Patent Application
20140230707
This application claims priority to Japanese Patent Application No. 2013-027496, filed Feb. 15, 2013, the content of which is hereby incorporated herein by reference in its entirety.
The present disclosure relates to a sewing machine that is configured to form stitches that represent an embroidery pattern, a non-transitory computer-readable medium, and a sewing machine system.
A sewing machine is known that in configured to easily set, on a sewing workpiece that is clamped in an embroidery frame, positions and angles where stitches that make up an embroidery pattern will be formed. For example, a sewing machine is known that is provided with an image capture device. The sewing machine may cause the image capture device to capture an image of a mark that a user has affixed to the sewing workpiece in a designated position. Based on the captured image of the mark, the sewing machine may automatically set, on the sewing workpiece, the positions and the angles for the stitches that make up the embroidery pattern.
A camera is installed as the image capture device in the sewing machine that is described above. The configuration of the sewing machine is therefore complex, and the sewing machine is comparatively expensive.
Various embodiments of the broad principles derived herein provide a sewing machine, a non-transitory computer-readable medium and a sewing machine system that make it possible to easily set, on a sewing workpiece, at least one of a position and an angle where a stitch will be formed that makes up a portion of an embroidery pattern, without making the configuration of the sewing machine complicated.
Various embodiments herein provide a sewing machine that includes an embroidery frame moving portion, a sewing portion, a communication portion, a processor, and a memory. The embroidery frame moving portion is configured to move an embroidery frame in a movement direction. The sewing portion is configured to form a stitch in a sewing workpiece that is clamped in the embroidery frame. The communication portion is configured to perform transmission and receiving of data to and from an external device. The memory is configured to store computer-readable instructions. When executed by the processor, the computer-readable instructions cause the processor to perform the steps of specifying an embroidery pattern to be formed in the sewing workpiece that is clamped in the embroidery frame, and a size of the embroidery pattern, outputting the size of the embroidery pattern through the communication portion to a device that is provided with an image capture portion, acquiring positioning data through the communication portion, setting at least one of the position and the angle of the embroidery pattern on the sewing workpiece, based on the positioning data, acquiring embroidery data, and causing the embroidery frame moving portion and the sewing portion to form the stitches that make up the embroidery pattern on the sewing workpiece, based on the embroidery data. The positioning data are data that the device has computed based on image data for an image that has been captured of a range that includes at least one reference mark and at least one indicator mark. The positioning data indicate at least one of a position and an angle of the at least one indicator mark in relation to the at least one reference mark. The at least one reference mark is provided on the embroidery frame. The at least one indicator mark is positioned in an area inside the embroidery frame on the sewing workpiece that is clamped in the embroidery frame. The positioning data are output from the device to the sewing machine in response to determining by the device that the embroidery pattern can be positioned in a sewing area in a case where at least one of a position and an angle of the embroidery pattern on the sewing workpiece is set based on the size of the embroidery pattern and on the positioning data. The sewing area is an area that is set inside the embroidery frame. The embroidery data are data for forming stitches that make up the embroidery pattern at at least one of the position and the angle of the embroidery pattern on the sewing workpiece that has been set.
Various embodiments also provide a non-transitory computer-readable medium that stores computer-readable instructions. When executed by a processor of a sewing machine that includes an embroidery frame moving portion that is configured to move an embroidery frame in a moving direction, a sewing portion that is configured to form a stitch in a sewing workpiece that is clamped in the embroidery frame, and a communication portion that is configured to perform transmission and receiving of data to and from an external device, the computer-readable instructions cause the processor to perform the steps of specifying an embroidery pattern to be formed in the sewing workpiece that is clamped in the embroidery frame, and a size of the embroidery pattern, outputting the size of the embroidery pattern through the communication portion to a device that is provided with an image capture portion, acquiring positioning data through the communication portion, setting at least one of the position and the angle of the embroidery pattern on the sewing workpiece, based on the positioning data, acquiring embroidery data, and causing the embroidery frame moving portion and the sewing portion to form the stitches that make up the embroidery pattern on the sewing workpiece, based on the embroidery data. The positioning data are data that the device has computed based on image data for an image that has been captured of a range that includes at least one reference mark and at least one indicator mark. The positioning data indicate at least one of a position and an angle of the at least one indicator mark in relation to the at least one reference mark. The at least one reference mark is provided on the embroidery frame. The at least one indicator mark is positioned in an area inside the embroidery frame on the sewing workpiece that is clamped in the embroidery frame. The positioning data are output from the device to the sewing machine in response to determining by the device that the embroidery pattern can be positioned in a sewing area in a case where at least one of a position and an angle of the embroidery pattern on the sewing workpiece is set based on the size of the embroidery pattern and on the positioning data. The sewing area is an area that is set inside the embroidery frame. The embroidery data are data for forming stitches that make up the embroidery pattern at at least one of the position and the angle of the embroidery pattern on the sewing workpiece that has been set.
