40 when viewed in a plane.
A sewing head 22 (or an embroidery head can also be used) having a well known structure is placed on a front side of the horizontal frame block 18. The sewing head 22 has a needle bar case (not shown) that supports a plurality of needle bars (a sewing needle is secured to each of the needle bars) so as to be vertically movable; thread take-up levers (not shown) each of which repeat operation for pulling up a needle thread inserted into the sewing needle and returning the needle thread to its original position, to thus perform swaying operation; and presser feet (not shown) that are attached to a lower end of the sewing head 22 to press processed fabric during performance of sewing operation. The presser feet are also vertically actuated in synchronism with vertical movement of the needle bars. The sewing needles, the thread take-up levers, and the presser feet perform sewing (in particular embroidery sewing) of the processed fabric by means of cooperated operation with corresponding shuttles to be rotationally actuated (not shown). The shuttles are disposed below the table 30 and supported on the respective beds 20.
The table 30 assumes a shape of a substantially rectangular plate and is horizontally interposed between the pair consisting of the vertical frame blocks 12 and 14. Specifically, a plurality of frame members (not shown) each of which assumes a substantially C-shaped cross sectional profile are laid, on an upper surface of the horizontal frame block 16, at predetermined intervals along the front-back direction. The table 30 is put on upper surfaces of the respective frame members and above the beds 20. The table 30 is thus disposed while vertically spaced apart from the beds 20 by a predetermined interval. Cutouts 32 are formed in respective lateral sides of the table 30 to set the respective vertical frame blocks 12 and 14. The beds 20 and the frame members are put, on the upper surface of the horizontal frame block 16, but in different areas thereof.
Slit-like cutouts 34a and 34b are formed in the table 30 in such a way that a projecting member (specifically the shaft portion 90, 110) of a ball screw mechanism block 80, 100, which make up the sewing frame actuation block 60, are inserted into the table 30 and become movable in the horizontal direction (the Y1-Y2 direction). Further, slit-like openings 36a and 36b are formed in the table 30 in such a way that projecting members (specifically support members 139) of the right-left direction actuation blocks 130 are inserted into the table and become movable in the horizontal direction (the direction X1-X2). Specifically, the plurality of slit-like cutouts 34a and 34b are formed in alignment with front-back direction and from a pair of respective long sides of the table toward the inside of the table along the direction Y1-Y2. The cutouts 34a formed in a frontal long side of the table and the cutouts 34b formed in a dorsal long side of the same are situated opposite each other (i.e., at the same positions in the right-left direction). The cutouts 34b are formed on respective extensions of the cutouts 34a. Each of cutout pairs is formed from the mutually-opposed cutouts 34a and 34b. As will be described later, the sewing frame actuation block 60 of the embodiment is provided with the two front-back direction actuation blocks 70. The two slit-like cutouts 34a are formed on one long side of the table 30 along the Y1-Y2 direction, whilst the two slit-like cutouts 34b are formed on the other long side of the same along the Y1-Y2 direction. The cutouts 34a and the cutouts 34b are formed at mutually-opposed positions (the same positions in the right-left direction). A distance between the two cutouts 34a is determined in such a way that a substantially equal distance exists among four adjacent front-back direction actuation blocks 70 and 71. Specifically, the distance between the two cutouts 34a is set in such a way that a distance between the left front-back direction actuation block 71 in
The slit-like openings 36a and 36b are formed in right and left ends of the table 30 along the right-left direction; namely, the openings 36a are formed in a left area of the table, and the openings 36b are formed in a right area of the same. The openings 36a are formed in the outside (the left side) of the leftmost cutouts 34a and 34b of the plurality of cutouts 34a and 34b. Further, the openings 36b are formed in the outside (the right side) of the rightmost cutouts 34a and 34b of the plurality of cutouts 34a and 34b. The openings 36a and the openings 36b are formed in mutually-opposed positions (i.e., at the same positions in the front-back direction). The openings 36b are formed on extensions of the respective openings 36a. The openings 36a and 36b opposing each other make up a pair of openings. As will be described later, the sewing frame actuation block 60 of the present embodiment is provided with the three right-left direction actuation blocks 130. To this end, the three slit-like openings 36a are formed in one end area along a short side (a left-side area) of the table 30, whereas the three slit-like openings 36b are formed in the other end area along the other short side (a right-side area) of the table 30. The openings 36a are formed in the outside (left side) of the leftmost cutouts 34a and 34b of the plurality of cutouts 34a and 34b, whilst the openings 36b are formed in the outside (right side) of the rightmost cutouts 34a and 34b of the plurality of cutouts 34a and 34b. The openings 36a and 36b are formed in mutually-opposed positions (i.e., the same positions in the front-back direction), and the openings 36b are formed on extensions of the respective openings 36a. The opening 36a and the corresponding opening 36b make up a pair of openings. The center opening 36a of the three openings 36a is placed at a substantially intermediate position between the cutout 34a and the cutout 34b with respect to the front-back direction. The remaining two openings 36a are substantially equidistant from the center opening 36a. Likewise, the center opening 36b of the three openings 36b is placed at a substantially intermediate position between the cutouts 34a and the cutouts 34b with respect to the front-back direction. The remaining two openings 36b are located at substantially equidistant from the center opening 36b.
A direction along which the cutouts 34a and 34b are aligned and a direction along which the openings 36a and 36b are aligned form a right angle. The cutouts 34a and the cutouts 34b are formed so as to assume the same width, and the openings 36a and the openings 36b are formed so as to assume the same width.
Surroundings of the respective cutouts 34a and 34b and surroundings of the respective openings 36a and 36b in the upper surface of the table 30 are formed as recesses that recede from the upper surface of the table 30. Slit plates 38 each of which is a plate-like member having a slit are provided in the respective recesses. Each of the slit plates 38 is a plate-like member having a substantially C-shaped geometry when viewed in plane. Upper surfaces of the respective slit plates are flush with the upper surface of the table 30. The slits of the slit plates 38 fitted into the respective cutouts 34a and 34b are formed so as to become smaller in width than the cutouts 34a and 34b and the openings 36a and 36b. The slits of the slit plates 38 fitted into the respective openings 36a and 36b are formed so as to become equal to or smaller in width than the openings 36a and 36b (or narrower than the openings 36a and 36b) and greater in width than the slits of the slit plates 38 to be fitted into the cutouts 34a and 34b. Specifically, the shaft portions 90 and 110 protrude from the slits of the respective slit plates 38 fitted into the cutouts 34a and 34b, whereas the pair of support members 139 protrude from the slits of the respective slit plates 38 fitted into the openings 36a and 36b. Accordingly, the slits of the slit plates 38 of the openings 36a and 36b are formed so as to become larger in width than the slits of the slit plates 38 of the cutouts 34a and 34b. The openings 36a and 36b are consequently formed so as to become greater in width than the cutouts 34a and 34b.
Moreover, the openings 40 are formed, at a predetermined interval along the right-left direction, in a substantially center area of the table 30 in its front-back direction. The shuttles (not shown) are situated at locations of the respective openings 40, and sewing needles (not shown) are situated at elevated positions above the respective openings 40.
The sewing frame 50 (which may also be embodied as a fabric holding frame, a movable frame, or an embroidery frame) is a frame member for holding processed fabric in a stretched fashion. The sewing frame is placed at an elevated location above the table 30. The sewing frame 50 has a sewing frame body 51 and a clip 59.
The sewing frame body 51 assumes a shape of a rectangular frame when viewed in plane and has a frontal long side 52, a dorsal long side 54, a left short side 56, and a right short side 58. Each of the long sides 52 and 54 and the short sides 56 and 58 assumes an elongated strip shape when viewed in plane, as well as assuming a shape of a substantially C-shaped frame as a transverse cross sectional profile. Specifically, as shown in
The clips 59 are formed inside the sewing frame body 51. Each of the clips 59 includes a frame-like plate portion 59a continually extending from an inner lower end of the sewing frame body 51, a belt-like projection 59b formed on an upper surface of the plate-like portion 59a, and a cap portion 59c removably attached to the projection 59b. Processed fabric is stretchedly nipped between the projection 59b and the cap portion 59c.
