This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application Nos. 2020-166554, filed on Sep. 30, 2020, and 2021-126096, filed on Jul. 30, 2021, in the Japan Patent Office, the entire disclosure of each of which is incorporated by reference herein.
Embodiments of the present disclosure relate to a liquid application unit for a linear medium, a liquid application apparatus, a dyeing embroidery system, a control method, and a storage medium.
In recent years, there has been known a technique of an in-line type dyeing embroidery apparatus that dyes (colors) a thread in a preceding stage of an embroidery unit.
A technology of controlling an embroidery apparatus, for example, performs embroidery using a continuous upper thread whose color changes such that a color change point of the upper thread is not exposed on the surface of the embroidery. In the technology, embroidery data is created for performing embroidery such that the color change point of the upper thread whose color changes is not visible from the upper side.
However, as a property of the thread, when the thread for dyeing is drawn out from a supplier such as a bobbin, a winding curl and the rotation speed of the thread vary depending on the outer diameter (outer winding diameter) of the remaining amount of the thread on the bobbin. If the strength of the winding curl of the thread is different, the amount of elongation of the thread toward the downstream side changes when the winding curl is released.
According to an embodiment of the present disclosure, there is provided a liquid application unit that includes a supply member, a liquid application device, and an application controller. The supply member includes a cylindrical or columnar winding core around which a linear medium is wound. The liquid application device applies liquid to the linear medium unwound and fed from the supply member. The application controller adjusts a liquid application length of the liquid applied by the liquid application unit to the linear medium in a feed direction of the linear medium. The application controller adjusts the liquid application length in the feed direction of the linear medium in accordance with a winding thickness of a remaining amount of the linear medium from an outer peripheral surface of the winding core.
According to another embodiment of the present disclosure, there is provided a control method for a liquid application apparatus that includes: a supply member including a cylindrical or columnar winding core around which a linear medium is wound; and a liquid application device to apply liquid to the linear medium unwound and fed from the supply member. The control method includes: detecting or calculating a winding thickness of a remaining amount of the linear medium from an outer peripheral surface of the winding core; adjusting a liquid application length of the liquid applied by the liquid application device to the linear medium in a feed direction of the linear medium in accordance with the winding thickness of the remaining amount of the linear medium; and applying, by the liquid application device, the liquid to the linear medium being ted at the liquid application length adjusted in the feed direction.
According to still another embodiment of the present disclosure, there is provided a non-transitory computer-readable storage medium storing program code for causing an information processing apparatus to execute control of a liquid application apparatus that includes: a supply member including a cylindrical or columnar winding core around which a linear medium is wound; and a liquid application device configured to apply liquid to the linear medium unwound and fed from the supply member. The control includes: detecting or calculating a winding thickness of a remaining amount of the linear medium from an outer peripheral surface of the winding core; adjusting a liquid application length of the liquid applied by the liquid application device to the linear medium in a feed direction of the linear medium in accordance with the winding thickness of the remaining amount of the linear medium; and applying, by the liquid application device, the liquid to the linear medium being fed at the liquid application length adjusted in the feed direction.
The aforementioned and other aspects, features, and advantages of the present disclosure would be better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted.
In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner and achieve similar results.
Although the embodiments are described with technical limitations with reference to the attached drawings, such description is not intended to limit the scope of the disclosure and all of the components or elements described in the embodiments of this disclosure are not necessarily indispensable.
Hereinafter, embodiments of the present disclosure are described with reference to the drawings. In the following drawings, the same components are denoted by the same reference numerals, and redundant description may be omitted.
First, a dyeing embroidery apparatus including a liquid application unit according to a first embodiment of the present disclosure is described with reference to
Referring to
The liquid application unit 100 serving as a dyeing unit includes a supply member 102 around which an upper thread 101 is wound, a liquid application device 103, a fixing device 104, and a post-processing device 105. The liquid application unit 100 according to the present embodiment is a dyeing unit that dyes a thread by a liquid discharge method.
