This application claims priority from JP2011-245417, filed on Nov. 9, 2011, the content of which is hereby incorporated by reference.
The present disclosure relates to a sewing machine that performs positioning between a plurality of patterns using images of markers arranged on a sewing target object held by an embroidery frame, and to a non-transitory computer-readable storage medium storing a sewing machine control program.
Generally, a sewing machine capable of embroidery sewing performs embroidery sewing in a sewable area, using an embroidery frame that holds a sewing target object. The sewable area is set inside the embroidery frame in accordance with a type of the embroidery frame. In this type of sewing machine, an embroidery pattern that is larger than the sewable area is divided into a plurality of patterns that are smaller than the sewable area, and sewing data corresponding to the plurality of patterns is stored. This sewing machine sequentially sews the plurality of divided patterns in accordance with the sewing data, thereby sewing the embroidery pattern that is larger than the sewable area. Every time one of the plurality of divided patterns is sewn, a user reattaches a work cloth, which is the sewing target object, with respect to the embroidery frame. The sewing machine is provided with an image capturing device, and captures images of markers arranged on a surface of the work cloth, before and after the reattachment of the work cloth. Then, based on these images of the markers, the sewing machine performs positioning between the plurality of patterns.
In order for the above-described sewing machine to accurately perform positioning between the plurality of patterns, it is necessary to arrange the markers on the work cloth within a range that satisfies a predetermined condition. However, when the markers are not arranged in appropriate positions (for example, when the user himself/herself does not recognize this condition, or when the user cannot identify the appropriate positions), the sewing machine cannot perform positioning between the plurality of patterns based on the images of the markers.
The present disclosure allows a user to arrange markers in appropriate positions when using a sewing machine that is capable of performing positioning between a plurality of patterns based on images of the markers.
A sewing machine according to a first aspect of the present disclosure includes an imaging device that captures an image of a sewing target object held by an embroidery frame, a notification device that notifies a predetermined position, a processor, and a memory that stores instructions. The processor acquires settings related to a layout of a second pattern with respect to a first pattern. The first pattern is a pattern that is sewn in a first holding position of the sewing target object by the embroidery frame. The second pattern is a pattern that is sewn subsequently to the first pattern in a second holding position is a second holding position of the sewing target object by the embroidery frame. The second holding position is different from the first holding position. Based on the acquired settings, the processor identifies, as a marker layout position, a position which is located within a sewable area of the sewing target object in the first holding position and which is also located within an estimated range in which the second pattern is to be sewn. The processor causes the notification device to notify the identified marker layout position. The processor acquires first image data indicating an image including a marker arranged on the sewing target object, the image being captured by the imaging device in the first holding position after the marker layout position has been notified by the notification device. Further, the processor acquires second image data indicating an image including the marker, the image being captured by the imaging device in the second holding position after the first image data has been acquired. The processor determines a layout of the second pattern with respect to the sewing target object in the second holding position, based on the acquired settings, the first image data and the second image data.
A non-transitory computer-readable storage medium storing a sewing machine control program according to a second aspect of the present disclosure includes instructions that instruct a sewing machine to execute steps of acquiring settings related to a layout of a second pattern with respect to a first pattern. The first pattern is a pattern that is sewn in a first holding position of a sewing target object held by an embroidery frame. The second pattern is a pattern that is sewn subsequently to the first pattern in a second holding position of the sewing target object held by the embroidery frame. The second holding position is different from the first holding position. The instructions further instruct the sewing machine to execute steps including: identifying, based on the acquired settings, a position which is located within a sewable area of the sewing target object in the first holding position and which is also located within an estimated range in which the second pattern is to be sewn, as a marker layout position; causing a notification device to notify the identified marker layout position; acquiring first image data indicating an image including a marker arranged on the sewing target object, the image being captured by an imaging device in the first holding position after the marker layout position has been notified by the notification device; acquiring second image data indicating an image including the marker, the image being captured by the imaging device in the second holding position after the first image data has been acquired; and determining a layout of the second pattern with respect to the sewing target object in the second holding position, based on the acquired settings, the first image data and the second image data.
A sewing machine according to a third aspect of the present disclosure includes a processor and a memory that stores instructions. The processor acquires settings related to a layout of a second pattern with respect to a first pattern. The first pattern is a pattern that is sewn in a first holding position of a sewing target object held by an embroidery frame. The second pattern is a pattern that is sewn subsequently to the first pattern in a second holding position is a second holding position of the sewing target object held by the embroidery frame. The second holding position is different from the first holding position. Based on the acquired settings, the processor identifies, as a marker layout position, a position which is located within a sewable area of the sewing target object in the first holding position and which is also located within an estimated range in which the second pattern is to be sewn. The processor sends a notification instruction to a notification device. The notification instruction causes the notification device to notify the identified marker layout position. The processor acquires, after the notification instruction has been sent to the notification device, first image data indicating an image including a marker arranged on the sewing target object by sending a first imaging instruction to an imaging device in the first holding position. Further, the processor acquires, after the first image data has been acquired, second image data indicating an image including the marker by sending a second imaging instruction to the imaging device in the second holding position. The processor determines a layout of the second pattern with respect to the sewing target object in the second holding position, based on the acquired settings, the first image data and the second image data.