As shown in
The sewing frame actuation block 60 is for actuating the sewing frame 50 in both the right-left direction and the front-back direction and includes the front-back direction actuation blocks 70 and 71 for actuating the sewing frame 50 in the front-back direction and the right-left direction actuation block 130 for actuating the sewing frame 50 in the right-left direction. The front-back direction actuation block 70 is provided in number equal to the pair of cutouts formed in the table 30; namely, the two front-back direction actuation blocks 70 are provided. The two front-back direction actuation blocks 71 are also provided. Moreover, the right-left direction actuation block 130 is provided in number equal to the pair of openings formed in the table 30, and the three pairs (a total of six) of right-left direction actuation blocks 130 are provided.
As shown in
The ball screw mechanism block 80 includes a bracket 82 (which may also be embodied as a “support frame,” and the same also applies to its counterpart) to be attached to the upper surface of the bed 20, a motor 84 (a first motor), a ball screw 86 (a first ball screw) that is supported by the bracket 82 in a rotatable fashion and that is connected at one end thereof to and rotated by the motor 84, and the movable member 87 (a first movable member) that is screw-engaged with the screw ball in a screwable manner as a result of rotation of the ball screw 86.
The bracket 82 includes an elongated rectangular substantially-plate-like horizontal member 82 that is horizontally placed; a plate-like upright portion 82b that stands upright on one end of the horizontal member 82a (i.e., an end facing the motor); and a plate-like upright portion 82c that stands upright on the other end of the horizontal member 82a. The horizontal member 82a has a plate-like portion 82a-1 assuming the shape of an elongated rectangular plate and a rail portion 82a-2 that is laid on an upper surface of the plate-like portion 82a-1 and along its longitudinal direction in parallel with the ball screw 86. The upright portions 82b and 82c axially support the ball screw 86 in a rotatable manner. Specifically, each of the upright portions 82b and 82c is provided with a bearing (not shown). The ball screw 86 is axially supported by means of the bearings. The motor 84 is fixed to the outside of the upright portion 82b, and an output shaft of the motor 84 is fixed to an end of the ball screw 86.
A thread groove used for screw engagement with the movable member 87 is formed in a peripheral surface of the ball screw 86. An end of the ball screw 86 that is on the opposite side of the end facing the motor 84 is formed so as to protrude from the upright portion 82c. Specifically, the ball screw 86 is formed so as to protrude from the upright portion 82c that opposite to the side of the upright portion facing the motor.
The movable member 87 includes a nut 88, the shaft portion 90, and an engagement roller (an engagement member) 92. The nut 88 includes a nut body 88a screw-engaged with the ball screw 86 and a slider 88b secured to a lower surface of the nut body 88a. A groove to be engaged with the rail portion 82a-2 is provided on a lower surface side of the slider 88b, and the slider 88b performs sliding action along the rail portion 82a-2. A threaded bore with which the ball screw 86 is to be screw-engaged is formed in the nut body 88a. The nut 88 is thereby configured so as to move along the ball screw 86 as a result of rotation of the ball screw 86. For instance, the movable member 87 is configured so as to move forward as the motor 84 rotates clockwise. In contrast, the movable member 87 is configured so as to move backward as the motor 84 rotates counterclockwise. However, the movable member can be actuated in reverse.
The shaft portion 90 is fixedly attached to an upper surface of the nut body 88a and inserted into the cutout 34a of the table 30 and the slit of the slit plate 38 with play; namely, allowance, to thus protrude from the upper surface of the table 30. The shaft portion 90 is inserted into the cutout 34a and the slit plate 38 while spaced apart from their edges. The engagement roller 92 is axially attached to a shaft portion 90 so as to become rotatable and protrude upward from the upper surface of the table 30. The engagement roller 92 provided so as to be rotatable with respect to the shaft portion 90 is engaged with a groove of the long side 52 of the sewing frame 50.
The ball screw mechanism block 100 is structurally same to the ball screw mechanism block 80; hence, its detailed descriptions are omitted. Specifically, the ball screw mechanism block 100 has a bracket 102 attached to the upper surface of the bed 20, a motor 104 (a second motor), a ball screw 106 (a second ball screw) that is supported by the bracket 102 in a rotatable fashion and that is connected at one end thereof to and rotated by the motor 104, and the movable member 107 (a second movable member) that is screw-engaged with the ball screw in a screwable manner as a result of rotation of a ball screw 106. The bracket 102, the motor 104, and the ball screw 106 are same in structure to their counterparts; namely, the bracket 82, the motor 84, and the ball screw 86. The bracket 102 has a horizontal member 102a, which includes a plate-like portion 102a-1 and a rail portion 102b-2, and upright portions 102b and 102c. The movable member 107 is same in structure of the movable member 87 and has a nut 108, the shaft portion 110, and the engagement roller (an engagement member) 112. The nut 108 includes a nut body 108a screw-engaged with the ball screw 106 and a slider 108b secured to a lower surface of the nut body 108a. A groove to be engaged with the rail portion 102a-2 is formed in a lower surface of the slider 108b that slides along the rail portion 102a-2, and the slider 108b thereby moves along the ball screw 106 as the ball screw 106 rotates. For instance, the movable member 107 is configured so as to move backward as the motor 104 rotates clockwise. The movable member 107 is configured so as to move forward as the motor 104 rotates counterclockwise. The movable member can also be actuated in reverse. The movable member 107 is spaced apart from the movable member 87. The shaft portion 110 of the front-back direction actuation block 70 is inserted into the cutout 34b of the table 30 and the slit of the slit plate 38 with play so as to protrude from the upper surface of the table 30. The engagement roller 112 provided so as to be rotatable with respect to the shaft portion 110 is engaged with the groove of the long side 54 of the sewing frame 50.
In one front-back direction actuation block 70, the ball screw mechanism block 80 and the ball screw mechanism block 100 are disposed opposite each other. Specifically, the ball screw mechanism block 80 and the ball screw mechanism block 100 are placed in such a way that portions of the blocks where the motors 84 and 104 are set face outside. A first actuation block, which is referred to in claims, is built from the motors 84 and 104 in the front-back drive block 70.
The couplings 120 and 122 are shaft couplings. The coupling 120 coaxially couples the ball screw 86 to the joint member 124, and the coupling 122 coaxially couples the ball screw 106 to the joint member 124. Specifically, as shown in
The joint member 124 and the couplings 120 and 122 can also be built from one coupling (a joint member). Specifically, as shown in
As above, the ball screw 86, the joint member 124, and the ball screw 106 are entirely built in one piece from the coupling members 120 and 122, thereby forming one shaft-shaped member 125. The ball screw 86, the joint member 124, and the ball screw 106 are joined together in such a way that their axial lines are aligned to each other. The shaft-shaped members 125 of the respective front-back direction actuation blocks 70 correspond to a “ball screw for first front-back direction actuation block” and “first space holding means” referred to in the claims. Further, a configuration of the front-back direction actuation block 70 except the motors 84 and 104 and the movable members 87 and 107 corresponds to a support that supports the first actuation block (the motors 84 and 104) and that support the first movable member (the movable member 87) and the second movable member (the movable member 107) so as to be movable in the front-back direction. In the ball screw mechanism block 80, the bracket 82 and the ball screw 86 correspond to a support that supports the first actuation block (the motor 84) and that supports the first movable member so as to be movable in the front-back direction. In the ball screw mechanism block 100, the bracket 102 and the ball screw 106 correspond to a support that supports the first actuation block (the motor 104) and that supports the second movable member so as to be movable in the front-back direction.
