Patent Application
20110048304
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application 2009-198202, filed on Aug. 28, 2009, the entire contents of which are incorporated herein by reference.
The present disclosure relates to a sewing machine system configured by a sewing machine and a thread spool storage device communicably interconnected through a communication element and a thread spool storage device for use with the sewing machine system.
Sewing machines are known to utilize multiple colors of threads in operations such as embroidery pattern sewing. In doing so, multiple thread spools or bobbins each carrying different thread color are stored at their designated places such as a storage device. Then, on execution, the user is to retrieve the thread spool or the bobbin, whichever is required, carrying the desired thread color from the storage device.
One typical example of a storage device is a bobbin storage container for storing supply of multiple bobbins for use with a sewing machine. The bobbin storage container is configured by multiple layers of independent bobbin support bases each having multiple bobbin support pins. Each of the bobbin bases are pivoted rotatably to a base shaft. Under such configuration, the user is required to find the bobbin carrying the desired thread color from the multiplicity of bobbins with his/her very eyes and thus necessitates troublesome search on the part of the user.
A possible solution to such problem may be a thread spool stand. A thread spool stand is configured by a thread support base with six threads spool pins extending from the base to allow attachment of six thread spools. The thread spool stand is connected to the embroidery sewing machine through a dedicated cable. The thread spool base is driven rotatably by a motor and the rotational position of thread spool stand is sensed by a position sensor. When the thread spool stand receives a thread color code from the sewing machine, the motor is controlled to drive the thread spool base in rotation to bring the thread spool corresponding to the thread color code in front of the user.
Because the thread spool stand requires a number of components such as the motor, position sensor, and the motor controller, the overall configuration becomes somewhat complicated. Further, since the size of the device increases with the capacity to hold greater number of thread spools, the device becomes more costly and space consuming. Because of such tradeoffs it is not easy to increase the number of thread spools and thus to undertake embroidering using large number of thread colors.
One object of the present disclosure is to provide a sewing machine system allowing readily retrievable storage of multiplicity of thread spools of various colors for use in a sewing machine and a thread spool storage device.
According to one aspect of the present disclosure, there is provided a sewing machine system including a sewing machine capable of sewing patterns with a plurality of thread colors based on pattern data; and a thread spool storage device that is provided with a plurality of compartments for storing a plurality of thread spools and that is communicably connected to the sewing machine by a communication element. The sewing machine includes a pattern selection validator that validates a selection of the pattern data containing a plurality of thread color data, a thread color information storage that stores a mapping of thread color information of the thread spools to the compartments of the thread spool storage device, a compartment identifier that, when the selection of the pattern data is validated by the pattern selection validator, searches the thread color information storage to find the thread color information pertaining to the thread color data contained in the pattern data and that transmits compartment identification information that locates the compartment being mapped to the found thread color information to the thread spool storage device. The thread spool storage device includes a compartment location indicator that indicates a location of at least one of the compartments, and a location indication controller that controls the compartment location indicator to indicate the locations of the compartments based on the compartment identification information obtained from the sewing machine by way of the communication element.
Other objects, features and advantages of the present disclosure will become clear upon reviewing the following description of the illustrative aspects with reference to the accompanying drawings, in which,
A description will be given hereinafter on a first exemplary embodiment of the present disclosure with reference to
Though neither shown nor described in detail, head 6 contains components such as needle bar, presser bar, and presser foot 7. Bed 3 allows detachable attachment of embroidery frame transfer device 8 which in turn allows detachable attachment of embroidery frame 11. Though not shown in detail, embroidery frame transfer device 8 well known in the field is provided with Y-direction transfer mechanism 9 and an X-direction transfer mechanism contained in body 8a of embroidery frame transfer device 8. These transfer mechanisms transfer embroidery frame 11 in the front and rear direction represented as the Y direction and the left and right direction represented as the X direction. The aforementioned needle bar and the presser bar are supported movably up and down by head 6. At the lower end of needle bar, a sewing needle not shown is attached, whereas at the lower end of presser bar, presser foot 7 is attached which is used in embroidering. Bed 3 further contains rotary shuttle not shown acting as a thread loop taker. A sewing machine as such exemplified in
Sewing machine 1 is further provided with a sewing machine motor, a needle-bar drive mechanism that drives the needle bar, a thread take-up, and a thread take-up mechanism that drives the thread take-up, and a shuttle drive mechanism that drives the rotary shuttle neither of which are shown. The needle bar, the thread take-up, and the rotary shuttle are driven in synchronism with the sewing machine motor by way of the foregoing drive mechanisms. The needle bar, the thread take-up, and the rotary shuttle cooperate to form stitches on a workplace cloth.