The embroidery unit 110 includes a lower thread bobbin 112 around which a lower thread 111 is wound, an embroidery head 113 to which the upper thread 101 is fed, and an embroidery table 114. In the embroidery unit 110, the embroidery head 113 controls the movement (hand movement) of a needle N through which the upper thread 101 passes, to perform embroidery on a cloth C using the lower thread 111 fed in response to the feed of the upper thread 101.
In the liquid application unit 100, a thread 101 drawn out from the supply member (also referred to as an upper thread spool or supplier) 102 is guided by a roller 108 and a roller 109 and continuously routed to the embroidery head 113.
The liquid application device 103 includes a maintenance unit 35 including a plurality of liquid discharge heads 30K, 30C, 30M, and 30Y and a plurality of individual maintenance units 36K, 36C, 36M, and 36Y. The plurality of liquid discharge heads 30K, 30C, 30M, and 30Y (also collectively referred to as liquid discharge heads 30) discharge and apply liquids (dyeing liquids) of different colors to the thread 101 drawn out from the supply member 102 and fed. The plurality of individual maintenance units 36K, 36C, 36M, and 36Y (also collectively referred to as individual maintenance units 36) perform maintenance of the liquid discharge heads 30K, 30C, 30M, and 30Y.
Hereinafter, the direction in which the thread is fed from the liquid application device 103 to the embroidery unit 110 is referred to as X, the depth direction of the dyeing embroidery apparatus 1 (or the width direction of the thread is referred to as Y, and the height direction (vertical direction) is referred to as Z.
With reference to
The maintenance units 36K, 36C, 36M, and 36Y respectively, are disposed below the liquid discharge heads 30K, 30C, 30M, and 30Y of the respective colors. As a maintenance recovery operation, the maintenance units 36K, 36C, 36M, and 36Y for example, cap the liquid discharge heads 30K, 30C, 30M, and 30Y when the liquid discharge heads 30K, 30C, 30M, and 30Y are not in use, receive dummy discharge of liquid droplets from the liquid discharge heads 30K, 30C, 30M, and 30Y, perform suction circulating operation of the nozzles in a state in which a dummy discharge receptacle is close to the heads, and perform a wiping operation of the nozzles.
Here, as illustrated in
In
With reference to
The post-processing device 105 includes, for example, a cleaner that cleans the thread 101, a tension adjuster that adjusts the tension of the thread 101, a feed amount detector that detects the amount of movement of the thread 101, and a lubricant applicator that lubricates the surface of the thread 101.
A liquid application unit 100 serving as a dyeing unit according to an embodiment of the present embodiment includes at least the liquid application device 103 that applies colored liquid to the thread 101. The fixing device 104 and the post-processing device 105 may not be included.
In the embroidery unit 110, the embroidery head 113 is an embroidery device that embroiders a pattern on a cloth C using the upper thread 101 and the lower thread 111.
In the present embodiment, the dyeing embroidery apparatus is described as an example of the liquid application apparatus. However, a liquid application apparatus according to an embodiment of the present disclosure is not limited to the dyeing embroidery apparatus and may be, for example, an apparatus using a linear medium such as a thread, for example, an apparatus such as a loom or a sewing machine.
Also note that the term “thread” includes glass fiber thread; wool thread; cotton thread; synthetic fiber thread; metallic thread; mixed thread of wool, cotton, polymer, or metal; and linear object (linear member or continuous material) to which yarn, filament, or liquid is applied. The term “thread” also includes braided cord and flatly braided cord.
Examples of the linear medium that can be dyed with liquid according to an embodiment of the present disclosure include, in addition to the above-described linear member, a belt-shaped member (continuous base material) to which liquid can be applied, such as a rope, a cable, or a cord. Any linear medium is a medium that has a narrow width and is continuous in the feed direction.
Winding thickness of remaining amount of thread of supplier and winding curl of thread and elongation of thread
Here, with reference to
Parts (a) and (b) of
As illustrated in parts (a) and (b) of
As illustrated in part (a) of
Accordingly, in a state where the thread is wound around the winding core 21 before use, the thread located at a position where the winding outer diameter R is smaller is more strongly curled or twisted to maintain the shape.