Various embodiments further provide a sewing machine system that includes a sewing machine, an embroidery frame, and a device. The sewing machine includes an embroidery frame moving portion, a sewing portion, a first communication portion, a first processor, and a first memory. The embroidery frame moving portion is configured to be removably mounted with the embroidery frame and to move the embroidery frame in a movement direction. The sewing portion is configured to form a stitch in a sewing workpiece that is clamped in the embroidery frame. The sewing portion includes a needle bar. The first communication portion is configured to perform transmission and receiving of data to and from an external device. The first memory is configured to store computer-readable instructions. When executed by the first processor, the computer-readable instructions cause the first processor to perform the steps of specifying an embroidery pattern to be formed in the sewing workpiece that is clamped in the embroidery frame, and a size of the embroidery pattern, outputting the size of the embroidery pattern to the device through the first communication portion, acquiring, through the first communication portion, positioning data that has been output from the device, setting at least one of the position and the angle of the embroidery pattern on the sewing workpiece, based on the positioning data, acquiring embroidery data, causing the embroidery frame moving portion and the sewing portion to form the stitches that make up the embroidery pattern on the sewing workpiece, based on the embroidery data. The positioning data are data that the device has computed based on image data for an image that has been captured of a range that includes at least one reference mark and at least one indicator mark. The positioning data indicate at least one of a position and an angle of the at least one indicator mark in relation to the at least one reference mark. The at least one reference mark is provided on the embroidery frame. The at least one indicator mark is positioned in an area inside the embroidery frame on the sewing workpiece that is clamped in the embroidery frame. The embroidery data are data for forming stitches that make up the embroidery pattern at at least one of the position and the angle of the embroidery pattern on the sewing workpiece that has been set. The embroidery frame includes a mounting portion and a clamping portion. The mounting portion is configured to be mounted on and removed from the embroidery frame moving portion. The clamping portion includes a first frame and a second frame. The first frame and the second frame are configured to clamp the sewing workpiece. The clamping portion has the at least one reference mark that is disposed at a visible position on a side of the clamping portion that is opposite the needle bar in a state in which the sewing workpiece is clamped. The device includes an image capture portion, a second communication portion, a second processor, and a second memory. The image capture portion is configured to create image data. The second communication portion is configured to perform transmission and receiving of data to and from an external device. The second memory is configured to store computer-readable instructions. When executed by the second processor, the computer-readable instructions cause the second processor to perform the steps of causing the image capture portion to capture the image of the range that includes the at least one reference mark and the at least one indicator mark, and to create the image data for the image, acquiring, through the second communication portion, the size of the embroidery pattern that has been output from the sewing machine, computing the positioning data based on the image data, determining whether the embroidery pattern can be positioned in a sewing area in a case where at least one of the position and the angle of the embroidery pattern on the sewing workpiece is set based on the positioning data and the size of the embroidery pattern, and outputting the positioning data to the sewing machine through the second communication portion, in response to determining that the embroidery pattern can be positioned in the sewing area. The sewing area is an area that is set inside the embroidery frame.
Embodiments will be described below in detail with reference to the accompanying drawings in which:
Hereinafter, an embodiment will be explained with reference to the drawings. First, a sewing machine system 100 will be explained with reference to
The sewing machine 1 is configured to sew an embroidery pattern. As shown in
A needle plate (not shown in the drawings) is provided in the top face of the bed 11. A feed dog (not shown in the drawings), a feed mechanism 85 (refer to
A well-known embroidery device 2 that is used during embroidery sewing can be mounted on the bed 11. When the embroidery device 2 is mounted on the sewing machine 1, the embroidery device 2 and the sewing machine 1 are electrically connected. When the embroidery device 2 and the sewing machine 1 are electrically connected, the embroidery device 2 can move a sewing workpiece 5 that is held by the embroidery frame 53. The embroidery device 2 includes a body 51 and a carriage 52.
The carriage 52 is provided on the top side of the body 51. The carriage 52 has a three-dimensional rectangular shape, with its longer axis extending in the front-rear direction. The carriage 52 includes a frame holder (not shown in the drawings), a Y axis moving mechanism 88 (refer to
An X axis moving mechanism 87 (refer to
A liquid crystal display (hereinafter called the LCD) 15 is provided on the front face of the pillar 12. Images that include various items such as commands, illustrations, setting values, messages, and the like may be displayed on the LCD 15. A touch panel 26 that is configured to detect a position that is pressed is provided on the front side of the LCD 15. When the user performs a pressing operation on the touch panel 26 using a finger or a stylus pen, the position that is pressed is detected by the touch panel 26. The item that has been selected within the image is then recognized based on the pressed position that has been detected. Hereinafter, the operation in which the touch panel 26 is pressed by the user will be called a panel operation. The user can use a panel operation to select a pattern to be sewn or a command to be executed.
A connector (not shown in the drawings) is provided in the right side face of the pillar 12. The sewing machine 1 can be connected to an external device through the connector. Examples of the external device include a personal computer (PC), an image capture device, and a portable terminal, for example.
A cover 16 that can be opened and closed is provided in an upper portion of the arm 13.
A presser mechanism 90 (refer to
In the sewing machine 1, when a stitch is formed using the embroidery device 2, the embroidery frame 53 is moved by the Y axis moving mechanism 88 and the X axis moving mechanism 87 to a needle drop point that is indicated in terms of an embroidery coordinate system that is specific to the sewing machine 1. The embroidery coordinate system is the coordinate system for the X axis motor 82 and the Y axis motor 83 that are configured to move the carriage 52. In the present embodiment, the embroidery coordinate system is set as will now be described. The left-right direction of the sewing machine 1 is the X axis direction, and the direction from left to right is the positive direction on the X axis. The front-rear direction of the sewing machine 1 is the Y axis direction, and the direction from front to rear is the positive direction on the Y axis. The needle drop point is the point where the sewing needle 28, which is positioned directly above a needle hole 36 (refer to
The physical configuration of the portable terminal 3 will be explained with reference to
The physical configuration of embroidery frame 53 will be explained with reference to
In a state in which the clamping portion 54 has clamped the sewing workpiece 5 and the embroidery frame 53 is mounted in the frame holder of the embroidery device 2, the top face of the first frame 55 can be visually recognized on the side that faces the needle bar 29 of the sewing machine 1. Reference marks 151 to 154 are respectively disposed at the left rear, the right rear, the right front, and the left front of top face of the first frame 55. Reference marks 155 and 156 are respectively disposed on the right side and the left side of the top face of the first frame 55, approximately midway between the front edge and the rear edge of the first frame 55. Hereinafter, when the plurality of the reference marks 151 to 156 are referenced collectively, they will be called the reference marks 150, and when one of the plurality of the reference marks 151 to 156 is referenced without being specifically identified, it will be called the reference mark 150. The reference marks 150 may be used as references when at least one of a position and an angle of an indicator mark 110 that will be described later is computed based on image data for an image of the embroidery frame 53 that is captured in a state in which the sewing workpiece 5 is clamped in the embroidery frame 53. Each of the reference marks 151 to 154 is a mark that is expressed in the form of a single round, black pattern (hereinafter simply called the round, black pattern). It is preferable for the positioning of the reference marks 151 to 154 to be determined by taking into consideration an area in which the indicator mark 110 is possibly disposed, that is, a sewing area 45. The sewing area 45 is an area that is set inside the first frame 55 and within which a stitch can be formed by the sewing machine 1. The sewing area 45 differs according to the type of the embroidery frame 53. In the present embodiment, the reference marks 151 to 154 are disposed close to four corners of the sewing area 45, respectively. Each of the reference marks 155 and 156 is a circular pattern whose diameter is slightly larger than the diameter of the reference marks 151 to 154. The positions of the reference marks 155 and 156 are set by taking into consideration an image capture range in a case where an image of the entire area inside the embroidery frame 53 cannot be captured, as in a case where the image is captured in a state in which the embroidery frame 53 is mounted on the embroidery device 2, for example. In the present embodiment, the positions of the reference marks 155 and 156 are set, as described above, by taking into consideration the case where the image is captured in a state in which the embroidery frame 53 is mounted on the embroidery device 2. The colors, sizes, and shapes of the reference marks 150 are set such that the contrast with the color of the first frame 55 will be clear.