Exemplary embodiments of the invention will be described below in detail with reference to the accompanying drawings in which:
Hereinafter, an embodiment of the present disclosure will be explained with reference to the drawings. A configuration of a multi-needle sewing machine (hereinafter simply referred to as a sewing machine) 1 according to the embodiment will be explained with reference to
As shown in
A cover 38 is provided on a lower portion of a right side surface of the needle bar case 21. An image sensor holding mechanism (not shown in the drawings) is attached to the inner side of the cover 38. The image sensor holding mechanism is provided with an image sensor 50 (refer to
An operation portion 6 is provided on the right side of a central portion in the front-rear direction of the arm portion 4. The operation portion 6 is provided with a liquid crystal display (LCD) 7, a touch panel 8 and a start/stop switch 41. The LCD 7 may display various types of information, such as operation images used by a user to input a command, for example. The touch panel 8 may be used to receive a command from the user. The user can select or set various types of conditions, such as a sewing pattern and a sewing condition, by performing a pressing operation (this operation is hereinafter referred to as a “panel operation”), using a finger or a touch pen, on sections of the touch panel 8 that correspond to positions of input keys etc. displayed on the LCD 7. The start/stop switch 41 may be used to issue a command to start or stop sewing.
A cylinder-shaped cylinder bed 10, which extends to the front from a lower end portion of the pillar 3, is provided below the arm portion 4. A shuttle (not shown in the drawings) is provided inside a leading end portion of the cylinder bed 10. The shuttle houses a bobbin (not shown in the drawings) on which a bobbin thread (not shown in the drawings) is wound. A shuttle drive mechanism (not shown in the drawings) is provided inside the cylinder bed 10. The shuttle drive mechanism (not shown in the drawings) may rotatably drive the shuttle. A needle plate 16, having a rectangular shape in a plan view, is provided on an upper surface of the cylinder bed 10. The needle plate 16 is provided with a needle hole 36 through which the needle 35 (refer to
A pair of left and right thread spool bases 12 are provided on a back surface side of an upper surface of the arm portion 4. The number of thread spools 13 that can be mounted on the pair of the thread spool bases 12 is ten, which is the same as the number of the needle bars 31. A needle thread 15 is supplied from one of the thread spools 13 mounted on the thread spool bases 12. The needle thread 15 is supplied, via a thread guide 17, a tensioner 18, a thread take-up lever 19 and the like, to a needle hole (not shown in the drawings) of each of the needles 35 attached to the lower end of each of the needle bars 31.
A Y carriage 23 of an embroidery frame movement mechanism 11 (refer to
The embroidery frame 84 and the embroidery frame movement mechanism 11 will be explained with reference to
A sewable area 86 may be automatically set on the inner side of the inner frame 82 by a CPU 61 (refer to
The embroidery frame movement mechanism 11 is provided with a holder 24, an X carriage 22, an X-axis drive mechanism (not shown in the drawings), the Y carriage 23 and a Y-axis movement mechanism (not shown in the drawings). The holder 24 may detachably support the embroidery frame 84. The holder 24 is provided with a mounting portion 91, a right arm portion 92 and a left arm portion 93. The mounting portion 91 is a plate member having a rectangular shape in a plan view. The mounting portion 91 is longer in the left-right direction. The right arm portion 92 is a plate member extending in the front-rear direction. The right arm portion 92 is fixed to the right end of the mounting portion 91. The left arm portion 93 is a plate member extending in the front-rear direction. The left arm portion 93 is fixed to a left portion of the mounting portion 91 such that the position in the left-right direction with respect to the mounting portion 91 can be adjusted. The right arm portion 92 is engaged with the one of the coupling portions 89 of the embroidery frame 84 while the left arm portion 93 is engaged with the other of the coupling portions 89.
The X carriage 22 is a plate member and is longer in the left-right direction. A part of the X carriage 22 protrudes toward the front from the front face of the Y carriage 23. The mounting portion 91 of the holder 24 is attached to the X carriage 22. The X-axis drive mechanism (not shown in the drawings) is provided with a linear movement mechanism (not shown in the drawings). The linear movement mechanism is provided with a timing pulley (not shown in the drawings) and a timing belt (not shown in the drawings). The linear movement mechanism causes the X carriage 22 to move in the left-right direction (in the X-axis direction) using the X-axis motor 132 as a driving source.
The Y carriage 23 has a box shape and is longer in the left-right direction. The Y carriage 23 supports the X carriage 22 such that the X carriage 22 can move in the left-right direction. The Y-axis movement mechanism (not shown in the drawings) is provided with a pair of left and right movable objects (not shown in the drawings) and a linear movement mechanism (not shown in the drawings). The movable objects are connected to lower portions of the left and right ends of the Y carriage 23, and vertically pass through the guide grooves 25 (refer to
An electrical configuration of the sewing machine 1 will be explained with reference to
The needle drive portion 120 is provided with a drive shaft motor 122, drive circuits 121 and 123, and a needle bar case motor 45. The drive shaft motor 122 causes the needle bar 31 to reciprocate in the up-down direction. The drive circuit 121 may drive the drive shaft motor 122 in accordance with a control signal from the control portion 60. The needle bar case motor 45 causes the needle bar case 21 to move in the left-right direction. The drive circuit 123 may drive the needle bar case motor 45 in accordance with a control signal from the control portion 60.
The sewing target drive portion 130 is provided with the X-axis motor 132, drive circuits 131 and 133, and the Y-axis motor 134. The X-axis motor 132 may drive the embroidery frame movement mechanism 11 and thereby causes the embroidery frame 84 (refer to
The operation portion 6 is provided with the touch panel 8, a drive circuit 135, the LCD 7 and the start/stop switch 41. The drive circuit 135 may drive the LCD 7 in accordance with a control signal from the control portion 60.