Thus, when the remaining amount of the thread is large, as illustrated in part (b) of
As described above, when the thread is supplied from the supply member 102 which is a bobbin, the strength of the winding curl of the supplied thread changes depending on the winding outer diameter R that is the outer diameter of the outermost thread. The larger the winding outer diameter R, that is, the thicker the winding thickness T of the remaining thread amount, the weaker the winding curl of the thread. On the other hand, the smaller the winding outer diameter R and the smaller the winding thickness T of the remaining amount of the thread, the stronger the winding curl of the thread. When the strength of the winding curl of the thread changes, the amount of elongation when the thread is pulled after being unwound also changes.
When the strength of the winding curl of the thread changes due to the decrease in the winding outer diameter R of the thread before dyeing in the supply member 102 due to the consumption of the thread, the amount of elongation when the thread is pulled after being unwound also changes. In the process in which the thread is fed and supplied to the embroidery unit 110 via the liquid application device 103 serving as a dyeing section, the behavior of the thread changes due to the difference in the strength of the winding curl of the thread. When the winding curl is weak, the elongation amount of the thread on the downstream side is small. On the other hand, when the winding curl is strong, the thread is elongated downstream.
To be more specific, as illustrated in
Therefore, in the present embodiment, in consideration of the difference in the characteristics of the winding curl of the thread in the supplier, the dyeing length of the thread at the time of dyeing is changed in accordance with the winding outer diameter R of the thread before the thread is supplied in the supply member 102, that is, in accordance with the winding thickness T of the remaining thread amount. Such a configuration prevents the positional deviation of color in the embroidery unit 110 in the subsequent stage.
Here, the elongation of the thread due to the elongation of the winding curl of the thread is likely to be longer as the feed distance is longer. As illustrated in
Specifically, when the inter-unit distance is short, the amount of change in the length of elongation due to a decrease in the winding thickness of the remaining amount of thread in the supply member 102 decreases. When the inter-unit distance is long, the amount of change in the length of elongation due to a decrease in the winding thickness of the remaining amount of thread increases. Therefore, it is preferable that the correction value according to the winding thickness in the correlation table is set for each head. As illustrated in
In the case of setting the correction calculation formula as well, in consideration of the difference in the inter-unit distances, the change rate of the correction value according to the winding thickness is larger for the head on the more upstream side (for example, the liquid discharge head 30K) where the inter-unit distance from the embroidery head 113 is longer, and the change rate of the correction value according to the winding thickness is smaller for the head on the more downstream side (for example, the liquid discharge head 30Y). In the dyeing data in each head using the correction value calculated from the correction calculation formula, when the embroidery head 113 on the downstream side requires the dyeing region having the same length, the correction formula is set for the dyeing length such that the dyeing length of the head on the more upstream side is shorter (30K≤30C≤30M≤30Y) in consideration of the elongation on the downstream side.
As illustrated in
In
As a premise for executing the correction of the dyeing length described above, the winding thickness of the remaining thread amount in the supply member 102 is acquired. As a method of acquiring the winding thickness of the remaining thread amount, for example, there are direct acquisition by detection with a sensor and indirect acquisition by calculation with a calculation formula.
An optical sensor 25 illustrated in
An ultrasonic sensor 26 illustrated in
In the contact sensor 27 illustrated in
The computing mechanism 400 is a main controller of the dyeing embroidery apparatus 1 and is implemented by, for example, an information processing apparatus (computer) such as a central processing unit (CPU).
The head driver 39 drives the liquid discharge heads 30Y, 30M, 30C, and 30K to discharge ink droplets from the nozzles so as to dye the thread at the dyeing length set based on the dyeing data output from the computing mechanism 400.
The embroidery unit 110 is provided with an embroidery-apparatus computing mechanism for executing an embroidery operation based on embroidery data.
Details of the computing mechanism 400 are described with reference to
The computing mechanism 400 includes an input unit 41, an initial-dyeing-data creation unit 42, a correction-value correlation-data storage unit 43, a dyeing-length correction-value setting unit 44, and a dyeing-data adjusting unit 45.