A type mark 160 is disposed on the front side of the top face of the first frame 55. The type mark 160 is a mark that indicates the type of the embroidery frame 53 and the orientation of the embroidery frame 53 within a captured image that will be described later. As described previously, selected one of the plurality of types of the embroidery frames 53 that differ from one another in at least one of size and shape can be mounted on the embroidery device 2. In the explanation that follows, a case in which selected one of three types of the embroidery frames 53 that differ in size can be mounted on the embroidery device 2 will be used as an example.
The type mark 161 of the first frame 551 of the embroidery frame 53 for which the ID is 1 includes one round, black pattern. The type mark 162 of the first frame 552 of the embroidery frame 53 for which the ID is 2 includes two round, black patterns. The type mark 163 of the first frame 553 of the embroidery frame 53 for which the ID is 3 includes three round, black patterns. The type mark 160 may be used in processing that determines the type of the embroidery frame 53 that will be used for the sewing, based on the image data for the image of the embroidery frame 53 that is captured in a state in which the sewing workpiece 5 is clamped in the embroidery frame 53. Hereinafter, when the type marks 161 to 163 are referenced collectively, they will be called the type marks 160, and when one of the type marks 161 to 163 is referenced without being specifically identified, it will be called the type mark 160. Hereinafter, when the first frames 551 to 553 are referenced collectively, they will be called the first frames 55, and when one of the first frames 551 to 553 is referenced without being specifically identified, it will be called the first frame 55. In the present embodiment, the first frame 55 is mounted in the second frame 56, with the side where the type mark 160 is provided being defined as the front side of the embroidery frame 53. In the present embodiment, each of the reference marks 150 and the type marks 160 is printed on the top face of the first frame 55 during the manufacturing of the first frame 55. Therefore, the position of each of the reference marks 150 and the type marks 160 is fixed in relation to the embroidery frame 53.
An electrical configuration of the sewing machine 1 will be explained with reference to
The operation switches 21, the touch panel 26, a detection portion 27, and drive circuits 70 to 76 are electrically connected to the input/output interface 66. The detection portion 27 is configured to detect whether or not the embroidery frame 53 has been mounted in embroidery device 2, to detect the type of the embroidery frame 53 that has been mounted in the embroidery device 2, and to input the detection results to the CPU 61 through the input/output interface 66. The drive circuits 70 to 76 may respectively drive the presser motor 89, the sewing machine motor 79, the feed motor 80, the swinging motor 81, the X axis motor 82, the Y axis motor 83, and the LCD 15.
An electrical configuration of the portable terminal 3 will be explained with reference to
The operation switch 131, the touch panel 132, a microphone 133, a speaker 134, the display portion 135, and the camera 136 are connected to the input/output interface 128. The microphone 133 is configured to convert ambient sounds into audio data and inputs the audio data to the input/output interface 128. The speaker 134 is configured to output sound based on audio data that is output from the input/output interface 128. The display portion 135 is configured to display an image based on image data. The display portion 135 may be a liquid crystal display, for example. The camera 136 is configured to capture an image of a specified image capture range and to create image data. The created image data may be stored in the RAM 123.
The indicator mark 110 will be explained with reference to
The first circle 101 is drawn with the center point of the square sheet 108 serving as the first center point 111. The second circle 102 is drawn in a position where it is tangent to the first circle 101 and where a virtual straight line (not shown in the drawings) that passes through the first center point 111 and the second center point 112 is parallel to one side of the sheet 108. The diameter of the second circle 102 is smaller than the diameter of the first circle 101. The line segment 103 and the line segment 104 are line segments that are superposed on the virtual straight line (not shown in the drawings) that passes through the first center point 111 and the second center point 112, and they respectively extend from the first circle 101 and the second circle 102 to an outer edge of the sheet 108. The line segment 105 and the line segment 106 are line segments that are superposed on a virtual straight line (not shown in the drawings) that passes through the first center point 111 of the first circle 101 and is orthogonal to the line segment 103, and each of them extends from an outer edge of the first circle 101 to an outer edge of the sheet 108. In the present embodiment, the first center point 111 and the second center point 112 are characteristic points of the indicator mark 110.
An embroidery pattern, the pattern data, and embroidery data will be explained using the embroidery pattern 200 that is shown in
The embroidery pattern 200 that is shown in
The embroidery data are data for forming the stitches that make up the embroidery pattern 200 at at least one of the position and the angle that the user has indicated by using the indicator mark 110. In the present embodiment, the embroidery data are data for forming the stitches that make up the embroidery pattern 200 at the position and the angle that the user has indicated by using the indicator mark 110. The embroidery data include coordinate data. In the present embodiment, all of the coordinate data in the embroidery data are specified such that the center point 202 of the embroidery pattern 200 (more specifically, the center point of the rectangle 201 that is the smallest rectangle within which the embroidery pattern 200 can be contained) is congruent with the first center point 111 of the indicator mark 110 in the embroidery coordinate system. Furthermore, in the present embodiment, the coordinate data in the embroidery data are specified such that the slope of a line segment that links the center point 202 of the embroidery pattern 200 to a point 203 matches the slope of a line segment that links the first center point 111 and the second center point 112 of the indicator mark 110 in the embroidery coordinate system.