The control portion 60 is provided with the CPU 61, a ROM 62, a RAM 63, an EEPROM 64 and an input/output (I/O) interface 66, and they are mutually connected by a signal line 65. The needle drive portion 120, the sewing target drive portion 130, the operation portion 6 and the image sensor 50 are respectively connected to the I/O interface 66.
The CPU 61 performs main control of the sewing machine 1. The CPU 61 performs various operations and processing that relate to sewing, in accordance with various programs stored in a program storage area (not shown in the drawings) of the ROM 62. Although not shown in the drawings, the ROM 62 is provided with a plurality of storage areas including the program storage area and a pattern storage area. Various programs to operate the sewing machine 1, including a main program, are stored in the program storage area. The main program is a program to perform main processing, which will be described later. Sewing data, which is data to sew a pattern (hereinafter also referred to as an “embroidery pattern”), is stored in the pattern storage area. The RAM 63 includes, if necessary, a storage area to store operation results etc. processed by the CPU 61. Various parameters for the sewing machine 1 to perform various types of processing are stored in the EEPROM 64. Further, each of the needle bars 31, and the color of the needle thread 15 that is supplied to the needle hole (not shown in the drawings) of each of the needles 35 attached to the lower end of each of the needle bars 31, are associated and stored in the EEPROM 64. The sewing data may be stored in the EEPROM 64.
Operations to form stitches on the sewing target object 39 held by the embroidery frame 84 will be explained with reference to
Sewing data of the present embodiment will be explained with reference to
As shown in
Coordinate data of the sewing data stored in the ROM 62 defines an initial layout of the embroidery pattern. The initial layout of the embroidery pattern is set such that a center point of the embroidery pattern matches the origin (the center point of the sewable area 86) of the embroidery coordinate system 100. The coordinate data of the sewing data is appropriately corrected when the layout of the embroidery pattern with respect to the sewing target object 39 is changed. In the present embodiment, the layout of the embroidery pattern with respect to the sewing target object 39 is set in accordance with the main processing, which will be described later. In the explanation below, the position of the embroidery pattern (more precisely, the center point of the embroidery pattern) and the angle of the embroidery pattern are set with respect to the sewing target object 39 held by the embroidery frame 84, using data represented by the embroidery coordinate system 100.
An image capturing range of the image sensor 50 (refer to
A marker 110 will be explained with reference to
A transparent adhesive is applied to a back surface of the base sheet 108. It is therefore possible to adhere the base sheet 108 onto the sewing target object 39. Normally, the base sheet 108 is adhered to a release paper (not shown in the drawings). The user peels the base sheet 108 from the release paper to uses the base sheet 108.
The main processing that is performed by the CPU 61 of the sewing machine 1 will be explained with reference to
The main processing shown in
In the main processing, first, a variable N is set to 1 and the set variable N is stored in the RAM 63 (step S1). The variable N is a variable to count the number of the patterns selected by the user. The variable N corresponds to a sewing order of the selected patterns. The CPU 61 stands by until an N-th pattern is selected (NO at step S2, step S2). At step S2, first, a selection screen 200 exemplified in
The size of the pattern display column 201 corresponds to the size of the sewable area 86 that is set in accordance with the attached embroidery frame 84. The up-down direction of the pattern display column 201 corresponds to the X-axis direction of the embroidery coordinate system 100. The left-right direction of the pattern display column 201 corresponds to the Y-axis direction of the embroidery coordinate system 100. In the pattern display column 201, a currently selected pattern is displayed together with a graphic that represents the range in which the currently selected pattern is sewn. In the present embodiment, the graphic that represents the range in which the pattern is sewn is shown by a rectangle 161. In a state in which the pattern is in an initial layout, the rectangle 161 that represents the range in which the pattern is sewn includes sides that are parallel in the left-right direction of the pattern display column 201, and sides that are parallel in the direction perpendicular to the up-down direction of the pattern display column 201. The size of the rectangle 161 and the attached embroidery frame 84, for example, are displayed in the pattern information column 202.
A plurality of patterns (the patterns 151 and 152, in the example of
In the initial processing, the variable N is 1 (YES at step S4). Therefore, the layout of the first pattern in the embroidery coordinate system 100 is determined (step S5). More specifically, the sewing data of the first pattern (the pattern 151) acquired at step S3 is edited based on a command from the user. The edited sewing data is corrected by a known method and the layout of the first pattern 151 with respect to the sewing target object 39 in the first holding position is determined. At step 5, first, an editing screen 210 exemplified in
The pattern editing column 213 includes various types of keys to command editing of the pattern, such as a group of movement keys 214 including eight direction keys, a ROTATE key 215 and the like. The user can command the pattern editing by selecting the keys displayed in the pattern editing column 213 through panel operations. For example, the user can move the pattern by a desired amount of movement from the initial layout by operating one of the eight direction keys included in the group of movement keys 214. By selecting the ROTATE key 215, the user can rotate the pattern by a desired angle from the initial layout, around the center point of the pattern on the displayed screen (not shown in the drawings). In addition, the user can also perform editing to change the size of the pattern, reverse the pattern and the like, via the editing screen 210. The commanded amount of movement and the rotation angle are also displayed in the pattern information column 212.