The plurality of front-back direction actuation blocks 70 are provided in parallel with each other along the front-back direction. The plurality of front-back direction actuation blocks 70 are configured in such a way that the movable members 87 and 107 move in parallel with each other. The front-back direction actuation blocks 70 have the same configuration.
Each of the front-back direction actuation blocks 70 is provided with two motors; namely, the motor 84 and the motor 104. The motors 84 and 104 are synchronously driven. The engagement roller 92 of the ball screw mechanism block 80 in the front-back direction actuation block 70 is engaged with the groove M of the long side 52 of the sewing frame 50, and the engagement roller 112 of the ball screw mechanism block 100 is engaged with the groove M of the long side 54 of the sewing frame 50.
The front-back direction actuation block 71 (a second front-back direction actuation block) is substantially analogous in structure to the front-back direction actuation block 70. However, they differ from each other in that a plate-like portion 72a-1 making up a bracket 72 is integrally formed as shown in
Specifically, the front-back direction actuation block 71 has the bracket 72 (a support or a support frame); the motor 84 (a third motor); the ball screw 86 (a third ball screw); the movable member 87 (a third movable member); the motor 104 (a fourth motor); the ball screw 106 (a fourth ball screw); the movable member 107 (a fourth movable member); the couplings 120 and 122; and the joint member 124.
The bracket 72 has a horizontal member 72a that assumes an elongated rectangular substantially-plate-like shape and that is horizontally provided; a plate-like upright portion 72b standing upright on one end of the horizontal member 72a (an end facing the motor 84); a plate-like upright portion 72e standing upright on the other end of the horizontal member 72a (an end facing the motor 104); and plate-like upright portions 72c and 72d spaced apart from each other at an interval on an upper surface of the horizontal member 72a and between the upright portions 72b and 72e. The horizontal member 72a has the plate-like portion 72a-1 that assumes the shape of an elongated rectangular plate and that has a length equivalent to a distance from the upright portion 72b to the upright portion 72e; a rail portion 72a-2 laid, along a longitudinal direction, between the upright portions 72b and 72c on an upper surface of the plate-like portion 72a-1 and in parallel with the ball screw 86; and a rail portion 72a-3 that is laid between the upright portions 72d and 72e on the upper surface of the plate-like portion 72a-1 and along its longitudinal directional in parallel with the ball screw 106.
The upright portions 72b and 72c axially support the ball screw 86 in a rotatable manner, and the upright portions 72d and 72e axially support the ball screw 106 in a rotatable manner. Specifically, each of the upright portions 72b, 72c, 72d, and 72e is provided with a bearing (not shown), and the ball screws 86 and 106 are axially supported by means of the bearings. More specifically, in relation to the bracket 82 and the bracket 102 in the front-back direction actuation block 70, the plate-like portion 82a-1 and the plate-like portion 102a-1 are joined into one plate-like portion 72a-1, whereby the bracket 82 and the bracket 102 are integrally joined. The bracket 72 corresponds to a “support that supports the third ball screw, the third motor, the fourth ball screw, and the fourth motor.”
The motor 84, the ball screw 86, the motor 104, the ball screw 106, and the couplings 120 and 122 are structurally same to their counterparts in the front-back direction actuation block 70, and hence their detailed explanations are omitted. The movable member 87 is structurally same to the nut 88 in the front-back direction actuation block 70, and the movable member 107 is structurally same to the nut 108 in the front-back direction actuation block 70. The movable member 87 and the movable member 107 are spaced apart from each other. The motor 84 and the motor 104 in the front-back direction actuation block 71 make up a second actuation block referred to in the claims.
In the front-back direction actuation block 71, shaft portions are not put on upper surfaces of the movable members 87 and 107 as distinct from the movable members 87 and 107 of the front-back direction actuation block 70. The connection members 49 are attached to side surfaces of the respective movable members 87 and 107 facing the sewing frame 50. The movable members 87 and 107 are fastened to the short sides 56 and 58 of the sewing frame 50 by way of the connection members 49. Specifically, as shown in
Even in each of the front-back direction actuation blocks 71, the ball screw 86, the joint member 124, and the ball screw 106 are entirely formed into one by means of the couplings 120 and 122 in the same way as in the front-back direction actuation blocks 70, whereby one shaft-shaped member 125 is built. The ball screw 86, the joint member 124, and the ball screw 106 are joined together in such a way that their axial lines are aligned to each other. The shaft-shaped members 125 of the front-back direction actuation blocks 71 correspond to “ball screws for second front-back direction actuation blocks” and “second space holding means” referred to in the claims. The configuration of the front-back direction actuation blocks 71 except the motors 84 and 104 and the movable members 87 and 107 (i.e., the bracket 72, the ball screws 86 and 106, the couplings 120 and 122, and the joint member 124) makes up a “support 71A that supports the second actuation block (the motors 84 and 104) and that supports the third movable member (the movable member 87) and the fourth movable member (the movable member 107) so as to be movable in the front-back direction.”
The two front-back direction actuation blocks 70 and the two front-back direction actuation blocks 71 are placed in parallel with each other. The ball screws 86 and 106 of the respective front-back direction actuation blocks 70 and the ball screws 86 and 106 of the respective front-back direction actuation blocks 71 are placed in parallel with each other. The movable members 87 and 107 of the front-back direction actuation blocks 70 and 71 are disposed so as to be movable in the front-back direction.
The front-back direction actuation blocks 71 placed along the short side 56 are supported by the movable members 137 (to be exact, the support members 139) of the right-left direction actuation blocks 130 placed in correspondence with the respective openings 36a. The front-back direction actuation blocks 71 placed along the short side 58 are supported by the movable members 137 (to be exact, the support members 139) of the right-left direction actuation blocks 130 placed in correspondence with the respective openings 36b.
The right-left direction actuation blocks 130 are structurally analogous to the ball screw mechanism blocks 80 and 100 except that the ball screws 136 do not protrude from respective upright portions 132c and that the movable members 137 structurally differ from the movable members 87 and 107. Specifically, each of the right-left direction actuation blocks 130 has a bracket 132 secured to the upper surface of the bed 20, a motor 134 (a third actuation block), the ball screw 136 (a fifth ball screw) that is supported by the bracket 132 in a rotatable fashion and that is connected at one end to the motor 134 and rotated by the motor 134, and the movable member 137 (a fifth movable member) that is screw-engaged with the ball screw in a screwable manner as a result of rotation of the ball screw 136. The bracket 132 and the motor 134 are structurally analogous to the bracket 82 and the motor 84. The bracket 132 has a horizontal member 132a, which includes a plate-like portion 132a-1 and a rail portion 132a-2, and upright portions 132b and 132c. A thread groove used for screw engagement with the movable member 137 is formed in a peripheral surface of the ball screw 136. An end of the ball screw 136 that is on the opposite side of the end facing the motor 134 does not to protrude from the upright portion 132c. Specifically, the movable member 137 (the fifth movable member) includes a nut 138 and the pair of support members 139 fastened to both sides of the nut 138. The nut 138 includes a nut body 138a screw-engaged with the ball screw 136 and a slider 138b secured to a lower surface of the nut body 138a. A groove to be engaged with the rail portion 132a-2 is provided on a lower surface side of the slider 138b, and the slider 138b performs sliding action along the rail portion 132a-2. The nut 138 is thereby configured so as to move along the ball screw 136 as a result of rotation of the ball screw 136. For instance, the movable member 137 is configured so as to move toward the motor 134 as the motor 134 rotates clockwise. In contrast, the movable member 137 is configured so as to move in a direction opposite to the motor 134 as the motor 134 rotates counterclockwise. However, the movable member can be actuated in reverse.