Processing that is performed in the sewing machine system 100 of the present embodiment will be explained with reference to
The CPU 121 of the portable terminal 3 starts the first processing when the user inputs a command to start the first processing. Specifically, when the CPU 121 detects the input of the command to start the first processing, the CPU 121 reads into the RAM 123 a program for performing the first processing, which is stored in the flash ROM 124 (refer to
As shown in
The CPU 121 determines whether or not data that include an image capture position transmission request have been received from the sewing machine 1 (Step S3). In the sewing machine system 100, in a case where the embroidery frame 53 is mounted on the embroidery device 2 when the first processing is performed, a determination is made that an image of the embroidery frame 53 will be captured in the state in which the embroidery frame 53 is mounted on the embroidery device 2. The sewing machine 1 moves the embroidery frame 53 to an image capture position that is suitable for capturing an image of the embroidery frame 53. In the present embodiment, the three types of the image capture positions are set as described previously. As will be described below, in a case where the embroidery frame 53 is mounted on the embroidery device 2 when the first processing is performed, the sewing machine 1 transmits the image capture position transmission request to the portable terminal 3. The image capture position transmission request is a request that asks the portable terminal 3 to transmit to the sewing machine 1 a command that specifies one of the three types of the image capture positions. In the present embodiment, the user operates the portable terminal 3 to designate one of the three types of the image capture positions.
In the sewing machine system 100, in a case where the embroidery frame 53 is mounted on the embroidery device 2, the sewing machine 1, having received the start signal that was transmitted at Step S2, transmits the image capture position transmission request to the portable terminal 3 within a specified time period (for example, three minutes). In a case where the image capture position transmission request is not received within the specified time period, the CPU 121 determines that the image capture position transmission request has not been received (NO at Step S3). In a case where the data that include the image capture position transmission request have been received (YES at Step S3), the CPU 121 stores the received data in the RAM 123. In some cases, frame data that will be described later may be included in the image capture position transmission request that was received at Step S3, along with the address of the sewing machine 1. The CPU 121 accepts the designation of the image capture position that has been input by the user and transmits information on the designated image capture position to the sewing machine 1 through the communication interface 125 (Step S4). In a case where the image capture position transmission request has not been received (NO at Step S3), as well as after the processing at Step S4, the CPU 121 determines whether or not data that were transmitted from the sewing machine 1 and include the pattern size have been received (Step S5). In a case where the data that were transmitted from the sewing machine 1 and include the pattern size have been received (YES at Step S5), the CPU 121 stores the received data in the RAM 123. In some cases, the frame data that will be described later may be included in the pattern size that was received at Step S5, along with the address of the sewing machine 1. In the present embodiment, in a case where the image capture position transmission request has been received (YES at Step S3), if the data that include the pattern size have not been received within a specified time period (for example, three minutes) after the image capture position was transmitted at Step S4, the CPU 121 determines that the pattern size has not been received (NO at Step S5). In a case where the image capture position transmission request has not been received (NO at Step S3), if the pattern size has not been received within a specified time period (for example, five minutes) after the start signal was transmitted, the CPU 121 determines that the pattern size has not been received (NO at Step S5). In a case where the data that were transmitted from the sewing machine 1 and include the pattern size have not been received within the specified time period (NO at Step S5), the CPU 121 displays an information receiving error message on the display portion 135 (Step S7), then returns the processing to Step S1. The information receiving error message at Step S7 notifies the user that information that is necessary for the processing that outputs the positioning data to the sewing machine 1 using the portable terminal 3 was not received from the sewing machine 1. Next, the CPU 121 determines whether or not the image capture permission has been acquired from the sewing machine 1 (Step S6). In the sewing machine system 100, the portable terminal 3 performs the processing that creates the image data after the portable terminal 3 has received the image capture permission from the sewing machine 1. This is because, in a case where the embroidery frame 53 is mounted on the embroidery device 2, the sewing machine system 100 causes the portable terminal 3 to perform the image capture after the embroidery frame 53 has been moved to the image capture position that the user has designated. In the present embodiment, in a case where the pattern size has been received (YES at Step S5), if the image capture permission is not received within a specified time period (for example, three minutes) after the pattern size was received, the CPU 121 determines that the image capture permission has not been received (NO at Step S6).
In a case where the image capture permission has not been received (NO at Step S6), the CPU 121 displays the information receiving error message on the display portion 135 (Step S7), then returns the processing to Step S1. In a case where the image capture permission has been received (YES at Step S6), the CPU 121 performs positioning data computation processing (Step S8). The positioning data computation processing will be explained with reference to
In a case where the image capture command has not been input (NO at Step S31), the CPU 121 waits until the image capture command is input. In a case where the image capture command has been input (YES at Step S31), the CPU 121 controls the camera 136 to create the image data for the image that has been captured of the image capture range, then stores the image data in the RAM 123 (Step S32). In the explanation that follows, a case in which the image in
The CPU 121 determines whether or not at least the reference marks 153 to 156, from among the reference marks 150, have been successfully detected (Step S34). As explained previously, in the present embodiment, the reference marks 151 to 154 are provided on the top face of the first frame 55, close to the four corners of the sewing area 45, respectively. That means that if all four of the reference marks 151 to 154 are included in the captured image, the area on the inside of the embroidery frame 53 and the indicator mark 110 are also included in the captured image. Therefore, in a case where the area in which the indicator mark 110 is possibly disposed is the entire sewing area 45, it is preferable for the reference marks 151 to 156 to be detected. A case in which the reference marks 151 to 156 are detected in the captured image based on the image data will be called a case in which the image is captured under a first image capture condition. In a case where the area in which the indicator mark 110 is possibly disposed is the front half of the sewing area 45, it is possible for the processing to be performed as long as the reference marks 153 to 156 are detected, even if the reference marks 151 and 152 are not detected. A case in which the reference marks 153 to 156 are detected in the captured image based on the image data, and at least one of the reference marks 151 and 152 is not detected, will be called a case in which the image is captured under a second image capture condition. Therefore, in the processing at Step S34, the portable terminal 3 checks whether or not at least the reference marks 153 to 156 are included in the captured image.