After editing the pattern, if the user selects a SEWING key 216 provided on the lower right side of the pattern editing column 213, editing content that has been commanded so far is ascertained, and the sewing data of the pattern is corrected by a known method and stored in the RAM 63. Then, a sewing screen 220 exemplified in
When the user confirms the edited pattern displayed in the pattern display column 221 of the sewing screen 220 and continuously performs sewing, the user inputs a sewing start command by depressing the start/stop switch 41 (refer to
When the sewing is completed, a message, an OK key and a CANCEL key are displayed (not shown in the drawings) overlapped on the command column 223 of the sewing screen 220. The message notifies the user that the sewing is completed, and inquires whether to sew the next pattern to be connected. When the user wants to sew an (N+1)-th pattern continuously to the N-th pattern for which the sewing is completed and the whole pattern including the N-th pattern and the (N+1)-th pattern does not fall within the sewable area 86, the user selects the OK key in order to perform pattern connection processing. On the other hand, when the CANCEL key is selected or the OK key is not selected for a predetermined time period (for five minutes, for example), it is determined that the pattern connection processing is not commanded (NO at step S9) and the main processing ends.
When the OK key is selected and it is determined that the pattern connection processing is commanded (YES at step S9), the variable N is incremented by 1 and the incremented variable N is stored in the RAM 63 (step S10). Further, although not shown in the drawings, the following two messages are displayed on the LCD 7 (step S11). One of the messages is a message that instructs the user not to change the holding position of the sewing target object 39 with respect to the embroidery frame 84, namely, not to remove the sewing target object 39 from the embroidery frame 84. The other message is a message that prompts the user to select the next pattern (the second pattern). The processing returns to step S2 and the selection screen 200 exemplified in
As shown in
A first reference is specified and accepted (step S32). The first reference is a reference relating to the first pattern. The first reference is used when a relative layout relationship between the first pattern and the second pattern is determined. At step S32, first, a first reference setting screen 240 exemplified in
The command column 243 includes a group of first specifying keys 244, a CANCEL key 245 and an OK key 246. Twelve first specifying keys included in the group of first specifying keys 244 are used to specify the above-described first reference. In the present embodiment, a combination of the first line segment 171 and the first point 172 is selected as the first reference. The combination corresponds to the key selected by the user from among the first specifying keys included in the group of first specifying keys 244. In the pattern display column 242, the first line segment 171 and the first point 172 corresponding to the selected first specifying key are displayed in an overlapping manner on the first pattern and the smallest rectangle 230A. In the example shown in
The CANCEL key 245 of the command column 243 is selected when redoing the specification of the first reference. The OK key 246 is selected when the specified first reference is confirmed. When the user specifies the first reference on the first reference setting screen 240 and confirms the first reference by selecting the OK key 246, the specified first reference is stored in the RAM 63. The layout of the first reference (the first line segment 171 and the first point 172) in the smallest rectangle 230A that corresponds to the first pattern can be identified based on the sewing data (the corrected sewing data, in a case where the first pattern has been edited and the sewing data has been corrected) of the first pattern. The layout of the first line segment 171 and the first point 172 identified by the coordinates of the embroidery coordinate system 100 is stored in the RAM 63.
A second reference is specified and accepted (step S33). The second reference is a reference relating to the second pattern. The second reference is used when the relative layout relationship between the first pattern and the second pattern is determined. At step S33, first, a second reference setting screen 250 exemplified in
The command column 253 includes a group of second specifying keys 254, a group of movement keys 257, a CANCEL key 255 and an OK key 256. Twelve second specifying keys included in the group of second specifying keys 254 are used to specify the above-described second reference. In the present embodiment, a combination of the second line segment 181 and the second point 182 is selected as the second reference. The combination corresponds to the key selected by the user from among the second specifying keys included in the group of second specifying keys 254. The pattern to be sewn next (the second pattern) is displayed in a central portion of the group of second specifying keys 254 that are arranged in a rectangular shape. In a case where the second pattern has been edited at step S31, the second pattern is displayed in a state in which the content of the editing is reflected. An X-axis direction key and a Y-axis direction key included in the group of movement keys 257 are respectively selected when the position of the second reference with respect to the first reference is to be moved in the X-axis direction and the Y-axis direction.
The first pattern, the smallest rectangle 230A, the second pattern, the smallest rectangle 230B and the second reference are displayed in the pattern display column 252. The first line segment 171 and the first point 172 are displayed in the smallest rectangle 230A in an overlapping manner. Based on the second reference specified using the second specifying key, the second pattern and the smallest rectangle 230B are arranged with respect to the first pattern and the smallest rectangle 230A. More specifically, as a general rule, the first pattern and the second pattern are arranged such that the extending direction of the first line segment 171 overlaps with the second line segment 181 and the first point 172 overlaps with the second point 182. When a command that causes the position of the second reference with respect to the first reference to move in the X-axis direction or the Y-axis direction is input using the group of movement keys 257, the second reference is moved in accordance with the specified amount of movement. In this case, the first pattern and the second pattern do not necessarily overlap with each other. In the example shown in
The CANCEL key 255 of the command column 253 is selected when redoing the specification of the second reference. The OK key 256 is selected when the specified second reference is confirmed. When the user specifies the second reference on the second reference setting screen 250 and confirms the second reference by selecting the OK key 256, the specified second reference is stored in the RAM 63. The layout of the second reference (the second line segment 181 and the second point 182) in the smallest rectangle 230B that corresponds to the second pattern can be identified based on the sewing data (the corrected sewing data, in a case where the second pattern has been edited and the sewing data has been corrected) of the second pattern. The layout of the second line segment 181 and the second point 182 identified by the coordinates of the embroidery coordinate system 100 is stored in the RAM 63 in association with the first reference identified at step S32. With the above processing, the layout relationship of the second pattern with respect to the first pattern is determined. At this time, the holding position of the sewing target object 39 by the embroidery frame 84 is the first holding position because the holding position has not been changed from the holding position set when the first pattern was sewn.