As shown in
The pair of right-left direction actuation blocks 130 are provided for each pair of openings including the opening 36a and the opening 36b. Three pairs of right-left direction actuation blocks 130 (a total of six right-left direction actuation blocks) are provided. The pair of right-left direction actuation blocks 130 corresponding to one pair of openings are provided so as to oppose each other (motors are respectively disposed at the outside of the pair of right-left direction actuation blocks 130 as shown in
The three right-left direction actuation blocks 130 provided in correspondence with the respective openings 36a are placed in parallel with each other. In connection with the front-back direction, the center right-left direction actuation block 130 of the three right-left direction actuation blocks 130 is placed at a substantially intermediate position of a front-back-oriented length of the front-back direction actuation block 70. The other two right-left direction actuation blocks 130 are substantially equidistant from the center right-left direction actuation block 130. The ball screws 136 of the right-left direction actuation blocks 130 (i.e., the right-left direction actuation blocks 130 located close to the short side 56) provided in correspondence with the respective openings 36a correspond to the fifth ball screws. Likewise, the three right-left direction actuation blocks 130 provided in correspondence with the respective openings 36b are placed in parallel with each other. In connection with the front-back direction, the center right-left direction actuation block 130 of the three right-left direction actuation blocks 130 is placed at a substantially intermediate position of the front-back-oriented length of the front-back direction actuation blocks 71. The other two right-left direction actuation blocks 130 are substantially equidistant from the center right-left direction actuation block 130. The ball screws 136 of the right-left direction actuation blocks 130 (i.e., the right-left direction actuation blocks 130 located close to the short side 58) provided in correspondence with the respective openings 36b correspond to sixth ball screws. Either the right-left direction actuation block 130 provided in correspondence with the opening 36a or the right-left direction actuation block 130 provided in correspondence with the opening 36b serves as a first right-left direction actuation block, and a remaining right-left direction actuation block serves as a second right-left direction actuation block. The motor 134 of the first right-left direction actuation block serves as a fifth motor, whilst the motor 134 of the second right-left direction actuation block serves as a sixth motor. In the fifteenth configuration, the motor 134 of the right-left direction actuation block 130 serves as the fifth motor.
As above, the front-back direction actuation block 71 is supported by means of the movable members 137 of the three right-left direction actuation blocks 130.
A direction of the ball screws 86 and 106 of the respective front-back direction actuation blocks 70 and 71 and a direction of the ball screws 136 of the respective right-left direction actuation blocks 130 are arranged at right angles to each other when viewed in plane.
The thread grooves formed in the respective peripheral surfaces of the ball screws 86, 106, and 136 making up the sewing frame actuation block 60 are formed at the same pitch in the same direction of rotation.
The control circuit 200 is a circuit for controlling operation of the motors 84, 104, and 134 of the sewing frame actuation block 60 and is connected to all of the motors in the sewing frame actuation block 60, thereby controlling operations of the respective motors. In relation to operation control of the motors 84 and 104 in the front-back direction actuation blocks 70 and 71, the control circuit 200 synchronously controls all of the motors 84 and 104 in the front-back direction actuation blocks 70 and 71. In particular, since the ball screws 86 and 106 are entirely formed integrally with the joint members 124, the motors 84 and 104 of one of the front-back direction actuation blocks 70 and 71 are synchronously controlled. Moreover, the respective motors 84 of the plurality of front-back direction actuation blocks 70 and 71 are also synchronously controlled, and the respective motors 104 of the plurality of front-back direction actuation blocks 70 and 71 are also synchronously controlled. Since the ball screws 86 and 106 are coupled together, the motor 84 and the motor 104 in each of the single the front-back direction actuation block 70 and the single front-back actuation 71 are controlled so as to rotate in opposite directions. Specifically, in each of the front-back direction actuation blocks 70, the motor 84 of the ball screw mechanism block 80 that actuates the long side 52 and the motor 104 of the ball screw mechanism block 100 that actuates the long side 54 are controlled so as to rotate in opposite directions. Likewise, even in each of the front-back direction actuation blocks 71, the motor 84 and the motor 104 are controlled so as to rotate in opposite directions. As mentioned above, in all of the plurality of front-back direction actuation blocks 70 and 71, operation of the motors 84 and 104 is controlled in such a way that the movable members 87 and 107 of the front-back direction actuation blocks 70 become equal to the movable members 87 and 107 of the front-back direction actuation blocks 71 in terms of a direction of movement and a movement distance.
Even in relation to operation control of the motors 134 of the right-left direction actuation blocks 130, the control circuit 200 synchronously controls all of the motors of the right-left direction actuation blocks 130. The motors 134 of the right-left direction actuation blocks 130 that actuate the front-back direction actuation blocks 71 connected to the short side 56 and the motors 134 of the right-left direction actuation blocks 130 that actuate the front-back direction actuation blocks 71 connected to the short side 58 are controlled so as to rotate in opposite directions. Operation of the motors 134 is controlled such that the movable members 137 in the respective right-left direction actuation blocks 130 become equal to each other in terms of a direction of movement and a movement distance.
In reality, the control circuit 200 has a storage device that stores programs for controlling operation of the motors, a CPU that controls the motors according to the programs stored in the storage device, and others.
Operation of the sewing machine 5 having the foregoing configuration is now described. While the sewing frame 50 is being actuated in the front-back direction and the right-left direction with processed fabric stretched across the sewing frame 50, the processed fabric is sewn (in particular, embroidered) by means of cooperative operation between a needle that is provided in the sewing head 22 and vertically actuated and the shuttle to be rotatively actuated.
In order to stretch the processed fabric across the sewing frame 50, the fabric is nipped between the projection 59b and the cap portion 59c.
In the sewing machine 5, the sewing frame 50 is actuated in both the front-back direction and the right-left direction under control of the control circuit 200. Specifically, the motors 84 and 104 of the front-back direction actuation blocks 70 and 71 are operated under control of the control circuit 200. As the motors 84 and 104 are driven, the ball screws 86 and 106 are rotated. As the ball screws 86 and 106 rotate, the movable members 87 and 107 move. Specifically, in each of the front-back direction actuation blocks 70, the movable member 87 moves in the front-back direction along the ball screw 86 and the rail portion 82a-2, and the movable member 107 moves in the front-back direction along the ball screw 106 and the rail portion 102a-2. In each of the front-back direction actuation blocks 71, the movable member 87 moves in the front-back direction along the ball screw 86 and the rail portion 72a-2, and the movable member 107 moves in the front-back direction along the ball screw 106 and the rail portion 72a-3. Further, under control of the control circuit 200, the motors 134 of the respective right-left direction actuation blocks 130 are driven. As the motors 134 are driven, the ball screws 136 rotate. Further, as the ball screws 136 rotate, the movable members 137 move in the right-left direction.
In each of the front-back direction actuation blocks 70, the engagement roller 92 supported by the nut 88 by way of the shaft portion 90 comes into engagement with the long side 52 of the sewing frame 50. Further, the engagement roller 112 supported by the nut 108 by way of the shaft portion 110 comes into engagement with the long side 54 of the sewing frame 50. Further, in each of the front-back direction actuation blocks 71, the movable members 87 and 107 are connected to the sewing frame 50 by way of the respective connection members 49. Therefore, the sewing frame 50 moves in the front-back direction as the movable members 87 and 107 are actuated. Further, the movable members 137 of the respective right-left direction actuation blocks 130 are fastened to the brackets 72 of the front-back direction actuation blocks 71. As the movable members 137 move, the sewing frame 50 moves in the right-left direction. On that occasion, the engagement rollers 92 engaged with the long side 52 slide along the groove M of the long side 52 with which the engagement rollers 92 remain in engagement, whereby the engagement rollers 112 engaged with the long side 54 slide along the groove M of the long side 54 with which the engagement rollers 112 remain in engagement.
In the sewing machine 5 of the present embodiment, all of the four sides of the sewing frame 50 are supported by means of the movable members (i.e., the pair of long sides 52 and 54 are supported by means of the movable members 87 and 107 of the front-back direction actuation block 70, and the pair of short sides 56 and 58 are supported by means of the movable members 87 and 107 of the front-back direction actuation block 71), whereby all of the sides of the sewing frame 50 are provided with the actuation mechanisms. Therefore, distortion of the sewing frame 50 can be minimized, and the sewing frame can be positioned with high accuracy.
