Sewing machine with detachable and independently driven loop taker module

Abstract

A sewing machine including a head portion for mounting a needle with a needle thread; a needle drive motor for driving the needle; a bed portion; and a loop taker module detachably fixed to the bed portion and including: a loop taker for catching a thread loop of the needle thread of the needle; and a loop taker drive motor for driving the loop taker.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a sewing machine including a head portion for mounting a needle and a bed portion for mounting a shuttle or other type of loop taker for seizing a thread loop in cooperation with the needle.

2. Description of the Related Art

Conventionally, there has been known a sewing machine including a bed portion, a column portion protruding upward from the bed portion, an arm portion protruding horizontally from the upper end of the column portion, and a head portion attached to the opposite end of the arm portion from the column portion and in confrontation with the bed portion. A principal shaft for driving the head portion via a sewing machine motor is disposed within the arm portion. A needle bar, and consequently the needle attached to the needle bar, and levers in the head portion are vertically driven by drive force from the principal shaft. A shuttle rotated by a lower shaft and for taking the thread loop in cooperation with the needle is disposed within the bed portion. Drive force for rotating the lower shaft is also provided from the principal shaft. Because the needle and the shuttle must be operated in synchronization, the lower shaft is connected to the principal shaft and driven by drive force from the principal shaft.

Japanese Patent Application Publication No. SHO-60-21750 describes a sewing machine provided with a needle drive motor for driving the sewing needle and a shuttle drive motor for driving the shuttle independently from the needle drive motor. The needle drive motor and the shuttle drive motor are controlled to operate in synchronization so that operation of the sewing needle and the shuttle is synchronized. This configuration enables sewing a series of stitches using perfect stitch, wherein the direction in which the stitches are formed is the same as the direction in which the workpiece cloth is fed. Perfect stitch enables stitches and tightness of stitches superior to, for example, pitch stitch.

Japanese Utility Application Publication No. SHO-61-15816 describes a similar sewing machine provided with a needle drive motor and a shuttle drive motor controlled to operate in synchronization to prevent skipping stitches and to enhance the tightness of stitches. Japanese Patent Application (Kokai) No. HEI-3-234291 describes a sewing machine including a sewing machine motor for driving the sewing machine needle via the principal shaft and a shuttle drive motor, which is different from the sewing machine motor, for driving the shuttle independently from the sewing machine motor. Further, a rotary encoder for detecting the rotational amount of the sewing machine principal shaft is also provided. A movement control means is provided for rotating the shuttle drive motor by an amount corresponding to an amount that the principal shaft is rotated by hand. This configuration enhances synchronization between the operations of the sewing needle and the shuttle.

Japanese Patent Application (Kokai) No. HEI- 4-51991 describes a multi-head type embroidery sewing machine wherein a needle bar drive mechanism, a lever drive mechanism, a cloth pressure foot drive mechanism, and a shuttle drive mechanism are all driven independently to increase versatility with respect to the different feel of the embroidery.

SUMMARY OF THE INVENTION

In all of the conventional sewing machines described above, the drive motor for driving the shuttle and the components of the transmission system for transmitting drive force from the drive motor to the shuttle are all fixedly mounted within the bed portion. This configuration prevents attempts to increase the usability of the shuttle drive motor and its transmission system. Because the shuttle drive motor and its transmission system can not be used commonly in a variety of sewing machines, a new shaft drive motor with its drive force transmission system needs to be designed and produced for each type of sewing machine, thereby increasing manufacture costs.

Because the shuttle drive motor and its drive force transmission system are fixedly mounted within the bed portion, it is also difficult to increase operation efficiency during repairs and assembly. In the case of a two-needle sewing machine, because the pair of shuttles are provided near each other within the bed portion, replacement of bobbins and correction of trouble in the vicinity of the bobbin and the shuttle is difficult to perform. Also, adjustment of the distance between the shuttles when adjusting the distance between the two needles is difficult and requires a complicated mechanism.

It is an objective of the present invention to overcome the above-described problems and to provide a sewing machine wherein the shuttle drive motor and its drive force transmission system are compatible with a variety of sewing machines, are easy to assemble and repair, and are inexpensive to produce.