The input unit 41 is, for example, a communication unit with an external device and receives an embroidery image. The input unit 41 may be an operation panel or the like. In the case of the operation panel, embroidery data is directly input by an operation of an operator. The embroidery image is image data (embroidery design data) serving as an original of an embroidery pattern on a cloth.
The initial-dyeing-data creation unit 42 processes the embroidery image to create initial dyeing data used in the liquid application unit 100 serving as the dyeing unit and embroidery data used in the embroidery unit 110. The input unit 41 and the initial-dyeing-data creation unit 42 may not be provided inside the dyeing embroidery apparatus 1, and the functions of the input unit 41 and the initial-dyeing-data creation unit 42 may be executed by an external control apparatus (information processing apparatus).
Here, the embroidery data is “data obtained by combining data of coordinates at which the needle is moved and items to be executed at the coordinates”. Specifically, the items to be executed at the coordinates include: (1) the needle is inserted into the cloth to catch the upper thread, the needle is returned to the surface of the cloth, and then the needle is moved to the next position to be inserted; (2) the embroidery is ended or interrupted (including switching to another needle and cutting the thread to move to a distant place where the embroidery is not continuous); and (3) the needle is moved to the initialization position (alignment position). As a file of embroidery data, formats such as “.dst” and “.pes” are generally known.
The correction-value correlation-data storage unit 43 stores in advance the correlation table illustrated in
At this time, the correlation data stored by the correction-value correlation-data storage unit 43 as described above is preferably for each head. At this time, the correlation data is set such that the amount of change in the correction value increases as the head is disposed on the more upstream side in the feed direction and decreases as the head is disposed on the more downstream side in the teed direction, so as to align the length of dyeing in the embroidery unit 110 in consideration of the difference in elongation of the thread due to the extension of the winding curl.
The dyeing-length correction-value setting unit 44 sets the correction value of the dyeing length based on the winding thickness of the remaining thread amount in the supply member 102 detected by the sensor 25 serving as the detector and the correlation table or the correction calculation formula stored in the correction-value correlation-data storage unit 43.
The dyeing-data adjusting unit 45 generates dyeing data in which the dyeing length is corrected by multiplying the dyeing length in the dyeing data (initial dyeing data) generated by the initial-dyeing-data creation unit 42 by the correction value set by the dyeing-length correction-value setting unit 44, and outputs the generated dyeing data to the head driver 39.
In the adjustment of the dyeing data, the dyeing-data adjusting unit 45 adjusts the change amount of the correction value to be larger, that is, the dyeing length (liquid application length) in the feed direction on the thread to be shorter for the head disposed on the more upstream side in the feed direction, and adjusts the dyeing length (body application length) in the feed direction on the thread to be longer for the head disposed on the more downstream side in the feed direction.
In addition to the configuration of
The winding-thickness-and-usage-amount correlation-data storage unit 46 stores in advance correlation data of a correlation table or a correlation calculation formula regarding the total of the dyeing lengths of all colors in the dyeing data and how much the winding thickness of the remaining thread amount in the supply member 102 changes depending on the thread used for dyeing at the dyeing length.
The previous-data storage unit 47 stores the winding thickness of the remaining thread amount at the previous calculation and the previous dyeing data.
The winding-thickness calculation unit 48 calculates the thread usage amount in the previous use from the previous dyeing data stored in the previous-data storage unit 47 and subtracts the calculated thread usage amount from the winding thickness of the remaining thread amount in the previous calculation, to calculate the winding thickness of the current remaining thread amount.
The dyeing-length correction-value setting unit 44α sets the correction value of the dyeing length for each head based on the winding thickness of the remaining thread amount calculated by the winding-thickness calculation unit 48 and the correlation table or the correction calculation formula stored in the correction-value correlation-data storage unit 43.
The dyeing-data adjusting unit 45α multiplies the dyeing length in the initial dyeing data, which is created by the initial-dyeing-data creation unit 42, by the correction value set by the dyeing-length correction-value setting unit 44α to create dyeing data in which the initial dyeing data has been corrected, and outputs the created dyeing data to the head driver 39.