In a case where at least one of the reference marks 153 to 156 has not been detected (NO at Step S34), the CPU 121 displays an error message on the display portion 135 (Step S35) and returns the processing to Step S31. The error message in the processing at Step S35 notifies the user that at least one of the reference marks 153 to 156 was not detected in the captured image and prompts the user to perform the image capture again. The user may check the error message and, after adjusting the image capture range, may input a command to perform the image capture again.
In a case where at least the reference marks 153 to 156 have been successfully detected (YES at Step S34), the CPU 121 determines whether or not the frame data are included in the data that were received at one of Step S3 and Step S5 in
In a case where the frame data are included in the data that were received at one of Step S3 and Step S5 (YES at Step S36), as well as after the processing at Step S40, the CPU 121 acquires the actual relative position, in relation to a standard position, for each one of the characteristic points that are included in the reference marks 150, in accordance with the type of the embroidery frame 53 and the image capture condition (Step S41). The type of the embroidery frame 53 is indicated by the frame data or was specified at Step S40. The image capture condition is a condition that is classified according to the reference marks 150 that were detected by the processing at Step S33. In the present embodiment, there are two types of the image capture condition, that is, the first image capture condition and the second image capture condition that were described above. In the present embodiment, the standard position is the origin point of the embroidery coordinate system, and the relative positions are expressed in terms of the coordinates of the embroidery coordinate system. In a case where the image has been captured under the first image capture condition, the CPU 121 refers to the sewing area table and acquires the relative positions of the characteristic points P1 to P4 that correspond to the type of the embroidery frame 53. In a case where the image has been captured under the second image capture condition, the CPU 121 refers to the sewing area table and acquires the relative positions of the characteristic points P3 to P6 that correspond to the type of the embroidery frame 53. In the specific example that is shown in
Based on the image data, the CPU 121 detects the orientation of the embroidery frame 53 within the captured image. In the present embodiment, the CPU 121 determines that, of the four sides of the substantially rectangular first frame 55, the side where the type mark 160 is located is the front side. Therefore, in the specific example that is shown in
Based on the correspondence relationships between the reference positions and the relative positions for the characteristic points of the reference marks 150, the CPU 121 corrects the image that is described by the image data that were created at Step S32 (Step S43). In the processing at Step S43 in the present embodiment, the CPU 121 corrects distortion in the captured image by using a known keystone correction method. In the processing at Step S43, the CPU 121 converts the captured image that is shown in
Based on the image data, the CPU 121 detects the indicator mark 110 in the captured image (Step S44). Any known image recognition method may be used for detecting the indicator mark 110. For example, the CPU 121 may preform edge detection and perform pattern matching using a template that shows the outlines of the first circle 101 and the second circle 102, as well as the line segments 103 to 106. For example, within the captured image, in the processing at Step S44, the CPU 121 may detect the positions of the two characteristic points in the indicator mark 110 as indicator positions. In a case where the indicator mark 110 is not detected (NO at Step S45), there is a strong possibility that the indicator mark 110 has not been affixed in an appropriate position or that the indicator mark 110 is not located within the image capture range. Accordingly, the CPU 121 displays an error message on the display portion 135 (Step S46) and returns the processing to Step S31. The error message in the processing at Step S46 prompts the user to affix the indicator mark 110 again in an area inside the sewing area 45 of the embroidery frame 53.
In a case where the indicator mark 110 is detected (YES at Step S45), the CPU 121 computes, as the positioning data, data that indicate the position and the angle of the indicator mark 110 in relation to the reference marks 150 (Step S47). Hereinafter, the position and the angle will simply be called the positioning. The plurality (specifically, six in the present embodiment) of the reference marks 150 are positioned on the embroidery frame 53, and their relative positions are known. Therefore, the CPU 121 is able to acquire the coordinates in the embroidery coordinate system that correspond to the indicator positions by computing the coordinates based on the reference positions of the characteristic points that are included in the reference marks 150, on the known relative positions that correspond to the reference positions, and on the indicator positions. Each of the indicator positions is a position, in the captured image, of each of the at least one characteristic point that is included in the indicator mark 110. In the present embodiment, the indicator mark 110 has the two characteristic points of the first center point 111 and the second center point 112. Accordingly, the CPU 121 may compute, as the positioning data, data that indicate the coordinates in the embroidery coordinate system of the first center point 111 and the second center point 112 of the indicator mark 110 that was detected at Step S44, for example. The coordinates of the first center point 111 in the embroidery coordinate system represent the position of the indicator mark 110 on the sewing workpiece 5 and are used to indicate the position of the embroidery pattern 200. The coordinates of the first center point 111 and the second center point 112 in the embroidery coordinate system represent the angle of the indicator mark 110 and are used to indicate the angle of the embroidery pattern 200. In addition to being represented by the coordinates of the first center point 111 and the second center point 112 in the embroidery coordinate system, the angle of the indicator mark 110 may be represented by the angle in relation to a reference (for example, the X axis or the Y axis of the embroidery coordinate system).
The CPU 121 sets the positioning of the embroidery pattern 200 based on the pattern size that was received by the processing at Step S5 in
The CPU 121 acquires information that indicates the range of the sewing area 45 that corresponds to the type of the embroidery frame 53 (Step S49). In the specific example, the CPU 121 refers to the sewing area table that is stored in the flash ROM 124 and acquires the X axis length X27 and the Y axis length Y27 that indicate, in terms of the embroidery coordinate system, the size of the sewing area 45 for the embroidery frame 53 for which the ID is 2. In the processing at Step S49, the CPU 121 sets the sewing area 45 that is shown inside the first frame 55 of the embroidery frame 53 in
As shown in
The second processing that is performed by the sewing machine 1 will be explained with reference to
The CPU 61 of the sewing machine 1 starts the second processing when the user inputs a command to start the second processing by a panel operation. When the CPU 61 detects the input of command to start the second processing, the CPU 61 reads into the RAM 63 the program for performing the second processing, which is stored in the ROM 62 (refer to
As shown in
The CPU 61 waits until a command is input to start communication with the portable terminal 3 (NO at Step S63). The command may be input by a panel operation by the user, for example. In a case where the command has been input (YES at Step S63), the CPU 61 waits until the CPU 61 receives the start signal that is transmitted from the portable terminal 3 (NO at Step S64). The start signal is transmitted from the portable terminal 3 by the processing at Step S2 in
The CPU 61 determines whether or not the embroidery frame 53 has been mounted, based on the result that has been output from the detection portion 27 (Step S65). In a case where the embroidery frame 53 has been mounted (YES at Step S65), the CPU 61 transmits the image capture position transmission request to the portable terminal 3 through the communication interface 65 (Step S66). The address of the portable terminal 3 is specified based on the start signal that was received at Step S64 and stored in the RAM 63. The CPU 61 may also include in the image capture position transmission request the frame data that are specified based on the result that has been output from the detection portion 27. The CPU 61 displays a waiting-to-receive message on the LCD 15 (Step S67). The waiting-to-receive message in the processing at Step S67 notifies the user that the sewing machine 1 is in a state of waiting for the image capture position to be transmitted from the portable terminal 3. The user may check the waiting-to-receive message and may perform an operation that uses the portable terminal 3.