To achieve the above described objectives, a sewing machine according to the present invention includes a head portion for mounting a needle with a needle thread; a needle drive means for driving the needle; a bed portion; and a loop taker module detachably fixed to the bed portion and including: a loop taker for catching a thread loop of the needle thread of the needle; and a loop taker drive means for driving the loop taker.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view partially in phantom schematically showing a two-needle sewing machine according to an embodiment of the present invention;

FIG. 2 is a front view showing a sewing system including the two-needle sewing machine of FIG. 1;

FIG. 3 is a view from a right side of the sewing system;

FIG. 4 is an enlarged view partially in phantom showing a cloth feed mechanism and a bed portion of the two-needle sewing machine, the bed portion including a shuttle module;

FIG. 5 is a plan view showing the bed portion and the cloth feed mechanism;

FIG. 6 is a side view partially in cross-section taken along line VI--VI of FIG. 5;

FIG. 7 is a plan view showing the drive system of the cloth feed mechanism and positional change possible by the bed portion;

FIG. 8 is a plan view showing a swing arm and other components of the cloth feed mechanism;

FIG. 9 is a cross-sectional view taken along line IX--IX of FIG. 7;

FIG. 10 is a plan view showing a pivot frame for enabling positional change of the bed portion shown in FIG. 7;

FIG. 11 is a plan view showing the shuttle module of the bed portion;

FIG. 12 is a cross-sectional view taken along line XII--XII of FIG. 13;

FIG. 13 is a rear view partially in phantom showing the shuttle module;

FIG. 14 is a front view partially in phantom showing the shuttle module;

FIG. 15 is a left-side view partially in phantom showing the shuttle module;

FIG. 16 is a cross-sectional view taken along line XVI--XVI of FIG. 14;

FIG. 17 is a cross-sectional view taken along line XVII--XVII of FIG. 11;

FIG. 18 is a perspective view partially in phantom schematically showing a two-needle sewing machine according to a modification of the embodiment; and

FIG. 19 is a side view showing a single-needle sewing machine according to another modification of the embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A sewing machine according to a preferred embodiment of the present invention will be described while referring to the accompanying drawings wherein like parts and components are designated by the same reference numerals to avoid duplicating description.

FIG. 1 is a perspective view partially in phantom showing a two-needle sewing machine 1 according to the present embodiment. The two-needle sewing machine is for simultaneously stitching in a close stitch both ends of trouser belt loops. The sewing machine 1 includes a bed portion 2; a column portion 3 extending upward from one end of the bed portion 2; an arm portion 4 extending horizontally, that is, in parallel with the bed portion 2, from the upper end of the column portion 3; and a head portion 5 at the end of the arm portion 4 opposite the end thereof connected to the column portion. A principal shaft 6 is disposed within the arm portion 4. A sewing motor 7, such as an induction motor, for driving the principal shaft 6 is provided protruding outward from the upper portion of the column portion 3. A needle bar crank mechanism 9 connected to the principal shaft 6 and to a vertically disposed needle bar 8 is disposed in the head portion 5. With this configuration, when the sewing machine motor 7 drives the principal shaft 6, the needle bar 8 is driven up and down via the needle bar crank mechanism 9. A needle support body 10 having a horizontal posture is attached to the lower tip of the needle bar 8. A pair of sewing needles 11a, 11b are connected to either tip of the needle support body 10. The sewing needle 11b is attached so that its position can be adjusted in frontward and rearward directions indicated by arrows in FIG. 1.

The bed portion 2 includes a bed portion body 12 and a shuttle module 13 disposed separated from the bed portion body 12 by a predetermined gap. A rotation shuttle 15 is provided to the bed portion body 12. A rotation shuttle 16 is provided to the shuttle module 13 at a position confronting the rotation shuttle 15. The oscillating shuttles 15, 16 are for catching thread loops. A thread bobbin is provided internally to each of the oscillating shuttles 15, 16. A shuttle shaft 17 for driving the oscillating shuttle 15 by drive power of the principal shaft 6 is disposed with a horizontal posture internally to the bed portion body 12. A crank rod 18 is connected to a crank portion 6a of the principal shaft 6. A sector gear 19 is connected to the crank rod 18. A gear 20 attached to the right tip of the shuttle shaft 17 as viewed in FIG. 1 is meshingly engaged with the sector gear 19 and reciprocally rotatably driven by the principal shaft 6 via the crank rod 18 and the sector gear 19. With this configuration, the oscillating shuttle 15 is driven in synchronization with vertical movement of the needle bar 8 in the same manner as in conventional sewing machines.