On the upper portion of arm 5, cover 5a is provided which can be opened and closed. In the lateral middle of arm 5, thread spool 10 is set that feeds needle thread to the sewing needle.
As shown in
Referring now to
Still referring to
Referring to
As shown in
Controller 21 receives input signals from input section 22. Controller 21 is responsible for controlling display 13 and the sewing operation in general. Controller 21 is further connected to nonvolatile memory 23.
Input section 22 includes earlier mentioned components such as key switches 12 at the front face of arm 5 and switches such as touch panel switches 13a.
Nonvolatile memory 23 stores collection of unique IDs hereinafter referred to as compartment ID which is associated with each of compartments 15A to 15P. Compartment ID specifies location information of each of compartments 15A to 15P through, for instance, identification by row number counted from the top and column number counted from the left. Further, thread color information of thread spools 10 stored in each of compartments 15A to 15P is associated with each of compartments 15A to 15P. Compartment ID and the thread color information of thread spools 10 are mapped to each other in the form of compartment ID-thread color database which is stored in nonvolatile memory 23. Nonvolatile memory 23 further pre-stores embroidery pattern data.
Referring now to
Next, a description will be given on the electric configuration of thread spool storage device 14. Control circuit 24 is capable of communicating with sewing machine 1 by way of USB cable 20. Control circuit 24 is provided with a detection circuit that detects the count or the presence/absence of thread spools 10 within each of drawers 16A to 16P based on optical sensors 19a to 19f provided at each of remainder sensors 19A to 19P. Control circuit 24 is further provided with remainder indicator circuit for indicating the count of thread spools based on the detection of the detection circuit and status LED indicator circuit pertaining to the display of status LEDs 17A to 17P. Remainder indicator circuit flickers the leftmost LED 18a among the 5 LEDs 18a to 18e of remainder indicator 18A provided in the corresponding compartment 15A when the count of detected thread spools 10 by remainder sensor 19A is 0. Remainder indicator circuit illuminates the leftmost LED lea when the count of detected thread spool is 1. Remainder indicator circuit illuminates the leftmost LED 18a and LED 18b second from the left when the count of detected thread spool is 2. Thereafter, the remainder indicator circuit increases the count of LED to be illuminated depending upon the count of detected thread spools and when 5 or more thread spools have been detected, all of LEDs 18a to 18e are illuminated. Compartments 15B to 15P operate in the same manner.
The status LED indicator circuit indicates the location of compartments 15A to 15P on status LEDs 17A to 17P based on the acquired compartment ID.
Referring now to the flowcharts indicated in
Description is given hereinafter on the process flow of controller 21 subdivided into steps S1 to S20. After power switch not shown of sewing machine 1 is turned on the process flow begins with Step S1 which presents a mapping of compartments 15A to 15P to thread color as exemplified as screen H1 in
To elaborate, thread colors of thread spools 10 set to compartments 15A to 15P are presented through status LED indicators Ia to Ip. For instance, in compartment ID-thread color data base, supposing that thread color green is associated with the compartment ID of compartment 15A, status LED image Ia which represents compartment 15A is displayed in green.
After presenting the relation of compartments 15A to 15P to thread color on display 13 at step S1, the process proceeds to step S2 in which determination is made as to whether or not input section 22 has been operated. The input operations which are the subjects of determination in this case are: (a) input operations for specifying thread color to each of compartments 15A to 15P: and (b) switch operation for switching the screen output of display 13 to embroidery pattern selection screen.