Further, all of the sides of the sewing frame are provided with the actuation mechanisms, and all of the sides of the sewing frame are actively positioned, thereby preventing distortion of the sewing frame, which would otherwise occur even when the processed fabric is pulled inside by means of tensile force of the processed fabric developing during sewing operation. Since the ball screw generally exhibits high rigidity, the rigidity of the shaft-shaped member built from the ball screws 86 and 106 and the joint member 124 can also be enhanced despite the tensile force developing during sewing operation. A potential of occurrence of deflection in the shaft-shaped member is small.
In particular, in each of the front-back direction actuation blocks 70 supporting the long sides 52 and 54 of the sewing frame 50 and the front-back direction actuation blocks 71 supporting the short sides 56 and 58, the ball screw 86 and the ball screw 106 are built into one by way of the joint member 124. Therefore, even when an attempt is made to move the nut (the movable member in the front-back direction actuation block 71) against force of the motor as a result of distortion (in particular, inner distortion) of the sewing frame 50, a ball screw screw-engaged with the nut (the movable member) is configured integrally with the other ball screw. Hence, the nut is prevented from moving against the force of the motor. Specifically, when the processed fabric is pulled inside as the fabric is sewn, the long sides 52 and 54 of the sewing frame 50 are also pulled inside. However, if the ball screws 86 and 106 are not integrally formed by means of the joint member 124, the nuts 88 and 108 (the movable members 87 and 107 of the front-back direction actuation block 71) will rotate the ball screws 86 and 106 against force of the motor, which may move the nuts 88 and 108 (the movable members 87 and 107). In the present embodiment, when the long sides 52 and 54 are pulled inside, both the nuts 88 and 108 attempt to move inside. However, rotation of the ball screw 86 which will arise when the nut 88 attempts to move inside and rotation of the ball screw 106 which will arise when the nut 108 attempts to move inside are opposite in direction to each other. Therefore, the nut 88 and the nut 108 will not move inside. Even in the front-back direction actuation block 71, when the long sides 52 and 54 are pulled inside, both the movable member 87 and the movable member 107 will attempt to move inside. However, rotation of the ball screw 86 which will arise when the movable member 87 attempts to move inside and rotation of the ball screw 106 which will arise when the movable member 107 attempts to move inside are opposite in direction to each other. Therefore, the movable member 87 and the movable member 107 will not move inside. Therefore, the potential of occurrence of distortion in the long sides 52 and 54 of the sewing frame 50 is extremely small.
In the front-back direction actuation block 70, only movements of the nut 88 (108) are restricted by means of the ball screw 86 (106) and the rail portion 82a-2 (102a-2). Therefore, smooth movement of the nuts 88 and 108 can be performed. Likewise, even in the front-back direction actuation block 71, only movements of the movable member 87 (107) are restricted by means of the ball screw 86 (106) and the rail portion 72a-2 (72a-3). Therefore, smooth movement of the movable members 87 and 107 can be performed. Specifically, in a case where the nut is equipped with a joint bar as described in connection with Patent Documents 3 and 4, movements of the nut will be restricted by the joint bar. Therefore, if a direction of the joint bar is not accurately in parallel with the ball screw, the nut cannot smoothly move. In the case of the present embodiment, since the nut is not equipped with the joint bar, the nut can smoothly move without being restricted in its movements by the joint bar.
In the front-back direction actuation block 70, the shaft-shaped member built from the ball screws 86 and 106 and the joint member 124 is axially supported by the upright portions 82c and 102c as well as by the upright portions 82b and 102b. Further, in the front-back direction actuation block 71, the shaft-shaped member built from the ball screws 86 and 106 and the joint member 124 is axially supported by the upright portions 72c and 72d as well as by the upright portions 72b and 72e. For these reasons, occurrence of deflection in the shaft-shaped members can be prevented.
In the present embodiment, the front-back direction actuation block 71 is connected to the short sides 56 and 58 and the front-back direction actuation block 71 is configured so as to be actuated in the right-left direction by means of the right-left direction actuation block 130. Occurrence of deflection of the short sides 56 and 58 can be prevented. Further, since occurrence of deflection of deflection of the short sides 56 and 58 can be prevented, occurrence of deflection of the long sides 52 and 54 can also be prevented. Specifically, consideration is given to a case where the front-back direction actuation blocks 71 are not provided; where the movable members 137 of the respective right-left direction actuation blocks 130 are structurally analogous to the movable members 87; and the engagement rollers engage with the short sides 56 and 58. In this case, longitudinal end areas of the sewing frame 50 (namely, the areas close to the short sides 56 and 58) are not supported by the front-back direction actuation blocks 70. Hence, when processed fabric is pulled inside as the fabric is sewn, the longitudinal end areas of the sewing frame 50 may be deflected inside with respect to the front-back direction. However, in the present embodiment, the front-back direction actuation blocks 71 are connected to the short sides 56 and 58, and the longitudinal end areas of the sewing frame 50 are supported by the front-back direction actuation block. Hence, the longitudinal end areas of the sewing frame 50 achieved in the longitudinal direction will not be deformed with respect to the front-back direction.
In the above descriptions, the front-back direction actuation blocks 70 and the front-back direction actuation blocks 71 have been described that each include the ball screw 86 and the ball screw 106 which are joined by means of the joint member 124. However, as shown in
Specifically, each of front-back direction actuation blocks 70′ shown in
Each of front-back direction actuation blocks 71′ shown in
The configuration of each of the front-back direction actuation blocks 70′ except the motors 84 and 104 and the movable members 87 and 107 makes up a support that supports the first actuation block (the motors 84 and 104) and that supports the first movable member and the second movable member so as to be movable in the front-back direction. The configuration (the bracket 82′ and the ball screw 86′) of each of the front-back 2Q direction actuation blocks 71′ except the motors 84 and 104 and the movable members 87 and 107 makes up a support 71A′ that supports the second actuation block (the motors 84 and 104) and that supports the third movable member (the movable member 87) and the fourth movable member (the movable member 107) so as to be movable in the front-back direction. In the embodiments shown in
In the above configuration, a single front-back direction actuation block 70 and a single front-back direction actuation block 71 each is provided with the two motors 84 and 104. One motor can also be provided for either end of the single front-back direction actuation block. Even in such a case, the front-back direction actuation blocks can actuate the sewing frame 50 in the front-back direction. However, when one motor is provided for either end of the single front-back direction actuation block, torque is given to the end of the ball screw connected to the motor in the shaft-shaped member or the ball screw that is built, by and large, from one ball screw, whereupon the shaft-shaped member (or the ball screw) rotates. Since the end of the ball screw opposite to its end connected to the motor is driven in a following manner, slight torsion occurs in the shaft-shaped member (or the ball screw). For this reason, there may arise a case where a slight lag will arise in response movement of the movable member situated at an opposite position on the shaft-shaped member with respect to its end connected to the motor. In this sense, it is preferable to provide motors at both ends of one front-back direction actuation block 70 as mentioned above.
In the above descriptions, the front-back direction actuation blocks 70 have been described as being provided in number of two, and the right-left direction actuation blocks 130 have also been described as being provided in number of three on either side of the table along its right-left direction. However, the essential requirement for the front-back direction actuation block 70 is to be provided in number of one or more (in number of three or more is also acceptable), and the essential requirement for the right-left direction actuation blocks 130 is to be provided in number of two or more.
In the sewing machine 5 of the present embodiment, the ball screw mechanisms have been described as being used for the front-back direction actuation blocks and the right-left direction actuation blocks that make up the sewing frame actuation block 60. However, the actuation blocks are not limited to the ball screw mechanisms. Timing belt mechanisms can also be used.