The CPU 61 determines whether or not the image capture position that was transmitted from the portable terminal 3 has been received (Step S68). In a case where the image capture position has not been received within a specified time period (for example, three minutes) after the image capture position transmission request was transmitted to the portable terminal 3 by the processing at Step S66 (NO at Step S68), the CPU 61 displays a receiving error message on the LCD 15 (Step S74), then returns the processing to Step S63. The receiving error message notifies the user that the data that were to be transmitted from the portable terminal 3 have not been received. The receiving error message may also be transmitted to the portable terminal 3 and displayed on the portable terminal 3.
In a case where the image capture position has been received (YES at Step S68), the CPU 61 controls the drive circuits 74 and 75 to move the embroidery frame 53 to the received image capture position (Step S69). The image capture position that the user designates differs according to the type of the embroidery frame 53. The CPU 61, referring to the image capture position table that is stored in the flash ROM 64, acquires the position of the embroidery frame 53 that corresponds to the image capture position that the user designated and the type of the embroidery frame 53, then moves the embroidery frame 53 to the acquired position. For example, in a case where the ID of the embroidery frame 53 is 2 and the image capture position is the left front, the embroidery frame 53 is moved to the position that is indicated by (X20, Y20). In a case where the embroidery frame 53 has not been mounted on the embroidery device 2 (NO at Step S65), as well as after the processing at Step S69, the CPU 61 transmits to the portable terminal 3, through the communication interface 65, the pattern size of the embroidery pattern 200 that was specified at Step S62 (Step S70). The address of the portable terminal 3 is specified based on the start signal that was received at Step S64 and stored in the RAM 63. The CPU 61 may also include in the pattern size the frame data that are specified based on the result that has been output from the detection portion 27. The CPU 61 specifies the pattern size based on the pattern data for the embroidery pattern 200 that were acquired at Step S62. After the processing at Step S70, the CPU 61 transmits the image capture permission to the portable terminal 3 through the communication interface 65 (Step S71). As described previously, when the portable terminal 3 receives the image capture permission, the portable terminal 3 accepts the command to perform image capture.
The CPU 61 displays a waiting-to-receive message on the LCD 15 (Step S72). The waiting-to-receive message in the processing at Step S72 notifies the user that the portable terminal 3 is in a state of being able to perform image capture and that the sewing machine 1 is in a state of waiting for the positioning data to be transmitted from the portable terminal 3. The user may check the waiting-to-receive message and may perform an operation that uses the portable terminal 3. The CPU 61 determines whether or not the positioning data have been received (Step S73). In a case where the positioning data have not been received from the portable terminal 3 within a specified time period (for example, five minutes) after the image capture permission was transmitted at Step S71, the CPU 61 determines that the positioning data have not been received (NO at Step S73). In that case, the CPU 61 displays the receiving error message on the LCD 15 (Step S74), then returns the processing to Step S63. The receiving error message may also be transmitted to the portable terminal 3.
In a case where the positioning data have been received (YES at Step S73), the CPU 61 transmits the successful receiving message to the portable terminal 3. As described previously, the successful receiving message is used in the portable terminal 3 for confirming that the positioning data have been received normally in the sewing machine 1. The CPU 61 sets the positioning of the embroidery pattern 200 based on the pattern data for the embroidery pattern 200 that was specified at Step S62 and on the positioning data that were received at Step S73, then displays the set positioning on the LCD 15 (Step S75). The method for setting the positioning of the embroidery pattern 200 is the same method that was used in the processing at Step S48 in
The CPU 61 corrects the pattern data such that the center point 202 of the embroidery pattern 200 is congruent with the first center point 111 of the indicator mark 110 in the embroidery coordinate system. The CPU 61 corrects the pattern data such that the slope of the line segment that links the center point 202 of the embroidery pattern 200 to the point 203 matches the slope of the line segment that links the first center point 111 and the second center point 112 of the indicator mark 110 in the embroidery coordinate system. The CPU 61 acquires the corrected pattern data as the embroidery data (Step S76).