The shuttle module 13 includes the oscillating shuttle 16 and a servomotor 21 for driving the oscillating shuttle 16 independently from the principal shaft 6. The shuttle module 13 includes a mechanism enabling shifting of its position between a usage position, in which it is used, to a retracted position rotated horizontally from the usage position by a predetermined pivoting angle. It should be noted that the oscillating shuttle 16 is further from the oscillating shuttle 15 and the head portion 5 in the retracted position than in the usage position. The shuttle module 13 is also configured so that its position can be manually adjusted forward and rearward in order to adjust the gap between the shuttles 15, 16 according to the changes in the distance between the sewing needles 11a, 11b and in order to adjust the positional relationship between the sewing needle 11b and the loop seizing beak of the oscillating shuttle 16. Detailed description of the configuration of the shuttle module 13 will be provided later.

First, a brief explanation of the overall configuration of the two-needle sewing machine 1 will be provided while referring to FIGS. 2 and on. FIG. 2 is a front view of the two-needle sewing machine 1 mounted on a work table 21. FIG. 3 is a view from the right side of FIG. 2.

As shown in FIGS. 2 and 3, the two-needle sewing machine 1 is mounted in the center portion of the work table 21. A control unit 140 and a manual operation unit 23 are attached to the undersurface of the work table 21. An operation panel 26 having a liquid crystal display 24 and an operation portion 25 is disposed with an upright posture to the right edge of the work table 21. A supply unit 27 for supplying a continuous material for forming belt loops is provided adjacent to the operation panel 26 on top of the work table 21. Further explanation of the supply unit 27 will be omitted.

Next, a brief explanation for a cloth feed mechanism 30 will be provided while referring to FIGS. 4 through 9.

As shown in FIGS. 4 through 6, cloth pressure feet 31a, 31b are disposed at positions corresponding to those of the sewing needles 11a, 11b. The cloth pressure foot 31a is supported by an L-shaped plate 33a attached to a vertical guide portion 32a at the front tip of a support arm 32. The cloth pressure foot 31b is supported on an L-shaped plate 33b attached to a vertical guide portion 32b at the front tip of a movable support arm 32A, which is engaged with the support arm 32 so as to be freely slidable frontward and rearward. The movable support arm 32A is releasingly fixed to the support arm 32 by two screws 34, each having a knob. The L-shaped plate 33a fixed to the cloth pressure foot 31a is driven vertically by an air cylinder 35a, which is mounted to the vertical guide 32a so as to be freely slidable in the vertical direction. The L-shaped plate 32b fixed to the cloth pressure foot 31b is driven vertically by an air cylinder 35b, which is mounted to the vertical guide portion 32b so as to be freely slidable in the vertical direction. The support arm 32 is fixed to a connection member 37 of an XY feed mechanism 36. The connection member 37 is fixed to a feed operation body 39. The air cylinders 35a, 35b are driven and controlled by the control unit 140.

A cloth reception plate 38 extends beneath the cloth pressure feet 31a, 31b in order to sandwich a workpiece cloth between itself and cloth pressure feet 31a, 31b. The cloth reception plate 38 is driven by the XY feed mechanism 36 to feed the cloth independently in the X direction, that is, rightward and leftward, and in the Y direction, that is, rearward and forward. The cloth reception plate 38 is fixed to the feed operation body 39 via a support plate 38a. With this configuration, the cloth reception plate 38 operates integrally with the cloth pressure feet 31a, 31b to feed the workpiece cloth while it is sandwiched between the cloth reception plate 38 and the cloth pressure feet 31a, 31b.

The XY feed mechanism 36 including the front/rear feed operation member 39 and a left/right feed operation member 49 will next be described while referring to FIGS. 5 through 9. A q axis servomotor 41 for supplying drive force to drive the front/rear feed operation member 39 and an R axis servomotor 43 for supplying drive force to drive the left/right feed operation member 49 are disposed within a case 40 of a bed portion base 12A of the bed portion 12. The q axis servomotor 41 drives a spiral cam shaft 42 and the R axis servomotor 43 drives a spiral cam shaft 44. A small ring 45b at one tip of an L-shaped swing arm 45 is meshingly engaged with the spiral cam shaft 42. A base portion 45a at the pivotable center of the swing arm 45 is pivotably rotatably fitted to the upper tip of a support shaft 46. A bridge 45c at the other tip of the swing arm 45 is meshingly engaged with a narrow engagement hole 39a extending frontward and rearward in the feed operation body 39. The base tip of a swing arm 47 is pivotably rotatably fitted on a support shaft 48. A small ring 47a positioned at the center of the swing arm 47 is meshingly engaged with the spiral cam shaft 44. A bridge 47b at the leftward most tip of the swing arm 47 is meshingly engaged with a cylindrical engagement hole 49a extending leftward and rightward through the feed operation body 49. A shaft portion 47c below the bridge 47b is connected to the base portion 45a.