After the embroidery frame 84 is moved to the image capturing position and image capture of the vicinity of the needle hole 36 (refer to
In order to complete the change of the holding position from the first holding position to the second holding position by changing the holding position only once, it is desirable that the markers 110 can be arranged within the sewable area 86 in the first holding position and the markers 110 can also be arranged within the sewable area 86 in the second holding position. Therefore, in the present embodiment, positions which are within the sewable area 86 in the first holding position and which are also within an estimated range in which the second pattern is to be sewn are identified as the marker layout positions, based on the first reference and the second reference (the layout relationship of the second pattern with respect to the first pattern) specified at step S32 and step S33 and stored in the RAM 63. Since the sewable area 86 in the second holding position is set by the user, the position of the sewable area 86 varies and cannot be ascertained. On the other hand, the estimated range in which the second pattern is to be sewn is included in the sewable area 86 in the second holding position. Further, if the layout relationship of the second pattern with respect to the first pattern is determined, the position of the sewable area 86 does not vary. Therefore, in the present embodiment, the marker layout positions are identified in accordance with the above-described conditions (i.e., within the sewable area 86 in the first holding position and also within the estimated range in which the second pattern is to be sewn).
For example, a case will be explained in which the layout relationship between the pattern 151, which is the first pattern, and the pattern 152, which is the second pattern, has been determined as in the example shown in
Note that, depending on the layout relationship between the first pattern and the second pattern, there is a case in which the two areas 110A and 110B cannot be arranged within the sewable area 86A in the first holding position and also within the estimated range in which the second pattern is to be sewn (within the smallest rectangle 230B corresponding to the second pattern). For example, as shown in
When the markers 110 are arranged within the sewable area 86A in the first holding position based only on the first reference of the first pattern, without taking account of the estimated range in which the second pattern is to be sewn, the markers 110 can be arranged in rectangle areas 160A and 160B whose centers are both the ends of the first line segment 171, as shown in
Further, if a command to move the position of the second reference with respect to the first reference is input at step S33, depending on the layout relationship between the first pattern and the second pattern, there is a case in which the estimated range (the smallest rectangle 230B) in which the second pattern is to be sewn is not included within the sewable area 86A in the first holding position, as shown in
An explanation will be given using the example shown in
As described above, when the marker layout positions are identified at step S40, in order to perform positioning between the first pattern and the second pattern, processing is performed that detects, from images captured by the image sensor 50, the two markers 110 attached to the areas 110A and 110B, which are the above-described marker layout positions. First, based on the notification instruction from the CPU 61, the embroidery frame 84 is moved to a position in which one of the areas 110A and 110B (the area 110A, for example) falls within the image capturing range 180 (refer to
A composite image 273 and an OK key 276 are displayed in the marker position display column 272. The composite image 273 is an image obtained by adding a red rectangle 274 to the image of the vicinity of the needle hole 36 output from the image sensor 50. In the processing that detects the first marker 110, the red rectangle 274 is displayed in a position that corresponds to one (the area 110A) of the areas 110A and 110B indicating the marker layout positions, in the image of the vicinity of the needle hole 36. The size of the rectangle 274 is approximately 1.5 times the size of the marker 110. A message that prompts the user to select the OK key 276 is displayed in the message column 271 after the marker 110 is arranged in an inside area of the rectangle 274. While confirming the marker position display column 272, the user attaches the marker 110 to the inside of the rectangle 274. As long as the OK key 276 is not selected, the processing that updates and displays the composite image 273 using the image captured by the image sensor 50 is repeated (NO at step S42, step S41).
When the user confirms that the marker 110 is attached to the inside of the rectangle 274 and selects the OK key 246 (YES at step S42), the imaging instruction is sent from the CPU 61 to the image sensor 50. Based on the imaging instruction, the image data output from the image sensor 50 is acquired and stored in the RAM 63 (step S43). Next, processing is performed that detects the marker 110 from a section of the image corresponding to the inside of the rectangle 274 (step S44). At step S44, when the marker 110 is detected from the section of the image corresponding to the inside of the rectangle 274, coordinates of the embroidery coordinate system 100 for the first center point 111 and the second center point 112 included in the marker 110 are identified.
The detection of the marker 110 and the identification of the coordinates are performed using a known method. Specifically, two-dimensional coordinates in an image coordinate system, which is a coordinate system of the image captured by the image sensor 50, are calculated for the first center point 111 and the second center point 112 of the marker 110, using Hough conversion processing, for example. After that, the two-dimensional coordinates of the image coordinate system are converted to three-dimensional coordinates of the world coordinate system. As described above, in the present embodiment, the embroidery coordinate system and the world coordinate system are associated with each other. Therefore, coordinates of the embroidery coordinate system 100 are calculated based on the three-dimensional coordinates of the world coordinate system calculated by image processing.