The CPU 61 waits until a command to start sewing is input (NO at Step S77). The command to start sewing may be input by user, using one of a panel operation and the operation switches 21. In a case where the command to start sewing has been input (YES at Step S77), the CPU 61 performs processing that sews the embroidery pattern 200 on the sewing workpiece 5 in accordance with the embroidery data that were acquired at Step S76 (Step S78). More specifically, the CPU 61 causes the embroidery device 2 to move the embroidery frame 53 by driving the X axis motor 82 and the Y axis motor 83 (refer to
According to the sewing machine system 100 that is described above, the portable terminal 3 is able to compute the positioning data based on the image data that were created by the processing at Step S32 in
The sewing machine 1 transmits the pattern size to the portable terminal 3 for the convenience of the user. The portable terminal 3 is able to determine, based on the positioning data and the pattern size, whether or not the embroidery pattern will fit within the sewing area 45 in a case where the embroidery pattern is positioned according to the positioning that was set based on the positioning data. Depending on the pattern size and the positioning of the indicator mark 110, if the positioning of the embroidery pattern is set based on the positioning data that were computed by the portable terminal 3, cases may occur in which the embroidery pattern does not fit within the sewing area 45. In this sort of case, if the portable terminal 3 simply outputs the positioning data to the sewing machine 1, and if the sewing machine 1 sets the positioning of the embroidery pattern based on the positioning data that were output, the user must check the result of the positioning in the sewing machine 1, and then perform an operation to position the embroidery pattern within the sewing area 45. In contrast to this, in the sewing machine system 100 of the present embodiment, if the sewing machine 1 sets the positioning of the embroidery pattern based on the positioning data that were acquired by the portable terminal 3, the embroidery pattern will definitely fit within the sewing area 45. Therefore, in the process in which the sewing machine 1 sets the positioning of the embroidery pattern based on the positioning data and forms the stitches that make up the embroidery pattern, the number of times that the user repeatedly performs operations of the sewing machine 1 and the portable terminal 3 can be kept to a minimum. In other words, it is possible to make the sewing machine 1 capable of easily setting the positioning of the embroidery pattern on the sewing workpiece 5, without making the configuration of the sewing machine 1 more complex. Furthermore, in a case where the portable terminal 3 has determined that the embroidery pattern cannot be positioned within the sewing area 45 based on the computed positioning data, information to that effect is displayed on the display portion 135. Based on that notification, the user can take measures such as changing the positioning of the indicator mark 110 on the sewing workpiece 5, changing the positioning of the sewing workpiece 5 in relation to the embroidery frame 53, or the like, and then performing image capture again.
With the known sewing machine that is provided with an image capture device that has an image capture range that is smaller than the sewing area 45 in the embroidery frame 53, cases occur in which the CPU must divide the entire sewing area 45 into a plurality of blocks, then perform processing that detects the indicator mark 110 by successively moving the embroidery frame 53 to positions that correspond to the individual blocks. In contrast to this, the portable terminal 3 in the present embodiment is a separate unit from the sewing machine 1. When the portable terminal 3 creates the image data, there is no restriction on the image capture range. For example, the portable terminal 3 is able to create the image data by capturing a single image that includes both the reference marks 150 and the indicator mark 110 that is positioned in the area within the embroidery frame 53 in a state in which the embroidery frame 53 has been removed from the embroidery device 2. Furthermore, by capturing an image of the embroidery frame 53 in a state in which the embroidery frame 53 has been removed from the embroidery device 2, the portable terminal 3 is able to create the image data in a state in which elements of the sewing machine 1 (for example, the needle bar 29 and the presser foot 30) are not included in the image capture range. The portable terminal 3 is able to make the processing that detects the indicator mark 110 based on the image data simpler than it would be in a case where the elements of the sewing machine are included in the image capture range.
On the other hand, there are some cases in which the user wants to perform the image capture in a state in which the embroidery frame 53 is mounted on the embroidery device 2, and to compute the positioning data based on the image data for the captured image. In a case where the embroidery frame 53 is mounted on the embroidery device 2 before the positioning data are acquired, the sewing machine 1 can move the embroidery frame 53 to the image capture position automatically. In the present embodiment, the user is able to select one of the three image capture positions by operating the portable terminal 3. In a case where an image is captured of the area within the embroidery frame 53 in a state in which the embroidery frame 53 is mounted on the embroidery device 2, it is sometimes impossible to fit the entire area within the embroidery frame 53 into the image capture range, depending on the type of the embroidery frame 53. The sewing machine 1 is able to determine automatically which of the reference marks 150 to use as reference positions for computing the positioning of the indicator mark 110, according to which of the reference marks 150 among the plurality of the reference marks 150 are included in the captured image. The selected one of the plurality of types of the embroidery frame 53 can be mounted on the embroidery device 2. Based on the result of the detection of the type of the embroidery frame 53, the sewing machine 1 can automatically move the embroidery frame 53 to the image capture position that corresponds to the type of the embroidery frame 53. The sewing machine 1 is therefore able to improve the convenience for the user in a case where an image is captured in a state in which the embroidery frame 53 is mounted on the embroidery device 2.
The sewing machine 1 performs the processing at Steps S67 and S72 in
Based on the captured image, the portable terminal 3 can detect the reference marks 150, the indicator mark 110, and the type mark 160, can automatically determine the type of the embroidery frame 53 and the orientation of the embroidery frame 53 in the captured image, and can compute the positioning data. Therefore, the user does not need to consider the orientation of the embroidery frame 53 in the captured image when the image capture is performed. The user also does not need to input information to the portable terminal 3 in order to specify the orientation of the embroidery frame 53 in the captured image. The portable terminal 3 can reliably avoid a situation in which the positioning data cannot be computed properly because the correspondence relationship between the orientation of the embroidery frame 53 in the captured image and the direction in which the embroidery frame 53 is mounted on the embroidery device 2 has not been set properly.
The embroidery device 2 of the present embodiment is configured such that the selected one of the plurality of types of the embroidery frames 53 can be mounted thereon. The size and the shape of the embroidery frame 53 vary according to the type of the embroidery frame 53. According to the processing at Step S65, the sewing machine 1 can automatically detect the type of the embroidery frame 53 and can transmit to the portable terminal 3 the frame data that describe the type of the embroidery frame 53. The portable terminal 3, having received the frame data, can specify the type of the embroidery frame 53 merely by performing the processing that receives the frame data, which is simpler than specifying the type of the embroidery frame 53 based on the type mark 160.
The portable terminal 3 can notify the user that at least one of the reference marks 150, the type mark 160, and the indicator mark 110 has not been detected. Based on the notification, the user can respond by performing the image capture again or the like. The portable terminal 3 is able to make the acquiring of the positioning data more convenient for the user than it would be in a case where the user is not notified that at least one of the reference marks 150, the type mark 160, and the indicator mark 110 has not been detected.
Various types of modifications may be made to the sewing machine 1 in the embodiment that is described above. For example, at least one of the modifications in the examples (A) to (E) that are described below may be applied as desired.