The front/rear feed operation member 49 is supported so as to be freely slidable in the frontward and rearward directions by a slide unit 49Y with respect to the base member 50. The left/right feed operation member 39 is supported so as to be freely slidable in the leftward and rightward directions by a slide unit 39X with respect to the front/rear feed operation member 49.

With this configuration, the front/rear feed operation member 49 can be fed frontward and rearward by drive of the R axis servomotor 43 as transmitted via the spiral cam shaft 44, the swing arm 47, and the slide unit 49Y. The front/rear feed operation member 39 can be fed leftward and rightward by drive of the q axis servomotor 41 as transmitted via the spiral cam shaft 42, the swing arm 47, and the slide unit 39X. However, strictly speaking, feed in the X direction and feed in the Y direction are performed via both motors 41, 43. With this configuration, feed amount in the X direction and the Y direction can be precisely controlled by controlling rotational amount and direction of the motors 41, 43 using the control unit 140. It should be noted that the above-described cloth feed mechanism 30 is similar to existing mechanisms.

Next, the shuttle module 13 will be explained.

First, an explanation will be provided for a position switching mechanism 55 for switching the position of the shuttle module 13 and a minute movement mechanism 56 for moving the shuttle module 13 slightly frontward and rearward.

As shown in FIGS. 4, 7, and 10, the shuttle module 13 is formed in a substantially parallelepiped block shape. A pivot frame 57 extends horizontally from the lower side of the bed portion 12 and is attached at its upper front surface to the shuttle module 13. An upright pivot shaft 58 having a head portion 58a for supporting the pivot frame 57 passes through a support hole 57a opened in the pivot frame 57 and into a hole 59 formed near the front left edge of the bed body 12. The support shaft 58 is formed with a hole in which is fitted a taper screw portion at the tip of a horizontal bolt 60 disposed between the head portion 58a of the support shaft 58 and the pivot frame 57. A low friction bearing 61 is provided for enabling the pivot frame 57 to pivot horizontally around the support shaft 58. The pivot frame 57 can be pivoted between a usage position shown by a solid line in FIG. 7 and a retracted position pivoted horizontally approximately 45 degrees from the usage position as shown by a chain line in FIG. 7.

A lock pin 62 for locking the shuttle module 13 in the usage position is driven vertically by an air cylinder 63 so that a tapered engagement portion 62a at the upper tip of the lock pin 62 engages in the engagement hole of a boss portion 64 of the bed body 12. A pair of left and right pressing members 65 abutting the lower surface of a bearing plate 66 are provided to the rear tip of the pivot frame 57. When the shuttle module 13 is to be switched from the usage position to the retracted position, the lock pin 62 is lowered by the air cylinder 63 and the shuttle module 13 is manually pivoted horizontally into the retracted position. The pressing members 65 follow the lower surface of the bearing plate 66 until the shuttle module 13 is switched into the retracted position. It should be noted that a stopper 67 is provided for stopping the shuttle module 13 in the usage position. Although, the shuttle module 13 is configured to be manually moved into the retracted position in the present embodiment, a spring member or an air cylinder can be provided to automatically switch the shuttle module 13 into the retracted position.

A proximity switch 68 for detecting the position of the lock pin 62 turns off when the lock pin 62 is pulled out of the engagement hole of the boss portion 64. A proximity switch 69 for detecting the position of the shuttle module 13 turns on when the shuttle module 13 is switched to the usage position. Detection signals from the switches 68, 69 are supplied to the control unit 140. Switching the shuttle module 13 to the retracted position exposes the forward portion of the oscillating shuttle 15 and the rear portion of the oscillating shuttle 16. Therefore, operations such as exchanging the bobbins within the oscillating shuttles 15, 16 and removing tangled needle and bobbin threads can be easily and efficiently executed.