First, in step S11 of
In step S12, the initial-dyeing-data creation unit 42 of the computing mechanism 400 creates initial dyeing data and embroidery data based on the embroidery image.
In step S13, the sensor 25 (or the sensor 26 or 27) measures the winding thickness that is the remaining amount of the thread in the supply member 102. As illustrated in
In step S14, the dyeing-length correction-value setting unit 44 (44α) of the computing mechanism 400 calls the correlation table or the correction calculation formula, and sets the correction value according to the winding thickness of the remaining thread amount for each head.
The detection or calculation of the winding thicknesses of steps S13 and S14 and the setting of the correction value according to the winding thicknesses may be performed in parallel with step S12 or may be performed before step S12.
In step S15, the dyeing-data adjusting unit 45 of the computing mechanism 400 adjusts the dyeing length for each head by using the correction value set in step S14 for the initial dyeing data created in step S12, to create dyeing data.
In step S16, the feeding of the thread is started according to the embroidery, the dyeing of the thread is started based on the dyeing data, and the embroidery operation is started based on the embroidery data using the dyed thread.
In step S17, the dyeing operation is terminated, the feeding of the thread is stopped, and the embroidery operation is terminated when the embroidery data ends.
As described above, in the dyeing embroidery apparatus 1 according to the present embodiment, the dyeing length (liquid application length) in the dyeing data is adjusted in accordance with the winding thickness of the remaining thread amount at which the characteristic of the winding curl of the thread (linear medium) in the supply member 102 changes. Such a configuration can restrain the occurrence of the applied position shift (color shift) in the embroidery head 113 on the downstream side in the feed direction due to the difference in the strength of the winding curl of the thread (linear medium) in the supply member 102, and enhance the embroidery quality in the embroidery unit 110.
In the first control example illustrated in
In the flow of
When a predetermined time of step S206 elapses (YES in step S207 of
In step S209, when the winding thickness of the remaining thread amount acquired in step S208 has changed by a predetermined value or more with respect to the winding thickness of the remaining thread amount previously acquired in step S203, the process proceeds to step S210. The dyeing-length correction-value setting unit 44 (44α) of the computing mechanism 400 calls a correlation table or a correction calculation formula and sets a correction value corresponding to the winding thickness of the remaining thread amount.
In step S211, the dyeing-data adjusting unit 45 (45α) of the computing mechanism 400 adjusts the dyeing length of the initial dyeing data created in step S202 by using correction values set in step S210.
In step S212, dyeing is performed with the dyeing data readjusted in step S211. Note that it is preferable that the re-adjustment (switching) of dyeing data in step S212 be performed in a period in which the dyeing operation is not performed for the color.
On the other hand, in a case where the winding thickness of the remaining thread amount acquired in step S209 has changed at the predetermined value or less from the winding thickness previously acquired in step S202, the process proceeds to step S213. When the predetermined time elapses again, the process returns to step S208.
When the re-adjustment of the dyeing data is performed in step S212, the process proceeds to the S213, and returns to the S208 after the predetermined time elapses again. On the other hand, if the predetermined time has not elapsed after the readjustment of the dyeing data in step S212, the dyeing operation is continued until the end of the dyeing data in step S214.
When the dyeing operation is completed in step S214, the dyeing operation and the thread feeding operation are terminated in step S215. Then, the embroidery operation is terminated with the end of the embroidery data. In the present flow, an example in which the winding thickness of the remaining thread amount is acquired at every predetermined time has been described. However, the winding thickness may be acquired at all times, and the dyeing length may be readjusted at any time during a period in which there is no dyeing data.
In this control, the winding thickness of the remaining thread amount is also acquired during the dyeing operation, and the adjustment of the dyeing length according to the winding thickness of the remaining thread amount is performed in real time during the dyeing operation so as to offset the difference in the elongation of the thread due to the difference in the winding curl. Such control is effective, for example, when the amount of embroidery is large and the remaining amount of thread in the supply member 102 changes greatly.