Specifically, in the sewing frame actuation block 60 of the sewing machine 5 of the present embodiment, front-back direction actuation blocks 140 (first front-back direction actuation blocks) shown in
As shown in
Each of the timing belt mechanism blocks 150 includes a substantially sleeve-shaped frame (a support frame) 152 attached to the upper surface of the bed 20; a support 154 attached to one end of the frame 152; a rotary pulley 156 rotatively attached to the support 154; a motor 158 (a first motor) attached to a side surface of the other end of the frame 152; a rotary pulley 160 attached to an output end of the motor 158; an endless timing belt 162 (a first timing belt); and a movable member 163 (a first movable member) that is fixedly attached to the timing belt 162 and that makes sliding action along a rail portion 152b of the frame 152.
As shown in
The motor 158 has a flange that can be attached to a side surface of the frame body 152a. A direction of a rotary shaft of the motor is orthogonal to the longitudinal direction of the frame 152. The rotary pulley 160 that is rotated by the motor 158 is also rotatable by way of an axial line orthogonal to the longitudinal direction of the frame 152 (i.e., the right-left direction). Cogs to engage with the timing belt 162 are formed on a peripheral surface of the rotary pulley 156 and a peripheral surface of the rotary pulley 160.
One end of the timing belt 162 is passed around the rotary pulley 156, and the other end of the same is passed around the rotary pulley 160. An upper side of the timing belt is situated above the frame 152. Further, a lower side of the timing belt is situated in the insert hole 153 of the frame 152. In reality, the timing belt 162 is in the form of an endless belt formed by bringing both ends of a band-like belt into contact with each other. The timing belt is configured by inserting the belt into the insert hole 153 and fixedly nipping both ends of the thus-inserted belt by use of a belt nip plate 164b and a fixture 164c while both of the ends of the belt remain in contact with each other (contacted portions of both ends of the belt are at this time situated between the belt nip plate 164b and the fixture 164c). Cogs are formed on an interior side of the timing belt 162.
The movable member 163 has a movable member body 164, a shaft portion 166, and an engagement roller 168. The movable member body 164 has a substantially plate-like slider 164a, the belt nip plate 164b, and the fixture 164c. A groove to engage the rail portion 152b is formed in a lower surface of the slider 164a, and the slider 164a also slides along the rail portion 152b. The belt nip plate 164b assumes a substantially plate-like shape, and cogs to engage the cogs provided on an inner side of the timing belt 162 are formed on an upper surface of the belt nip plate 164b. A shallow groove in which the timing belt 162 is to be placed is formed in a lower surface of the fixture 164c. The fixture 164c nips the timing belt 162 along with the belt nip plate 164b, thereby fixing the timing belt. While the timing belt 162 is sandwiched between the fixture 164c and the belt nip plate 164b, the belt nip plate 164b is superimposed on an upper surface of the slider 164a. In this state, the slider, the belt nip plate, and the fixture are integrally secured with screws 165, whereby the movable member body 164 is formed. Holes used for insertion of the screws 165 are opened at four corners of the fixture 164c and four corners of the belt nip plate 164b. Screw holes by way of which the screws 165 are secured are opened at four corners of the slider 164a.
The shaft portion 166 is fixedly attached to an upper surface of the fixture 164c and inserted into the cutout 34a of the table 30 and the slit of the slit plate 38 with play; namely, allowance, to thus protrude from the upper surface of the table 30. The engagement roller 168 is axially attached to the shaft portion 166 so as to become rotatable and situated at an elevated position above the upper surface of the table 30.
The timing belt mechanism block 170 is structurally analogous to the timing belt mechanism block 150 and; hence, its detailed explanations are omitted here for brevity. Specifically, the timing belt mechanism block 170 has a substantially sleeve-shaped frame block (a support frame) 172 attached to the upper surface of the bed 20; a support 174 attached to one end of the frame 172; a rotary pulley 176 attached to the support 174 in a rotatable fashion; a motor 178 (a second motor) attached to a side surface of the other end of the frame 172; a rotary pulley 180 attached to an output end of the motor 178; an endless timing belt 182 (a second timing belt); and a movable member 183 (a second movable member) that is fixedly attached to the timing belt 182 and that slides along a rail portion of the frame 172.
The frame 172, the support 174, the rotary pulley 176, the motor 178, the rotary pulley 180, the timing belt 182, and the movable member 183 are structurally analogous to respective portions of the timing belt mechanism block 150; namely, the frame 152, the support 154, the rotary pulley 156, the motor 158, the rotary pulley 160, the timing belt 162, and the movable member 163.
Specifically, the movable member 183 has a movable member body 184, a shaft portion 186, and an engagement roller 188. The movable member body 184 has a slider 184a that is structurally same to the slider 164a, a belt nip plate 184b that is structurally same to the belt nip plate 164b, and a fixture 184c that is structurally same to the fixture 164c. While the timing belt 182 is sandwiched between the fixture 184c and the belt nip plate 184b, the belt nip plate 184b is superimposed on an upper surface of the slider 184a and integrally secured with screws, whereby the movable member body 184 is formed. The shaft portion 186 is structurally same to the shaft portion 166, and the engagement roller 188 is structurally same to the engagement roller 168. The movable member 183 is spaced apart from the movable member 163. The motor 158 and the motor 178 belonging to each of the front-back direction actuation blocks 140 make up the first actuation block referred to in the claims.
The joint member 190 assumes a substantially rod-like shape and is fixedly interposed between the movable member 163 and the movable member 183. One end of the joint member 190 is fixed to the fixture 164c of the movable member 163, and the other end of the same is fixed to the fixture 184c of the movable member 183. The joint member 190 of each of the front-back direction actuation blocks 140 corresponds to “first space holding means” referred to in the claims. The configuration of each of the front-back direction actuation blocks 140 except the motors 158 and 178 and the movable members 163 and 183 acts as a support that supports a first actuation block (the motors 158 and 178) and also supports the first movable member (the movable member 163) and the second movable member (the movable member 183) so as to be movable in the front-back direction. In the timing belt mechanism block 150, the frame 152, the support 154, and the rotary pulleys 156 and 160 serve as a support that supports the first actuation block (the motor 158) and also supports the first movable member so as to be movable in the front-back direction. In the timing belt mechanism block 170, the frame 172, the support 174, and the rotary pulleys 176 and 180 serve as a support that supports the first actuation block (the motor 178) and also supports the second movable member so as to be movable in the front-back direction.
In each of the front-back direction actuation blocks 140, the timing belt 162 of the timing belt mechanism block 150 and the timing belt 182 of the timing belt mechanism block 170 are aligned to each other along the front-back direction. The movement path of the movable member 163 that is made up of upper part of the timing belt 162, lies in the extension of the movement path of the movable member 183 that is made up of upper part of the timing belt 182. The joint member 190 is set in alignment with the direction (front-back direction) of the timing belts 162 and 182.
The plurality of front-back direction actuation blocks 140 are aligned in parallel with each other in the front-back direction. In the plurality of front-back direction actuation blocks 140, the movable members 163 and 183 are configured so as to move in parallel with each other. The plurality of front-back direction actuation blocks 140 are structurally equal to each other in terms of a configuration.