Next, an explanation will be provided for the minute movement mechanism 56 for moving the shuttle module 13 slightly frontward and rearward in order to adjust the distance between the oscillating shuttles 15, 16 in coordination with adjustment in distance between the sewing needles 11a, 11b and for adjusting minute positional changes between the loop seizing beak of the oscillating shuttle 16 and the sewing needle 11b.

As shown in FIG. 4, to the lower surface of the pivot frame 57 is provided: a shuttle interval adjustment pulse motor 70; a ball screw shaft 71 driven frontward and rearward by the pulse motor 70; and a ball screw nut 72 in screwing engagement with the ball screw shaft 71. The pulse motor 70 is fixed to a bracket 57d of the pivot frame 57. The ball screw shaft 71 is rotatably supported on a pair of the brackets 57b, 57c of the pivot frame 57. A slot 74 elongated frontward and rearward is formed in the pivot frame 57. A pin member 73 fixed to the lower tip of the shuttle module 13 passes through the slot 74 and engages in an engagement hole of the ball screw nut 72 so that rotating movement of the ball screw nut 72 is restricted. The pin member 73 also connects the ball screw nut 72 with the shuttle module 13 so that these move frontward and rearward together.

With this configuration, the shuttle module 13 can be moved slightly forward or rearward via the pin member 73 by loosening two screw members 79, which are for fixing the shuttle module 13 to the pivot frame 57 in a manner to be described later with reference to FIG. 10, and by driving the ball screw shaft 71 by the pulse motor 70 so that the ball screw nut 72 moves slightly rearward or forward. A disc plate 76 of an origin detection unit 75 is fixed to the front tip of the ball screw shaft 71. An optical or electromagnetic origin sensor 77 for detecting small slits formed in the disc plate 76 is attached to the pivot frame 57. The detection signal from the origin sensor 77 is supplied to the control unit 140 so that the control unit 140 can control the pulse motor 70.

FIG. 10 is a plan view showing essential portions of the pivot frame 57 with the shuttle module 13 removed. Elongated slits 78 extending frontward and rearward are formed through the pivot frame 57. The screw members 79 extend downward through the elongated slit 78 and are screwingly engaged with the lower tip of the shuttle module 13. As mentioned above, the shuttle module 13 is fixed to the pivot frame 57 by the screw members 79, and by loosening the screw members 79, the shuttle module 13 can be moved slightly frontward and rearward. The shuttle module 13 can be removed from the pivot frame 57 by removing the screw members 79 entirely.

Further, as shown in FIG. 14, a shallow key groove 80 is formed extending frontward and rearward in the upper surface of the pivot frame 57 and a shallow key groove 81 opposing the key groove 80 is formed extending frontward and rearward direction in the lower tip surface of the shuttle module 13. A common key member 82 is mounted in these key grooves 81, 82 in order to prevent the shuttle module 13 from shifting leftward and rightward with respect to the pivot frame 57.

Next, a brief explanation will be provided for mechanisms within the shuttle module 13.

As shown in FIGS. 11 through 17, the shuttle module 13 includes a housing 90; a needle plate 91 attached by screws to the upper surface of the housing 90; the oscillating shuttle 16; a servomotor 22 for driving the oscillating shuttle 16 via a drive transmission system; a thread cutting mechanism 93 for cutting the needle thread and the bobbin thread; a lubrication supply mechanism 130; and an origin sensor 95 for detecting origin position of a drive shaft of a drive transmission system. The drive shaft 96 extends frontward and rearward through the shuttle module 13. The oscillating shuttle 16 is disposed in the vicinity of the upper tip of the shuttle module 13 and includes a driver 97 driven by the shuttle shaft 96; a middle shuttle 98 driven by the driver 97 and having a loop seizing beak 98a at its tip; a bobbin case 99 within the middle shuttle 98; and a large shuttle body 100.

As can be best seen in FIGS. 14 and 15, a motor housing indentation 101 is formed in the lower left side of the housing 90. A cylinder housing indentation 102 is formed in the upper left side of the housing 91 above the motor housing indentation 101. The servomotor 22 is disposed with a horizontal posture in the motor housing indentation 101. A cover plate 103 covers the left side surface of the motor housing indentation 101 and the cylinder housing indentation 102.