The liquid applicator 60K of the coating type according to the present embodiment includes, for example, a vessel 61 in which colored liquid CL is accommodated, a squeeze roller 62, a coating roller 63, and a pressure roller 64.
In this configuration, the colored liquid CL is drawn up by the rotation of the squeeze roller 62 driven by a motor. The colored liquid CL drawn up by the squeeze roller 62 is partially scraped off by a nip between the squeeze roller 62 and the coating roller 63 whose periphery is covered with an elastic body such as rubber, and the remaining colored liquid CL is thinly and uniformly spread on the coating roller 63. The colored liquid CL spread by the coating roller 63 is applied to a thread 101 sandwiched at a coating nip formed by the pressure roller 64 and the coating roller 63.
In the liquid applicator 60K, the pressure roller 64 is movable in the vertical direction. As illustrated in
On the other hand, as illustrated in
In the present embodiment, in a case where the dyeing length on the thread is adjusted, a period in which the coating nip is formed by sandwiching the thread 101 is adjusted by adjusting the lifting and lowering of the pressure roller 64. As illustrated in
In the dyeing embroidery apparatus 1A according to the present embodiment having such a configuration, the dyeing length (liquid application length) in the dyeing data is adjusted according to the winding thickness of the remaining amount of thread in the supply member 102. Such a configuration can restrain the occurrence of the application position shift (color shift) in the embroidery head 113 on the downstream side in the feed direction, which is due to the difference in the strength of the winding curl of the thread (linear medium) in the supply member 102, and enhance the embroidery quality in the embroidery unit 110.
The configuration of the pretreatment-liquid applicator 107 is substantially the same as the configuration of the liquid applicator 60 of the coating type illustrated in
In step S32, initial pretreatment-liquid application data is created in accordance with initial dyeing data when the initial dyeing data is created based on embroidery data.
In step S34, the initial dyeing data and the initial pretreatment-liquid application data are corrected with the correction value set based on the winding thickness in step S34, and the dyeing data including adjusted dyeing length and the pretreatment-liquid application data including adjusted application length are created. Since the pretreatment-liquid applicator 107 is positioned further upstream than the most-upstream liquid discharge head 30K, the rate of change of the correction value is set to be larger than that of the most-upstream liquid discharge head 30K. Therefore, when the pretreatment liquid is applied with the same length as the dyeing length, the adjusted application length is set to be shorter than the dyeing length of each color.
Thereafter, the pretreatment-liquid application operation is performed using the pretreatment-liquid application data, the dyeing operation is performed using the dyeing data, and the embroidery operation is started based on the embroidery data using the dyed thread (Step S35). When the dyeing data is finished (step S36), the dyeing and feeding operations are finished in step S37. Then, the embroidering operation is finished.
In
With such a configuration, in the dyeing embroidery apparatus 1B according to the present embodiment, the dyeing length (liquid application length) and the application length of the pretreatment liquid in the dyeing data is adjusted according to the winding thickness of the remaining amount of thread in the supply member 102. Such a configuration can restrain the occurrence of the application position shift (color shift) in the embroidery head 113 on the downstream side in the feed direction, which is due to the difference in characteristic of the strength of the winding curl of the thread (linear medium) in the supply member 102, and enhance the embroidery quality in the embroidery unit 110.
As illustrated in
However, in the present embodiment, since the dyeing apparatus 2 and the embroidery apparatus 3 are surrounded by separate housings, the inter-apparatus distance D between the dyeing apparatus 2 and the embroidery apparatus 3 changes according to the layout of the apparatuses. When the layout of the inter-apparatus distance D is changed, the inter-unit distance dd between the liquid application device 103 serving as the dyeing section and the embroidery head 303 is also changed. When the distance dd changes, the feed distance of the dyed thread also changes. As the feed distance of the thread increases, the difference in elongation in the downstream direction due to the difference in winding outer diameter at the time of winding the thread increases.
Therefore, in the present embodiment, the dyeing length is adjusted in consideration of the inter-unit distance dd corresponding to the inter-apparatus distance D between the dyeing apparatus 2 and the embroidery apparatus 3, which varies depending on the layout of the apparatuses.