(A) The configuration of the sewing machine 1 may be modified as desired. The sewing machine 1 may be a different type of sewing machine, such as an industrial sewing machine, a multi-needle sewing machine, or the like, for example. The sewing machine may also be a sewing machine that is configured as an integrated unit with the embroidery device, for example. Instead of being stored in the flash ROM 64, the pattern data for the embroidery pattern may be stored in another storage device in the sewing machine 1 (for example, the ROM 62). In a case where the sewing machine 1 includes a structural element to which a storage medium such as a memory card or the like can be connected, the sewing machine 1 may acquire pattern data that are stored in the storage medium and store the pattern data in a storage device of the sewing machine 1 (for example, the flash ROM 64). In a case where the sewing machine 1 includes a structural element to which an external device can be connected, either by wire or wirelessly, the sewing machine 1 may acquire pattern data that are stored in the external device and store the pattern data in a storage device. The sewing workpiece may be any object in which a stitch can be formed. The positioning data may be computed by an image capture unit that is provided with an image capture device, based on image data.
The device that is provided with the image capture device may be a device other than the portable terminal 3, such as a mobile telephone that is not a smartphone, a digital camera that is provided with a computation function, or the like, for example. The image capture device may be any device, such as a CCD camera or the like, that is capable of capturing an image and outputting image data for the captured image. The structure of the embroidery frame, such as its shape, size, or the like, may be modified as desired. For example, the embroidery frame may be such that the clamping portion of the embroidery frame includes an upper frame (the first frame) and a lower frame (the second frame) and that the upper frame and the lower frame are configured to clamp the sewing workpiece from above and below. In that case, in a state in which the sewing workpiece is clamped, the visible position on the side that faces the needle bar of the sewing machine is on the top face of the upper frame.
(B) The configurations of the various types of marks (the indicator mark 110, the reference marks 150, and the type mark 160) may each be modified as desired. For example, at least one of the size, the material, the design, and the color of a mark may be modified. The characteristic points of the marks that are used in the processing that is described above may be modified as desired. In a case where the marks that are described above include line segments that intersect one another, for example, the CPU 121 may identify a point of intersection as a characteristic point. The CPU 121 may also identify an endpoint of a line segment as a characteristic point.
The number of the indicator marks 110 and the number of the characteristic points that any one indicator mark 110 contains can be modified as desired. In a case where the positioning of the embroidery pattern is specified based on a plurality of the indicator marks 110, the positioning of the embroidery pattern, particularly the angle of the embroidery pattern, can be set with greater precision than in a case where the positioning of the embroidery pattern is specified based on one indicator mark 110. It is acceptable for the CPU 121 to detect at least one of the position and the angle of the indicator mark 110 as the positioning of the indicator mark 110, based on the image data. The characteristic points for specifying the positioning of the indicator mark 110 (in the embodiment that is described above, the first center point 111 and the second center point 112 of the indicator mark 110) and the method for computing the positioning may be modified as desired, taking into account the structure and the like of the indicator mark 110.
In the same manner, the number of the reference marks 150 and the number of the characteristic points that any one reference mark 150 contains can be modified as desired. For example, in a case where one reference mark includes a plurality of characteristic points, it is acceptable for only one reference mark to be provided. In a case where the CPU 121 performs keystone correction based on the characteristic points of the reference marks, as in the embodiment that is described above, it is preferable for there to be at least one reference mark and a total of at least four characteristic points included in the at least one reference mark. In a case where only one type of the embroidery frame 53 can be mounted on the embroidery device 2, in a case where the user inputs the type of the embroidery frame 53 to the portable terminal 3, and the like, it is acceptable for the type mark 160 not to be provided on the embroidery frame 53. The number of the type marks 160 and the number of the characteristic points that the type marks 160 contain can be modified as desired.
(C) The structure of the pattern data and the embroidery data and the methods for creating the pattern data and the embroidery data, may be modified as desired. For example, in a case where the embroidery pattern is a pattern to be sewn in a plurality of colors, the pattern data and the embroidery data may include thread color data. The thread color data indicate the colors of the threads that will form the stitches. The setting of the coordinates in the embroidery coordinate system may be determined in advance and may be modified as desired. The coordinate system for the coordinates that are indicated by the positioning data that are computed based on the image data may be different from the embroidery coordinate system, as long as the coordinates can be converted between the two systems. In that case, the sewing machine 1 may perform processing that converts the positioning data into data for the embroidery coordinate system.
(D) The program that contains the instructions for performing the first processing in
(E) The individual steps of the first processing in
(E-1) In a case where only one type of the embroidery frame 53 can be mounted in the sewing machine 1, in a case where the user inputs the type of the embroidery frame 53, and the like, the processing from Step S36 to Step S40 in
(E-2) In a case where the orientation of the embroidery frame 53 in the captured image is fixed, the portable terminal 3 may omit the processing at Step S42 in
(E-3) Some or all of the processing at Steps S7, S11, and S12 in
(E-4) In a case where the image is captured in a state in which the embroidery frame 53 is mounted on the embroidery device 2, the embroidery frame 53 may be moved to an image capture position that is set in advance. The embroidery frame 53 may be moved based on a command that the user has input directly to the sewing machine 1. The processing that moves the embroidery frame 53 to the image capture position may be omitted as necessary. The amount of movement from the initial position to the image capture position may also be the same, irrespective of the type of the embroidery frame 53. The image capture position may also be set to any position that is suitable for image capture.
(E-5) The CPU 61 of the sewing machine 1 may set one of the position and the angle of the embroidery pattern based on the positioning data. For example, in a case where the CPU 61 sets the position of the embroidery pattern based on the positioning data, the CPU 61 may set the angle of the embroidery pattern to an initial angle. The reference to be used when the CPU 61 sets one of the position and the angle of the embroidery pattern based on the positioning data may be set in advance, and may be modified as desired. Any known method may be used as the method for computing the positioning data, and the method is not limited to the method that was explained in the embodiment that is described above.
(E-6) The size of the embroidery pattern is not limited to the size of the smallest rectangle in which the embroidery pattern can be contained. For example, the size of the embroidery pattern may also be represented in terms of the diameter of the smallest circle in which the embroidery pattern can be contained. In that case, in the processing at Step S50 in
The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-027496 | Feb 2013 | JP | national |