As best seen in FIG. 16, a drive shaft 104 extends through the lower portion of the shuttle module 13 from the front to the rear of the shuttle module 13. A pulley 105 attached to the front tip of the drive shaft 104 and a pulley 106 fixed to the output shaft of the servomotor 22 are connected to move in association by a timing belt 106. As best seen in FIGS. 16 and 17, a sector gear 108 is reciprocally swingably driven around a shaft 109 by a crank rod 107 connected to move in association with a crank portion 104a of a drive shaft 104. A gear member 110 disposed on the shuttle shaft 96 is meshingly engaged with the sector gear 108. With this configuration, rotation of the drive shaft 104 drives the sector gear 108 to reciprocally pivot. The gear member 110 integrally reciprocally rotates with pivoting movement of the sector gear 108 so that the driver 97 of the oscillating shuttle 16 is driven to reciprocally rotate.

As shown in FIG. 12, the position of the shuttle shaft 96 in its axial direction is set by a collar 111, that is detachably mounted with the shuttle shaft 96 and that is fixed to the housing 90 by a screw 112. In addition, an eccentric screw 113 is provided to enable minute adjustment in the axial position of the shuttle shaft 96. By loosening the screw 112, the axial position of the shuttle shaft 96 can be adjusted by rotating the eccentric screw 113. A sleeve body 114 fitted around the shuttle shaft 96 is attached to the shuttle body 100 and fixed to the housing 90 by a screw 115. An eccentric screw 116 is provided to enable minute adjustment in the axial position of the large shuttle body 100. By loosening the screw 115, the axial position of the large shuttle body 100 can be adjusted by rotating the eccentric screw 116.

As shown in FIGS. 11 and 12, the thread cutting mechanism 93 includes: a mobile blade 121 of a mobile blade member 120 disposed below the needle plate 91; a fixed blade 123 fixed to the lower surface of the needle plate 91; and a thread guide plate 122 disposed beneath the blades 121, 123. The needle and bobbin threads 124 extending downward from the workpiece cloth through a guide hole 122a of the thread guide plate 122 and a needle hole of the needle plate 91 are cut by cooperative operation of the mobile blade 121, the fixed blade 123, and the thread guide plate 122. The front tip of the mobile blade member 120 is connected to a midway portion of a link plate 125. A right tip of the link plate 125 is freely rotatably connected to the housing 90 via a connection rod 126. The link plate 125 is swingable between a release position indicated by the solid line in FIG. 11 and an operation position indicated by a two-dot chain line in FIG. 11.

The link plate 125 is urged into the operation position by a pulling spring 127. From this condition, the link plate 125 is driven by drive force of the drive shaft 104 to cut the threads at a predetermined timing. The drive force of the drive shaft 104 is transmitted to the link plate 125 by the following configuration. As best seen in FIG. 13, the upper tip of the connection rod 126 is fixed to the right tip of the link plate 125. The lower tip of the connection rod 126 is fixed to the right tip of an arm member 127. A cam engagement ring 127a at the left tip of the arm member 127 is capable of abutting a cam surface 128a of a cam body 128 attached to the drive shaft 104.

The link plate 125 is switched from its release position to its operation position by an air cylinder 129 disposed in the cylinder housing indentation 102. As best shown in FIGS. 11 and 15, a rod 119 is connected to the left tip of the link plate 125 and depends downward. A nut member 129b at the tip of a rod 129a of the cylinder 129 presses against the rod 119 in order to maintain the link plate 125 in its release position. At a predetermined thread cut timing, the urging force of the air cylinder 129 is released, whereupon the link plate 125 is switched into its operation position by urging force of the pulling spring 127. Then, as shown in FIGS. 13 and 16, the cam engagement ring 127a abuts the cam surface 128a so that the link plate 125 operates according to the shape of the cam surface 128a via the connection rod 126, to cut the thread. Directly afterward, the air cylinder 129 is switched so that the link plate 125 returns to its released position. Although not shown in the drawings, a thread cutting valve of an air supply system for supplying air to the air cylinder 129 is controlled by the control unit 140. If for some reason, movement of the shuttle is stopped directly before a thread is to be cut, the link plate 125 is returned to its release position by the air cylinder 129 so that the thread cutting process is terminated. It should be noted that a solenoid can be used instead of the air cylinder 129.