When the marker 110 is not detected at step S44 (NO at step S45), a message that prompts the user to arrange the marker 110 in the rectangle 274 is displayed on the LCD 7 (step S46). The processing returns to step S41. When the marker 110 is detected (YES at step S45), it is determined whether the detected marker 110 is the second marker 110 (step S47). The sewing machine 1 of the present embodiment detects the two markers 110 that are attached to the positions corresponding to the areas 110A and 110B, and associates the layout of the markers 110 with the layout of the first reference in the first holding position. Therefore, when the detected marker 110 is the first marker 110 (NO at step S47), the control signal is output to the drive circuit 131 and the drive circuit 133 and the embroidery frame 84 is moved to a position to detect the second marker 110 (step S48). Specifically, the embroidery frame 84 is moved to a position where the other area (the area 110B) that is other than the area used in the processing for the first marker 110 falls within the image capturing range of the image sensor 50.
The processing returns to step S41 and processing to detect the second marker 110 is performed (step S41 to step S46). Note that, at step S41 of the processing for the second marker 110, the red rectangle 274 is displayed in a position corresponding to the area 110B. In a similar manner, when the second marker 110 is detected (YES at step S47), the layout of the markers 110 with respect to the first reference in the first holding position is identified based on coordinates of the detected two markers 110 and on coordinates of the first reference. The identified layout of the markers 110 is stored in the RAM 63 as a first marker layout (step S51).
The layout of the markers 110 includes at least one of the position and the angle of the markers 110. The sewing machine 1 of the present embodiment detects, as the layout of the markers 110, the position and the angle of the markers 110 based on coordinates of the embroidery coordinate system of the first center points 111 of the two markers 110. The position of the markers 110 is represented, for example, by the coordinates of the embroidery coordinate system of the first center point 111 of one of the two markers 110. The angle of the markers 110 is represented by an angle formed by the X-axis of the embroidery coordinate system and a vector directing from the first center point 111 of the one of the two markers 110 toward the first center point 111 of the other marker 110. A distinction between the two markers 110 is determined based on, for example, a relative position of the second center point 112 with respect to the first center point 111 in each of the markers 110. At step S51, the layout (the position and the angle) of the markers 110 is identified by associating the coordinates of the first center points 111 (refer to
In order to sew the next pattern (the second pattern), the LCD 7 displays a screen (not shown in the drawings) including a message and an OK key (step S52). The message prompts the user to change the holding position of the sewing target object 39 with respect to the embroidery frame 84. More specifically, the message instructs the user to remove the sewing target object 39 from the embroidery frame 84 and to re-attach the sewing target object 39. At this time, the change of the holding position is performed in a state in which the markers 110 are attached to the positions on the sewing target object 39 that correspond to the marker layout positions (the areas 110A and 110B shown in
When the reattachment processing is commanded by selecting the reattachment key (YES at step S53), the reattachment processing is performed (step S54,
As shown in
When the marker 110 is not detected (NO at step S74), the whole area inside the embroidery frame 84 is set as a detection target range and it is determined whether the processing is completed (step S75). When there is an area that has not been set as the detection target range (NO at step S75), the control signal is output to the drive circuits 131 and 133, and the embroidery frame 84 is moved to a position where the area that has not been set as the detection target range falls within the image capturing range of the image sensor 50 (step S76). The processing returns to step S72 and processing that detects the marker 110 from the image is performed. The inside area of the embroidery frame 84 is sequentially processed in this way. When the processing is completed for the whole area without detecting the marker 110 (YES at step S75), an error message informing that the two markers 110 cannot be detected is displayed on the LCD 7 (step S77). In this case, the user confirms whether the two markers 110 are located in the inside area of the embroidery frame 84. The processing returns to step S72 and the processing that detects the marker 110 from the image is performed.
When the marker 110 is detected (YES at step S74), it is determined whether the detected marker 110 is the second marker 110 (step S78). When the detected marker 110 is not the second marker 110 (NO at step S78), the processing proceeds to step S75. As described above, until the marker 110 is detected, the image is acquired in the inside area of the embroidery frame 84 by moving the embroidery frame 84, and processing that detects the second marker 110 is performed. When the processing is repeated and the second marker 110 is detected (YES at step S78), the processing proceeds to step S79. The layout of the markers 110 before reattachment (in the example shown in
For example, in the first holding position corresponding to the sewable area 86A shown in
Next, it is determined whether the value of the variable M is 2, namely, whether the detection processing has already been performed twice (step S81). When the value of the variable M is not 2 (NO at step S81), the variable M is incremented by 1 (step S82). Subsequently, second-time detection processing of the markers 110 in the temporary holding position is performed (step S83 to step S91). In order to change from the temporary holding position to the second holding position, this detection processing prompts the user to re-attach the markers 110 to appropriate positions, and detects the re-attached markers 110. The content of the processing is almost the same as the content of the detection processing (step S40 to step S48 of
First, at step S83, the marker layout positions are identified in the following manner. At step S79, the coordinates representing the markers 110 and the first reference (the first line segment 171 and the first point 172) have been identified in the embroidery coordinate system 100 in the temporary holding position. Therefore, based on the already determined layout relationship between the first pattern and the second pattern, the layout of the estimated range in which the second pattern is to be sewn can be identified in the temporary holding position. Positions which are located within the sewable area 86C of the temporary holding position and which are also located within the estimated range in which the second pattern is to be sewn are identified as the marker layout positions. In the example shown in
Then, in a similar manner to the processing at step S41 to step S48 (refer to
After the temporary marker layout has been updated (step S95), the processing returns to step S80. Since the second-time detection processing ends and the variable M has been set to 2 (YES at step S80), a message indicating that the layout of the markers 110 with respect to the first reference is updated and an OK key (not shown in the drawings) are displayed on the LCD 7 (step S96). When the OK key is selected, a message that prompts the user to change the holding position of the sewing target object 39 and an OK key (not shown in the drawings) are displayed on the LCD 7 (step S97).