Color specification under case (a) begins with the user operation of the touch panel switch 13a associated with the desired compartment image Ha to Hp in screen H1. Then, the user proceeds to touch the touch panel switch 13a associated with the desired color image within the color pallet Cr, whereafter switch 13a associated with “SET” image Hset is touched. The above described sequence of touch operation is referred to as color specification input. Based on the color specification input (step S3: Yes), the compartment ID corresponding to either of the touch operated compartment images Ha to Hp is associated with the color information of the touch operated color image within the color pallet Cr. The color information thus designated to the compartment ID is stored in nonvolatile memory 23 (step S4).
Switching the screen output of display 13 to embroidery pattern selection screen for case (b) is effected by touching either of screen switch control Ga and screen switch control Gb presented on screen H1. When this operation has been made (step S5: YES), the succeeding step S6 changes the screen output to embroidery pattern selection screen not shown. The embroidery pattern selection screen displays samples of embroidery patterns which can be selected. The user is to select one of the embroidery patterns through touch operation. The selection made at this stage is considered as a provisional selection. When determining that provisional embroidery pattern selection is made, step S7 makes a YES decision and the process proceeds to step S8.
At step S8, the compartment ID corresponding to all the colors to be used in sewing the embroidery pattern provisionally selected at step S7 are transmitted to the thread spool storage device 14. To elaborate, step S8 begins with the task of reading the embroidery pattern data for the embroidery pattern provisionally selected at step S7 from nonvolatile memory 23. This is followed by the task of searching the thread color information (i.e. compartment ID-thread color data base) of thread spool 10 stored in nonvolatile memory 23 to find color information that matches the thread color data contained in the provisionally selected embroidery pattern data. Then, compartment ID associated with the thread color information for which a match was found by the search are transmitted to thread spool storage device 14. The operation of thread spool storage device 14 carried out in step S8, that is, indication or alert produced by status LEDs 17A to 17P will be later described in detail.
Then, when a pattern selection validation switch not shown is operated, a YES decision is made at step S9 which is an indication that the embroidery pattern has been finally selected and the process proceeds to step S10. Step S10 transmits the compartment ID associated with the first sewn thread color among the thread color data contained in the finally selected embroidery pattern data to thread spool storage device 14. Taking the example of a case where the embroidery pattern data indicated in
Thereafter, when sewing operation is started by operating start/stop key 12a (step S1: YES), the process proceeds to step S12 which initiates the sewing of the first color. At this instance, embroidery frame transfer device 8 is controlled based on color-wise needle transfer data providing the needle transfer data pertaining to a given single color, which is red in this case, in coordination with the needle bar, the thread take-up, and the rotary shuttle to execute a series of sewing operation pertaining to the thread color “red”. Then, the subsequent step S13 determines the presence/absence of a thread change code for the next color-wise needle transfer data and if found (step S13: YES), the process proceeds to step S14. Step S14 reads the thread color data corresponding to the second thread change code, in this case “blue” according to the example shown in
Then, when sewing of a given color in this case for the color “red” is completed based on color-wise needle transfer data (steps 15: YES), a request for prompting thread replacement is made through a request screen outputted on display 13 (step S16). Thread spool storage device 14, on the other hand, produces an indication as later described in step T8 to inform the user of the location of the compartment 15A to 15P where “blue” thread spool 10 is stored based on the transmitted compartment ID. Responsively, the user is prompted by the request screen to take out the “blue” thread spool 10 from compartment 15A to 15P and replace it with the “red” thread spool 10 currently attached to sewing machine 1. Then, when start/stop switch key 12a is operated again to restart the sewing operation, a YES decision is made at step S17 and the process proceeds to step S12 to start sewing based on the color-wise needle transfer data for the subsequent given single color of thread. Then, as described earlier, if step S13 determines the presence of the next thread change code, steps S14 to S17 are executed. In the current example, steps S14 to S17 are repeated for the three colors “red”, “blue”, and “yellow” identified by the thread color code and when sewing is started based on the color-wise needle transfer data for the final color “green”, step S13 makes a No decision meaning that no more thread change code exists. In such case the process proceeds to step S18 and turn off command transmitted to thread spool storage device 14 for turning off each and every status LED 17A to 17P.