The front-back direction actuation blocks 141 used in place of the front-back direction actuation blocks 71 are structurally, substantially same to the front-back direction actuation blocks 140 in
A bottom portion 152a-1 (see
The movable member 163 of the front-back direction actuation block 141 is built from the slider 164a, the belt nip plate 164b, and the fixture 164c (i.e., the movable member 163 corresponds to the movable member body 164 in the timing belt mechanism block 150). The connection members 49 are attached to respective side surfaces of the movable members 163 (in particular, the side surfaces of the fixtures 164c of the movable members 163) facing the sewing frame 50. The movable members 163 are secured to the respective short sides 56 and 58 of the sewing frame 50 by way of the connection members 49. Specifically, the vertical members 49b of the respective connection members 49 are secured to the movable members 163 (in particular, the fixtures 164c of the movable members 163). Further, the horizontal members 49a are fixed to the short sides 56 and 58 of the sewing frame 50, whereby the movable members 163 and the sewing frame 50 are connected to each other. Likewise, the movable member 183 is built from the slider 184a, the belt nip plate 184b, and the fixture 184c (i.e., the movable member 183 corresponds to the movable member body 184 of the timing belt mechanism block 170). The connection members 49 are attached to side surfaces of each of the movable members 183 (in particular, side surfaces of the fixture 184c of each of the movable members 183) facing the sewing frame 50, and the movable members 183 are fixed to the short sides 56 and 58 of the sewing frame 50 by way of the connection members 49. Specifically, the vertical members 49b of the respective connection members 49 are secured to the respective movable members 183 (in particular, the fixtures 184c of the respective movable members 183). Further, the horizontal members 49a are fixed to the short sides 56 and 58 of the sewing frame 50, whereby the movable members 183 and the sewing frame 50 are connected together. As mentioned above, the front-back direction actuation blocks 141 are placed substantially flush with the sewing frame 50 in much the same way as the front-back direction actuation blocks 71. In
A configuration of each of the front-back direction actuation blocks 141 except the motors 158 and 178 and the movable members 163 and 183 (i.e., the frame 151, the supports 154 and 174, the rotary pulleys 156, 160, 176, and 180, the timing belts 162 and 182, and the joint member 190) makes up a “support 141A that supports a second actuation block (the motors 158 and 178) and also supports a third movable member (the movable member 163) and a fourth movable member (the movable member 183) so as to be movable in the front-back direction”. The timing belt 162 of the front-back direction actuation block 141 corresponds to a third timing belt, and the timing belt 182 of the front-back direction actuation block 141 corresponds to a fourth timing belt. Further, the motor 158 of the front-back direction actuation block 141 corresponds to a third motor, and the motor 178 of the front-back direction actuation block 141 corresponds to a fourth motor. The movable member 163 of the front-back direction actuation block 141 corresponds to the third movable member, and the movable member 183 of the front-back direction actuation block 141 corresponds to the fourth movable member. The frame 151, the support 154, the rotary pulley 156, the rotary pulley 160, the support 174, the rotary pulley 176, and the rotary pulley 180 make up a “support that supports the third motor and the fourth motor and also supports the third timing belt and the fourth timing belt in a revolving manner”. The motors 158 and 178 of the front-back direction actuation block 141 make up the second actuation block referred to in the claims. The joint member 190 in each of the front-back direction actuation blocks 141 corresponds to the “second space holding means” referred to in the claims.
The right-left direction actuation blocks 195 used in place of the right-left direction actuation blocks 130 are substantially similar, in structure, to the timing belt mechanism blocks 150 shown in
Specifically, each of the right-left direction actuation blocks 195 includes a substantially sleeve-shaped frame 195-2 attached to the upper surface of the bed 20; a support 195-4 attached to one end of the frame 195-2; a rotary pulley 195-6 rotatively attached to the support 195-4; a motor 195-8 (a third actuation block) attached to a side surface of the other end of the frame 195-2; a rotary pulley 195-10 attached to an output end of the motor 195-8; an endless timing belt 195-12 (a third timing belt); and a movable member 195-13 (a third movable member) that is fixedly secured to the timing belt 195-12 and that slides along a rail of the frame 195-2.
The frame 195-2, the support 195-4, the rotary pulley 195-6, the motor 195-8, the rotary pulley 195-10, and the timing belt 195-12 are structurally same to their counterparts of the timing belt mechanism block 150; namely, the frame 152, the support 154, the rotary pulley 156, the motor 158, the rotary pulley 160, and the timing belt 162.
The pair of right-left direction actuation blocks 195 corresponding to the pair of openings (the pair consisting of the opening 36a and the opening 36b) are placed so as to oppose each other. In the mutually-opposed right-left direction actuation blocks 195, one timing belt 195-12 is configured so as to lie in an extension of the other timing belt 195-12. The right-left direction actuation block 195 is provided in number of three on either side of the table along its right-left direction. The three right-left direction actuation blocks 195 are placed in parallel with each other. In the three right-left direction actuation blocks 195, the movable members 195-13 are configured so as to move in parallel with each other.
Each of the movable members 195-13 is made up of a movable member body 195-13a and the pair of support members 139. Specifically, the vertical members 139a of the respective L-shaped plate-like support members 139 are attached to both sides of the movable member body 195-13a. The movable member body 195-13a is structurally same to the movable member 163 in the front-back direction actuation block 141, and the vertical member 139a of the support member 139 is attached to either side of the movable member body 195-13a [in particular, either side of a fixture (the fixture structurally same to the fixture 164c)]. The horizontal members 139b of the support members 139 are secured to a lower surface of the plate-like portion 151a of the front-back direction actuation block 141.
The movable member 195-13 of the right-left direction actuation block 195 corresponds to a fifth movable member. The timing belt 195-12 of the right-left direction actuation block 195 provided in correspondence with the opening 36a (i.e., the right-left direction actuation block 195 disposed along the short side 56) corresponds to a fifth timing belt. Further, the timing belt 195-12 of the right-left direction actuation block 195 disposed in correspondence with the opening 36b (i.e., the right-left direction actuation block 195 disposed along the short side 58) corresponds to a sixth timing belt. Either the right-left direction actuation block 195 disposed in correspondence with the opening 36a or the right-left direction actuation block 195 disposed in correspondence with the opening 36b serves as a first right-left direction actuation block, and a remaining one serves as a second right-left direction actuation block. The motor 195-8 of the first right-left direction actuation block corresponds to a fifth motor, and the motor 195-8 of the second right-left direction actuation block corresponds to a sixth motor. In the foregoing sixteenth configuration, the motor 195-8 of the right-left direction actuation block 195 corresponds to the fifth motor.
When viewed in plane, a direction of the timing belts 162 and 182 of the respective front-back direction actuation blocks 140 and 141 is oriented at right angles to a direction of the timing belts 195-12 of the respective right-left direction actuation blocks 195.
The engagement roller 168 of the timing belt mechanism block 150 in each of the front-back direction actuation blocks 140 engages with the groove M of the long side 52 of the sewing frame 50. The engagement roller 188 of the timing belt mechanism block 170 engages with the groove M of the long side 54 of the sewing frame 50.
Cogs formed on the inner side of each of the timing belts 162, 182, and 195-12 that make up the sewing frame actuation block 60 are formed at the same pitch.
As above, even when the timing belt mechanism is used, the front-back direction actuation block 140 is disposed in number of two on either side of the table along its front-back direction, and the right-left direction actuation block 195 is disposed in number of three on either side of the table along its right-left direction. When the front-back direction actuation blocks and the right-left direction actuation blocks of the sewing frame actuation block 60 are made up of timing belt mechanisms as shown in
The control circuit 200 controls operation of the motors 158, 178, and 195-8 of the sewing frame actuation block 60. The control circuit 200 is connected to all of the motors in the sewing frame actuation block 60 and controls operation of the respective motors. Specifically, in relation to operation control of the motors 158 and 178 of the front-back direction actuation blocks 140 and 141, the control circuit 200 performs synchronous control of all of the motors 158 and 178 of the respective front-back direction actuation blocks 140 and 141. In particular, since the movable member 163 and the movable member 183 are joined together by means of the joint member 190, the motors 158 and 178 belonging to any one of the front-back direction actuation blocks 140 and 141 are synchronously controlled. The respective motors 158 in the plurality of front-back direction actuation blocks 140 and the plurality of front-back direction actuation blocks 141 are also synchronously controlled. Likewise, the respective motors 178 in the plurality of front-back direction actuation blocks 140 and the plurality of front-back direction actuation blocks 141 are synchronously controlled. Since the movable member 163 and the movable member 183 are joined together by means of the joint member 190 (see
Even in relation to operation control of the motors 195-8 of the respective right-left direction actuation blocks 195, the control circuit 200 synchronously controls all of the motors of the right-left direction actuation blocks 195. Incidentally, the motors 195-8 of the right-left direction actuation blocks 195 that actuate the front-back direction actuation blocks 141 connected to the short side 56 and the motors 195-8 of the right-left direction actuation blocks 195 that actuate the front-back direction actuation blocks 141 connected to the short side 58 are controlled so as to rotate in opposite directions. Specifically, operation of the motors 195-8 is controlled in such a way that the movable members 195-13 of the respective right-left direction actuation blocks 195 become equal to each other in terms of a direction of movement and a movement distance.