Next, an explanation will be provided for the lubrication supply mechanism 130. As shown in FIG. 16, an oil tank 131 is provided in an indentation portion 117 formed in the housing 90 at the front side of the drive shaft 104. A wick 132 for supplying oil from the oil tank 131 to sliding portions between the sleeve body 114 and the shuttle shaft 96 extends from the oil tank 131 to a hole formed in the sleeve body 114.

The following is an explanation of operations of the two-needle sewing machine 1. The oscillating shuttle 15, the servomotor 22 for driving the oscillating shuttle 15 independently from the principal shaft 6, and the drive transmission system are formed into a unit in the shuttle module 13. Because the shuttle module 13 is detachably provided to the two-needle sewing machine 1, the drive system can be simplified and made more compact than if the oscillating shuttle 15 were driven by the principal shaft 6. The oscillating shuttle 15 which is nearest the column portion 3 of the two-needle sewing machine 1 is configured to be driven by drive force of the principal shaft 6. Therefore, the oscillating shuttle 15 can be driven by a drive system using a relatively simple configuration. Also, a servomotor need not be provided for the oscillating shuttle 15 so that the two-needle sewing machine 1 is less expensive to produce.

When the shuttle module 13 is switched from its usage position, which is at a 45 degree angle horizontal from its retracted position, the front portion of the oscillating shuttle 15 and the rear portion of the oscillating shuttle 16 are exposed so that the replacement of the bobbins in the oscillating shuttles 15, 16 and removal of tangled threads can be more efficiently performed.

Further, the minute movement mechanism 56 for moving the shuttle module 13 slightly frontward and rearward enables the position of the oscillating shuttle 15 to be automatically minutely adjusted frontward and rearward. As a result, adjustment of the distance between the two shuttles can be easily adjusted to match adjustments in the distance between the needles. Also, the positional relationship between the sewing needle 11b and the loop seizing beak 98a of the oscillating shuttle 15 can be adjusted by the minute movement mechanism 56. Because the shuttle module 13 is provided in an integral unit, assembly of the sewing machine and its operation can be performed more efficiently. When one of the mechanisms or components in the shuttle module 13 becomes defective or breaks down, the shuttle module 13 can be easily detached from the pivot frame 57 and repaired. Also, the shuttle module 13 can be used with a variety of different types of sewing machines so that design and production costs of each of the different types of sewing machines can be reduced.

Because the thread cutting mechanism 93 is in the shuttle module 13, the thread can be automatically cut by operating the air cylinder 129 by commands from the control unit 140. As a result, sewing operations can be more efficiently performed. Also, because the oil supply mechanism 130 has a simple configuration for supplying oil to the sliding portions of the shuttle shaft 91 within the shuttle module 13, there is no need to manually oil the sliding portions. Oil will never run out so that high reliability can be maintained.

Next, modifications of the embodiment will be described.

FIG. 18 is a schematic view of a two-needle sewing machine 1A according to a modification of the embodiment. The two-needle sewing machine 1A includes a pair of rotary hooks 15A, 16A. In order to drive the full rotary hooks 16A using the drive force of the principle shaft 6, a pulley 51 attached to the principle shaft 6 and a pulley 52 attached to the tip of the shuttle shaft 17 are connected by an endless timing belt 53 spanning therebetween. With this configuration, the principle shaft 6 and the shuttle shaft 17 are rotated at the same speed. Although a shuttle module 13A is provided with substantially the same configuration as the shuttle module 13, the shuttle module 13A includes a rotary hook 16A; a servomotor 22A for driving the rotary hook 16A independently from the principle shaft 6; and a drive transmission system for transmitting drive force of the servomotor 21A to the rotary hook 16A.

Other components of the configuration of the shuttle module 13A are substantially the same as those of the shuttle module 13. The two-needle sewing machine 1A differs from the two-needle sewing machine 1 only in that the rotary hooks 15A, 16A are used instead of the oscillating shuttles 15, 16. Therefore, the operations and the effects of the two-needle sewing machine 1A are substantially the same as those of the two-needle sewing machine 1.

As shown in FIG. 19, a shuttle module 13B with the same configuration as the shuttle module 13 can be provided to a bed portion of a single needle sewing machine 1B. Similarly, a shuttle module having the same configuration as the shuttle module 13 can be provided to each bed portion of a multi-head sewing device. For example, the present invention could be applied to a sewing machine provided with two or more thread loop shuttles operated in synchronization with two or more needles. In this case, the thread loop shuttle nearest the column portion could be connected to move with the principle shaft and the other thread loop shuttles could be combined in a unit with their respective motors in a single shuttle module detachably fixed to the bed portion of the sewing machine. In each case, the thread loop shuttle can be either an oscillating shuttle or a rotary hook.