After completing the sewing based on the last color-wise needle transfer data (step S19: YES), a message is outputted on display 13 indicating to that effect (step S20).
Next, the operation of control circuit 24 of thread storage device 14 is described by also referring to
Based on the remainder indication, the user is allowed to readily notice which of compartments 15A to 15P of thread spool storage device 14 has few thread spools or no thread spools at all. Further, the user is allowed to verify the thread color designated to each of compartments 15A to 15P though screen H1 outputted to display 13 of sewing machine 1 as earlier described in step S1. Thus, the user is able to preemptively supply thread spool 10 to compartments 15A to 15P in need.
Step T3 determines whether or not the compartment ID associated with the thread color information of the provisionally selected embroidery pattern transmitted from sewing machine 1 at step S8 has been received. If so (step T3; YES), the process proceeds to step T4 to continuously illuminate status LED 17A to 17P indicating the location of the compartment designated by the compartment ID. Thus, the location of the compartment associated with each of the thread colors, in this case, “red”, “blue”, “yellow”, and “green” contained in the provisionally selected embroidery pattern data is informed to the user. Advantageously, the user is given advance notice of where the thread spools 10 of the 4 colors used in the embroidering of the provisionally selected embroidery pattern is stored.
Step T5 corresponds to step S10 carried out by sewing machine 1. That is, a determination is made as to whether or not the compartment ID associated with the first used thread color information has been received. If so (step T5: YES), the process proceeds to step S6 to turn off the currently illuminated status LED 17A to 17P and status LED 17A to 17P associated with the compartment ID received at step T5 is flickered. Stated differently, mode transition takes place in which a continuous indication mode that produces continuous indication through the above described illumination of the status LEDs 17A to 17P for each and every color used in the embroidery pattern transitions to an intermittent indication mode that produces intermittent indication through flickering of the status LEDs 17A to 17P for only the first thread color used. The user is thus, given a notice as to which of the compartments 15A to 15P stores the first used thread spool 10 which is “red” in the current example. Responsively, the user is to take out the “red” thread spool 10 from compartment 15A to 15P and set it to sewing machine 1. After setting thread spool 10, step 11 is executed by sewing machine 1 which is an operation to start sewing.
As sewing with the first thread color is started at sewing machine 1, thread spool storage device 14 is standing by at step T7 to receive the compartment ID corresponding to the thread color of the second thread change code. When receiving the compartment ID from sewing machine 1 (step S7: YES), the process proceeds to step T8 which turns off the currently illuminated status LEDs 17A to 17P and flickers status LED 17A to 17P corresponding to the compartment ID. Thus, the user is given an advance notice on where the “blue” thread spool successively used is stored. This allows the user to take out the second color thread spool 10 to prepare for sewing of the second color while the sewing of the first color is ongoing.
If another transmission takes place at Step S14 from sewing machine 1, thread spool storage device 14 responsively executes step T7 and step T8. That is, by repeating step T7 and step T8 for the thread change codes designating “yellow” and “green”, the user is allowed to prepare thread spool, etc. for thread replacement in a smooth and efficient fashion.
If there is no more succeeding thread change code, meaning that sewing is started with the last color-wise needle transfer data, thread spool storage device 14 receives the turn off command transmitted at step S18 (step T9; YES). Responsively, the process proceeds to step T10 and turns off each and every status LED 17A to 17P that was flickering. Thus, the user is notified the fact that there is no more thread replacement.