After the message has been displayed, the user changes the holding position of the sewing target object 39 with respect to the embroidery frame 84 (refer to
The processing returns to step S53 after the holding position has been changed from the first holding position to the second holding position in accordance with the message displayed at step S52, or after the holding position has been changed to the second holding position via the temporary holding position in the reattachment processing. When the pattern layout key is selected at step S53 on the screen displayed on the LCD 7 (NO at step S53, yes at step S55), the second pattern layout processing is performed (step S56, refer to
As shown in
For example, as shown in
On the other hand, for example, let us consider a case in which the holding position is changed from the first holding position that corresponds to the sewable area 86A to the second holding position that corresponds to the sewable area 86B via the temporary holding position that corresponds to the sewable area 86C, as shown in
Next, based on the identified second marker layout and on the layout relationship of the second pattern with respect to the first pattern, the layout of the second pattern (the N-th pattern) with respect to the sewing target object 39 in the second holding position is determined (step S110). Further, at step S110, the sewing data of the N-th pattern is corrected based on the determined layout. Further, the determined layout (not shown in the drawings) of the N-th pattern is displayed on the LCD 7. After that, a message “Please remove the markers” (not shown in the drawings) is displayed on the LCD 7 (step S111). This completes the second pattern layout processing shown in
As shown in
As explained above, according to the sewing machine 1 of the present embodiment, the first pattern is sewn in a state in which the holding position of the sewing target object 39 by the embroidery frame 84 is the first position. Then, the layout of the second pattern with respect to the first pattern is determined based on the first reference and the second reference set in accordance with the commands input by the user. Before the holding position is changed to the second holding position in which the second pattern is sewn, the areas which are located within the sewable area 86 in the first holding position and which are also located within the estimated range in which the second pattern is to be sewn are identified as the marker layout positions. The image showing the marker layout positions is displayed on the screen displayed on the LCD 7. In a state in which the holding position is in the first holding position, the markers 110 are attached by the user to the positions corresponding to the marker layout positions on the sewing target object 39, and the image data of the image captured by the image sensor 50 is acquired. Based on the acquired image data, the layout of the markers 110 (the first marker layout) with respect to the first reference in the first holding position is identified. Further, after the holding position has been changed to the second holding position, the image data of the image captured by the image sensor 50 is acquired. Based on the acquired image data, the layout of the markers 110 (the second marker layout) with respect to the first reference in the second holding position is identified. The layout of the second pattern with respect to the sewing target object 39 in the second holding position is determined based on the layout of the second pattern with respect to the first pattern, the first marker layout and the second marker layout.
In this manner, in the sewing machine 1 of the present embodiment, the marker layout positions are identified and notified based on the settings (the first reference and the second reference) relating to the layout of the second pattern with respect to the first pattern. Therefore, the user can arrange the markers 110 in the notified marker layout positions. The marker layout positions are positions which are located within the sewable area 86 of the sewing target object 39 in the first holding position and which are also located within the estimated range in which the second pattern is to be sewn. Therefore, if the markers 110 are arranged in such positions, when the holding position of the sewing target object 39 is changed from the first holding position to the second holding position in order to sew the second pattern, there is a high possibility that both the markers 110 and the estimated range in which the second pattern is to be sewn fall within the sewable area 86 in the second holding position. That is, the user can easily arrange the markers 110 in appropriate positions. If the markers 110 and the estimated range in which the second pattern is to be sewn fall within the sewable area 86, thereafter, the positioning between the first pattern and the second pattern can be accurately performed by determining the layout of the second pattern with respect to the sewing target object 39 in the second holding position, based on the settings related to the layout of the second pattern with respect to the first pattern and based on the image data of the images including the markers 110 before and after the change of the holding position.
Further, in the present embodiment, the user is allowed to specify the first reference and the second reference by performing panel operations on the touch panel 8. Thus, the user can input and set a desired layout of the second pattern with respect to the first pattern. Further, since the image showing the marker layout positions is displayed on the LCD 7, the user can visually and easily identify the marker layout positions on the sewing target object 39. Thus, when the user actually arranges the markers 110 on the sewing target object 39, it is possible to reduce the possibility of arranging the markers 110 in erroneous positions. Further, in the sewing machine 1, under control of the CPU 61, the embroidery frame movement mechanism 11 can move the embroidery frame 84 such that the marker layout positions fall within the image capturing range 180 of the image sensor 50. Therefore, even when the sewable area 86 is wider than the image capturing range 180 of the image sensor 50, it is possible to reliably capture the image including the marker layout positions and to display the image on the LCD 7. Thus, the user can reliably arrange the markers 110 in the marker layout positions.
The sewing machine of the present disclosure is not limited to the above-described embodiment. As will be explained below, various modifications may be added.