The control apparatus 4 includes an input unit 401 and an initial-dyeing-data creation unit 402. The control apparatus 4 is, for example, an information processing apparatus (personal computer or PC). The inter-apparatus distance D is input to the input unit 401 together with the embroidery data. The input unit 401 is an operation unit or a communication unit capable of communicating with another apparatus via a network such as the Internet.
The dyeing apparatus 2 is different from the above-described embodiment in that the dyeing data is adjusted in consideration of the inter-apparatus distance in the calculation mechanism 240. The calculation mechanism 240 includes a distance information calculation unit 49 and calculates the inter-unit distance dd from the inter-apparatus distance D.
The distance-based correlation-data storage unit 43β stores correlation data corresponding to the inter-unit distance dd. The correlation data is a plurality of correction calculation formulas or a plurality of correlation tables.
In the control according to the present embodiment in consideration of the inter-apparatus distance, the liquid discharge heads 30K, 30C, 30M, and 30Y are arranged in the feed direction in the liquid application device 103 and the distances from the liquid discharge heads 30K, 30C, 30M, and 30Y to the embroidery head 303 are different from each other. Therefore, it is preferable to set the correction value corresponding to the winding thickness in the correction calculation formula for each of the liquid discharge heads 30K, 30C, 30M, and 30Y. The dyeing-data adjusting unit 45b outputs the dyeing-data corrected according to the inter-unit distance dd and the winding thickness to the head driver 39 of each of the liquid discharge heads 30K, 30C, 30M, and 30Y.
In the case of setting the correlation table, similarly, numerical values are stored in advance so that when the inter-apparatus distance is short, the amount of change in the correction value due to the decrease in the winding thickness is small, and when the inter-apparatus distance is long, the amount of change in the correction value due to the decrease in the winding thickness is large.
The embroidery apparatus 3 includes an embroidery-apparatus computing mechanism 310 that is a controller, and a needle driver 330 that drives a needle. The embroidery-data-and-stitch-data creating unit 311 in the embroidery-apparatus computing mechanism 310 acquires an embroidery image and initial dyeing data created by the initial-dyeing-data creation unit 402, and creates the embroidery data and the stitch data. The stitch data is data only for needle drop, which instructs the needle driver 330 for driving the needle N as to where to drop (stick) the needle next.
In step S42, the initial dyeing data and the embroidery data are created in the same manner as in step S12.
After the winding thickness of the remaining amount of the thread in the supply member 102 is measured or calculated in step S43, a correlation table or a correction calculation formula corresponding to the inter-apparatus distance (or inter-unit distance) is called to set a correction value in step S44. Steps S43 and S44 may be performed in parallel with step S42 or may be performed before step S42.
In step S45, the dyeing length in the initial dyeing data is adjusted with the correction value calculated in consideration of the inter-apparatus distance (or inter-unit distance). Thus, dyeing data including adjusted dyeing length is created.
Thereafter, the dyeing operation and the feeding operation are performed based on the dyeing data, and the embroidery operation is performed based on the embroidery data by using the dyed upper thread (step S46). The dyeing operation and the conveying operation are finished when the dyeing data ends, and the embroidering operation is finished when the embroidery data ends (step S47).
In
With such a configuration and control, in the dyeing embroidery system 5 according to the present embodiment, the dyeing length (liquid application length) in the dyeing data is adjusted in accordance with the winding thickness of the remaining amount of the thread in the supply member 102. Such a configuration can restrain the occurrence of the application position shift (color shift) in the embroidery head 303 of the embroidery apparatus 3 on the downstream side in the feed direction, which is due to the difference in the winding curl of the thread (linear medium) in the supply member 102, and enhance the embroidering quality the embroidery apparatus 3.
Although some embodiments and examples of the present disclosure have been described above, embodiments of the present disclosure are not limited to the above-described embodiments and examples. Various modifications and enhancements are possible in light of the above teachings, without departing from the scope of the present disclosure.
Number | Date | Country | Kind |
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2020-166554 | Sep 2020 | JP | national |
2021-126096 | Jul 2021 | JP | national |