Sewing machine system M according to the present exemplary embodiment automatically extracts the thread colors) used in the embroidery once sewing machine 1 selects the embroidery pattern data. Further, the compartment IDs which designate the locations of compartments 15A to 15P in which the thread spools 10 of the extracted thread colors are stored are transmitted automatically to thread spool storage device 14. Based on the transmitted compartment IDs, thread spool storage device 14 produces an indication to inform the user of the location of compartment where thread spool 10 used in sewing the selected embroidery pattern is stored. Thus, the user will be able to readily find where the designated thread spool 10 is stored without fail because the indication is produced by thread spool storage device 14 from which the designated thread spool 10 is actually stored and taken out. The above described configuration is further advantageous in keeping thread spool storage device 14 simple in construction without necessitating motors or any such complicated mechanism. Still further, because of the above described highly reliable configuration for finding the designated thread spool 10, the system will be able to manage increasing number of thread spools 10.
Thread spool storage device 14 is provided with status LEDs 17A to 17P one for each of compartments 15A to 15P. Thus, the location of compartment 15A to 15P designated by sewing machine 1 can be informed directly to the user especially because the indication is brought to the attention of the user by way of light with reliability.
Each of compartments 15A to 15P provided at thread spool storage device 14 is capable of storing more than one thread spools 10. Thus a stock of multiple thread spools 10 may be stored in each compartment 15A to 15P to reduce the frequency of replenishing thread spool 10. Further, the count of remaining thread spool or the presence/absence of thread spools within compartments 15A to 15P can be informed to the user in the form of a remainder indication through remainder indicators 18A to 18P based on the detection of remainder sensors 19A to 19P. Thus, thread spool 10 can be replenished prior to or after sewing in response to the indication and prevent situations where sewing has to be interrupted for the purpose of replenishing thread spool 10 during the ongoing sewing.
Remainder indicators 18A to 18P provided at thread spool storage device 14 are configured by LEDs 18a to 18e and are provided one by one to each of the compartments 15A to 15F. Thus, the remaining amount of thread spool 10 can be indicated through LEDs 18a to 18e for each individual compartment 15A to 15P. Further, because the indication is given by light, it is clearly noticeable to the user.
The embroidery pattern data of sewing machine 1 contains a thread change code that instructs changing of thread color to a specific color. As described earlier, sewing machine 1 initially transmits the compartment ID of the thread color first used to thread spool storage device 14 and thereafter transmits the compartment ID corresponding to the thread color information by the thread change code to thread spool storage device 14 prior to the timing of actual thread replacement. Based on the compartment ID associated with the first used color information, thread spool storage device 14, through its control circuit 24, informs the user of the location of compartment 15A to 15P designated by compartment ID through status LED 17A to 17P. The above described configuration allows thread spool storage device 14 to inform the user of thread spool 10 carrying the first used thread color and thread spool 10 which must be changed in a smooth and organized manner.
Further, according to sewing machine system M, selection of embroidery pattern is made at sewing machine 1 in two steps where the user makes a provisional selection of an embroidery pattern to be sewn and thereafter finalizes the selection by validating it. Thus, the location of compartment 15A to 15P associated with each and every thread color contained in the thread color data can be informed to the user through thread color storage device 14. This provides an advance notice to the user as to the location of compartments 15A to 15P associated with each and every thread color used in the embroidery pattern prior to finalizing the selection of embroidery pattern, which is convenient to the user in determining the embroidery pattern. Further, the locations of compartments 15A to 15P of the thread colors used in the provisionally selected embroidery pattern are given in a different mode of indication compared to the mode, of indication for the finally selected embroidery pattern. Thus, it is readily distinguishable to the user as to whether or not the indication pertains to the thread colors of the provisionally selected embroidery pattern.
More specifically, the mode of indication under the provisionally selected embroidery pattern is given in a continuous mode in which the illumination is continuous, whereas the mode of indication under the finally selected embroidery pattern is given in an intermittent mode in which the illumination is intermittent. The switch in the mode of indication from the continuous mode to the intermittent mode, which is visually recognizable by the user, makes it apparent to the user that the indication being presented to the user is based upon the finally selected information which was finally selected after having been provisionally selected.
Sewing machine 1 is provided with display 13 capable of displaying in color and that provides a mapping between the thread color and compartment location with which the thread color is associated. The user is thus, allowed to readily recognize which color of thread spool 10 is stored in which compartment.