For example, in the above-described embodiment, the first reference and the second reference specified by the user via panel operations are acquired as the settings related to the layout of the second pattern with respect to the first pattern. However, the settings related to the layout of the second pattern with respect to the first pattern need not necessarily be information input by the user via the touch panel 8. For example, there are cases in which an embroidery pattern that is larger than the sewable area is divided into a plurality of patterns that are smaller than the sewable area, and sewing data corresponding to the plurality of divided patterns is stored in the ROM 62 or the EEPROM 64 of the sewing machine 1. In this case, the layout relationship between the plurality of patterns is determined in advance. Therefore, settings related to the layout relationship between the plurality of patterns may be set in advance and stored in the ROM 62 or the EEPROM 64 such that the settings are included in the sewing data of the plurality of divided patterns. Note that, when the sewing machine 1 is provided with a connector that can be connected to an external storage device (for example, a memory card), sewing data stored in the external device may be read into the sewing machine 1 and used.
For example, a pattern 155 (
Therefore, the sewing data of the pattern 156 includes the coordinate data in the initial layout of the first line segment 171 and the first point 172, which are the first reference set in advance. The sewing data of the pattern 157 includes the coordinate data in the initial layout of the second line segment 181 and the second point 182, which are the second reference set in advance. Then, based on the coordinate data, it is defined that the first line segment 171 and the second line segment 181 are the same line segment, and the first point 172 and the second point 182 are the same point. More specifically, the layout relationship between the pattern 156 and the pattern 157 is set such that the first line segment 171 and the second line segment 181 overlap with each other and the first point 172 and the second point 182 overlap with each other, and the set layout relationship is stored in the ROM 62 or the EEPROM 64.
In this type of case, in the pattern connection processing of the sewing machine 1, when the patterns 156 and 157 are connected and sewn, the processing at step S32 to step S33 of the pattern connection processing (
Alternatively, sewing ranges of the respective patterns may be smallest rectangles having a same size, and the sewing data of each of the patterns may include, in addition to the coordinate data indicating positions of needle drop points, information that indicates a position of the corresponding smallest rectangle as a position in a matrix including rows in the X-axis direction and columns in the Y-axis direction. In the example shown in
As described above, the sewing machine 1 can identify and notify appropriate marker layout positions, in accordance with the settings related to the layout relationship between the pattern 156 and the pattern 157 included in the sewing data. Further, in accordance with the settings, it is possible to automatically perform appropriate positioning and to sew the pattern 155. Each time the patterns 156 and 157 are sewn sequentially, the user need not set the first reference and the second reference to connect the patterns 156 and 157.
Note that it is sufficient that the marker layout positions are positions which are located within the sewable area in the first holding position and which are also located within the estimated range in which the second pattern is to be sewn. Therefore, the marker layout positions need not necessarily be areas as exemplified in the above-described embodiment, and they may be points, for example. Further, when areas are identified as the marker layout positions, it is sufficient if at least a part of the areas is within the estimated range in which the second pattern is to be sewn. Further, the areas in this case need not necessarily be in contact, from the inside, with the corners of the smallest rectangle corresponding to the second pattern as exemplified in the embodiment, and the areas need not necessarily be in contact with the second line segment 181. Further, the method for notifying the marker layout positions may be changed as appropriate. For example, each of the marker layout positions may be displayed by a pattern, such as a cross or a star sign, or may be displayed by a contour that surrounds an area, such as a circle, an ellipse or a polygon. Further, the sewing machine 1 may be provided with a laser pointer, and the marker layout positions may be notified by directing a laser beam onto each of the marker layout positions. The sewing machine 1 may be provided with a projector and the marker layout positions may be projected onto the sewing target object.
It is sufficient that both the layouts of the first pattern and the second pattern include at least one of the position and the angle of the first pattern. Further, the graphics representing the ranges (estimated sewing ranges) in which the first pattern and the second pattern are to be sewn need not necessarily be the smallest rectangles corresponding to the first pattern and the second pattern. For example, each of the graphics may be one of a circle, an ellipse and a polygon in which each of the first pattern and the second pattern can be arranged. The first line segment 171 and the second line segment 181 may be a part of the contour of each of the graphics. It is sufficient that the first point 172 and the second point 182 are points that are included in the graphics, and they may be given points on the first line segment 171 and the second line segment 181 or may be points that are not on the first line segment 171 and the second line segment 181.
In the present embodiment, the sewing machine 1 having the plurality of needle bars 31 is shown as an example. However, an industrial-use sewing machine or a home-use sewing machine having a single needle bar may be used. The type and layout of the image sensor 50 may be changed as appropriate. For example, the image sensor 50 may be an imaging device other than the CMOS image sensor, such as a CCD camera.
The number of the markers 110 can be changed as appropriate. More specifically, the number of the markers 110 may be one or may be three or more. When the layout of the first pattern is identified based on a plurality of the markers 110, particularly, the angle can be accurately identified, as compared to a case in which the layout (the position and the angle) of the first pattern and the second pattern is identified based on the single marker 110. The layout of the markers 110 detected based on the image data may be at least one of the position and the angle of the markers 110. The configuration of the markers 110 may be changed as appropriate. The configuration of the markers 110 includes, for example, a size, a material, a design and a color of the markers 110. The method for arranging the markers 110 on the sewing target object 39 is not limited to attachment by adhesion, and another method, such as fastening by pins, may be used. The reference (the first center point 111 of the marker 110 in the above-described embodiment) to identify the layout of the markers 110, and its calculation method may be changed as appropriate, taking the configuration etc. of the markers 110 into consideration.
Number | Date | Country | Kind |
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2011-245417 | Nov 2011 | JP | national |