In reality, the control circuit 200 has a storage device that stores programs for controlling operation of the motors, a CPU that controls the motors according to the programs stored in the storage device, and others.
An explanation is now given to operation of the sewing machine accomplished when the front-back direction actuation blocks and the right-left direction actuation blocks, which make up the sewing frame actuation block 60, are built from the timing belt mechanisms as shown in
The sewing frame 50 is actuated in both the front-back direction and the right-left direction under control of the control circuit 200. Specifically, the motors 158 and 178 of the front-back direction actuation blocks 140 and 141 are operated under control of the control circuit 200. As the motors 158 and 178 are driven, the timing belts 162 and 182 revolve. As the timing belts 162 and 182 revolve, the movable members 163 and 183 move. Specifically, the movable members 163 and 183 move in the front-back direction. Moreover, under control of the control circuit 200, the motors 195-8 in the respective front-back direction actuation blocks 195 are operated. As the motors 195-8 are driven, the timing belts 195-12 revolve, whereupon the movable members 195-13 move in the right-left direction.
In each of the front-back direction actuation blocks 140, the engagement roller 168 engages with the long side 52 of the sewing frame 50, and the engagement roller 188 engages with the long side 54 of the sewing frame 50. Further, in each of the front-back direction actuation blocks 141, the movable members 163 and 183 are connected to the sewing frame 50 by way of the connection members 49. Hence, the sewing frame 50 moves in the front-back direction as the movable members 163 and 183 move. Furthermore, the movable member 195-13 in each of the right-left direction actuation blocks 195 is secured to the frame 151 of the corresponding front-back direction actuation block 141. Hence, as the movable members 195-13 move, the sewing frame 50 moves in the right-left direction.
Even when the front-back direction actuation blocks and the right-left direction actuation blocks that make up the sewing frame actuation block 60 are built from the timing belt mechanisms as shown in
All of the sides of the sewing frame are provided with the drive mechanisms and all of the sides of the sewing frame are actively positioned, thereby preventing distortion of the sewing frame, which would otherwise occur even when the processed fabric is pulled inside by means of tensile force of the processed fabric developing during sewing operation.
In particular, in each of the front-back direction actuation blocks 140 supporting the long sides 52 and 54 of the sewing frame 50 and each of the front-back direction actuation blocks 141 supporting the short sides 56 and 58 of the same, the movable members 163 and 183 are integrally formed by way of the joint member 190. Therefore, even when the movable members attempt to move against the force of the motors as a result of occurrence of distortion (in particular, inward distortion) in the sewing frame 50, the joint members 190 regulate movements of the movable members, so that the movable members will not move against the force of the motors. Namely, when processed fabric is pulled inside as the fabric is sewn, the long sides 52 and 54 of the sewing frame 50 are also pulled inside, and both the movable members 163 and 183 are pulled inside, too. Since the movable members 163 and 183 are secured to the joint member 190, they will not move inside. Accordingly, the potential of occurrence of distortion in the long sides 52 and 54 of the sewing frame 50 is extremely small.
In the present embodiment, the respective front-back direction actuation blocks 141 are connected to the short sides 56 and 58, and the respective front-back direction actuation blocks 141 are configured so as to be actuated in the right-left direction by means of the right-left direction actuation blocks 195. Occurrence of deflection of the short sides 56 and 58 can be prevented. Further, since occurrence of deflection of the short sides 56 and 58 can be prevented, occurrence of deflection of the long sides 52 and 54 can also be prevented. Specifically, consideration is given to a case where the front-back direction actuation blocks 141 are not provided; where the movable members 195-13 of the respective right-left direction actuation blocks 195 are structurally analogous to the movable members 163 of the respective front-back direction actuation blocks 140; and the engagement rollers engage with the short sides 56 and 58. In this case, longitudinal end areas of the sewing frame 50 (namely, the areas close to the short sides 56 and 58) are not supported by the front-back direction actuation blocks 140. Hence, when processed fabric is pulled inside as the fabric is sewn, the longitudinal end areas of the sewing frame 50 may be deflected inside with respect to the front-back direction. However, in the present embodiment, the front-back direction actuation blocks 141 are connected to the short sides 56 and 58, and the longitudinal end areas of the sewing frame 50 are supported by the front-back direction actuation blocks. Therefore, the longitudinal end areas of the sewing frame 50 will not be deflected in the front-back direction.
In the above descriptions, each of the front-back direction actuation blocks 140 and the front-back direction actuation blocks 141 is built from two timing belt mechanism blocks. However, each of the front-back direction actuation blocks can also be built from one timing belt mechanism block, and two movable members can be fixedly spaced apart from each other on the one timing belt (a timing belt for a second front-back direction actuation block). A joint member (a joint member having a configuration same to that of the joint member 190) can also be interposed between the two movable members. In this case, the number of motors used for actuating the timing belt comes to one. Alternatively, the motor can also be disposed on either side of the timing belt.
For instance, when each of the front-back direction actuation blocks 141 is built from one timing belt mechanism block, the front-back direction actuation block is configured as shown in
For instance, when each of the front-back direction actuation blocks 140 is made up of one timing belt mechanism block, the actuation block is configured as shown in
In the above descriptions, each of the front-back direction actuation blocks 70 is made up of the ball screw mechanism blocks 80 and 100, and each of the front-back direction actuation blocks 71 is made up of the ball screws 86 and 106. In this case, each of the right-left direction actuation blocks 130 is made up of the ball screw 136. However, each of the right-left direction actuation blocks can also be made up of the right-left direction actuation block 195 formed from the timing belt mechanism in lieu of the right-left direction actuation block 130. In the above descriptions, each of the front-back direction actuation blocks 140 is made up of the timing belt mechanism blocks 150 and 170, and each of the front-back direction actuation blocks 141 is made up of the timing belts 162 and 182. In this case, each of the right-left direction actuation blocks 195 is also made up of the timing belt 195-12. However, each of the right-left direction actuation blocks can also be made up of the right-left direction actuation block 130 (see
In the above descriptions, the ball screws 86, 106, 136, 86′, 286, 306, and 336 can also be given a designation “ball screw shaft” or a “ball screw spindle.”
In the above descriptions, the front-back direction actuation block 140 has been described as being provided in number of two on either side of the table, and the right-left direction actuation block 195 has been described as being provided in number of three on either side of the table along its right-left direction. However, the essential requirement for the front-back direction actuation block 140 is to be provided in number of one or more (in number of three or more is also acceptable), and the essential requirement for the right-left direction actuation blocks 195 is to be provided in number of two or more.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-215779 | Sep 2009 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2010/065330 | 9/7/2010 | WO | 00 | 3/16/2012 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2011/033969 | 3/24/2011 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4627369 | Conrad et al. | Dec 1986 | A |
| 5333561 | Katou | Aug 1994 | A |
| 6263815 | Furudate | Jul 2001 | B1 |
| 6293214 | Tajima | Sep 2001 | B1 |
| 20090173261 | Tajima | Jul 2009 | A1 |
| Number | Date | Country |
|---|---|---|
| 02005065959 | Mar 2005 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20120167810 A1 | Jul 2012 | US |