Thread spool storage device 14 is provided with status LEDs 17A to 17P which provides an indication of the location of the compartment where the designated thread color is located under the control of control circuit 24. To elaborate, control circuit 24 obtains compartment ID from sewing machine 1 by way of USB cable 20 and instructs status LEDs 17A to 17P to indicate the location of compartments 15A to 15P which are designated in the compartment ID. Thus, the location of compartments 15A to 15P which store thread spools 10 of thread colors used in the embroidering by sewing machine 1 is readily noticeable to the user with a simple system configuration. Thus, thread spool 10 of the thread color used in the embroidering is readily and reliably accessible to the user.
Statue LEDs 17A to 17P provided one for each of compartments 15A to 15P of thread spool storage device 14 indicates the location of compartments 15A to 15P designated by sewing machine 1 by way of light which is reliably noticeable to the user.
Each of compartments 15A to 15P provided at thread spool storage device 14 is capable of storing more than one thread spools 10. Thus a stock of multiple thread spools 10 may be stored in each compartment 15A to 15P to reduce the frequency of replenishing thread spool 10. Further, the count of remaining thread spool or the presence/absence of thread spools within compartments 15A to 15P can be informed to the user in the form of a remainder indication through remainder indicators 18A to 18P based on the detection of remainder sensors 19A to 19P. Thus, thread spool 10 can be replenished prior to or after sewing in response to the indication and prevent situations where sewing has to be interrupted for the purpose of replenishing thread spool 10 during the ongoing sewing.
Remainder indicators 18A to 18P provided at thread spool storage device 14 are each configured by 5 LEDs 18a to 18e and are each provided one by one to each of the compartments 15A to 15P. Thus, the remaining amount of thread spool 10 can be indicated through LEDs 18a to 18e for each individual compartment 15A to 15P. Further, because the indication is given by light, it is clearly noticeable to the user.
The configuration of sewing machine system M is not limited to the foregoing exemplary embodiments but may be modified as follows.
The thread color information designated for each of compartments 15A to 15P can be seen at a glance through status LED images la to lp of screen H1 as described in step S1. In addition to such mode of presentation, an approach exemplified in
Provision of drawers 16A to 16P to compartments 15A to 15P is not mandatory. Instead, the compartments may be configured in the form of a box, preferably with an operable/closable lid provided over the box opening, that allows thread spool 10 to be taken in out.
The count of LEDs 18a to 18e configuring the remainder indicators 18A to 18P is not limited to 5 but may be 3 or any other appropriate count. The color of light emitted by LEDs 18a to 18e may be modified as required. Remainder sensors 19A to 19P may be configured by a weight sensor instead of an optical sensor.
Status LED 17A to 17P may be configured to indicate the location of at least one of the compartments from the multiple compartments. Status LED 17A to 17P and remainder indicators 18A to 18B providing information by way of light may be replaced by other elements that provide information in different approaches such as a liquid crystal display and audio element.
Sewing machine 1 may be provided with a sensor that senses detachment of thread spool 10 from sewing machine 1. When the detachment of thread spool 10 is sensed by the sensor, thread spool storage device 14 may be configured to indicate the location of the compartment where the relevant thread spool 10 was originally stored.
In the foregoing exemplary embodiments, the mode of indication under the provisionally selected embroidery pattern is given in the continuous mode, whereas the mode of indication under the finally selected embroidery pattern is given in the intermittent mode. The above correlation may be interchanged as long as the two modes are distinguishable. In either case, the distinction can be made with a single set of indicator to advantageously simplify the system configuration.
In the foregoing exemplary embodiments, sewing machine 1 has been configured to accept only a single set of needle thread, however, it may be configured to accept multiple sets of needle threads. Further, the capacity of sewing machine 1 is not limited to forming embroidery patterns but may also be capable of forming utility patterns or any other patterns so long as such patterns have thread attributes such as color designated to them.
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 |
|---|---|---|---|
| 2009-198202 | Aug 2009 | JP | national |