The shuttle module 13 is only an example. A variety of modifications can be made to its configuration and to the components used therein. For example, a pulse motor can be used instead of the servomotor 22. Also, the oscillating shuttle or rotary hook can be driven directly by the pulse motor or the servomotor.

The positional switching mechanism 55 can be designed so that the retracted position is pivoted more than 45 degrees to, for example, 90 degrees with respect to the usage position.

Although the position switching mechanism 55 is described as a pivotal type position switching mechanism, a sliding type position switching mechanism is also conceivable. In this case, the slide type switching mechanism could be designed to allow switching the position of the shuttle module 13 between the usage position and the retracted position wherein the retracted position is shifted about 10 cm in front of the usage position. When the sewing machine is in use, the shuttle module 13 can be fixed in place by a screw or a bolt. In this case, sufficient space can be secured to allow a user to insert his or her hand between the pair of oscillating shuttles 15, 16 by unscrewing the screw or the bolt and switching the shuttle module 13 to its retracted position. This facilitates bobbin replacement and thread processes performed on the oscillating shuttles 15, 16. The switching action of the shuttle module 13 can be performed manually or via an air cylinder or a solenoid. The sliding type position switching mechanism can be applied to any of the sewing machines shown in the attached drawings. Additionally, a variety of modifications can be made to the thread cutting mechanism or to the oil supply mechanism.

Although the present invention is described in the embodiment as applied to a sewing machine using the shuttles 15, 16, the present invention could also be applied to any sewing machine using any type of loop taker, such as a looper type, a rotary hook type, or an oscillating shuttle type. An example of a looper type is described in U.S. Pat. No. 3,742,880, the disclosure of which is incorporated herein by reference. An example of a rotary hook type is described in U.S. Pat. No. 2,085,699, the disclosure of which is incorporated herein by reference. An example of an oscillating shuttle type is described in U.S. Pat. No. 3,006,298, the disclosure of which is incorporated herein by reference.

Operations can be further facilitated by employing an air cylinder or a solenoid to switch the position of the shuttle module 13.

The shuttle module 13 can be switched from the usage position to the retracted position by unlocking the lock pin 62, and pressing the front tip of the shuttle module 13frontward or rearward, whereupon the pivot frame 57 and the shuttle module 13 pivot around the support shaft 58 and into the retracted position. To return the shuttle module 13 to its retracted position, the reverse procedure is followed.

Because the loop taker, or shuttle in this embodiment, is driven by an independent shuttle drive means, or drive motor, the shuttle drive means can be more compact and have a simpler configuration with fewer parts. The loop taker module, or shuttle module, can also be provided in a more compact shape. Because the loop taker module is formed into an independent unit and also detachably fixed to the sewing machine body, operation efficiency during assembly and repair is increased. Particularly, the production costs of a variety of sewing machines can be decreased and usability of the loop taker module is increased because the loop taker module can be used in a variety of different sewing machines.

The shuttle drive means of the loop taker module is controlled to drive the loop taker in synchronization with vertical movement of the needle bar, and consequently its needle. At the same time, rotational speed and rotational position of the loop taker can be controlled by controlling the drive means according to sewing conditions. Therefore, the shuttle can be controlled with much greater precision than were it driven by the principal shaft of the sewing machine.

By using a servomotor or a pulse motor as the drive means, it is easy to control drive of an oscillating shuttle or a rotary hook shuttle.

The loop taker module can be switched using a position switching mechanism between its usage position and its retracted position by either pivoting the loop taker module in a horizontal direction or sliding the loop taker module in an axial direction of the principal shaft. When the loop taker module is pivoted horizontally, it can be pivoted either around a leftward portion of the loop taker module, a rightward portion of the loop taker module, or substantially center of the loop taker module in the lengthwise direction of the loop taker module. Further, the loop taker module can be pivoted either clockwise or counterclockwise from the usage position to the retracted position.

The loop taker module can alternatively be slid in the axial direction of the shuttle motor shaft between the usage position and the retracted position. In this case, the loop taker module is slid in the lengthwise direction of the bed portion away from the column portion by a predetermined distance from the usage position into the retracted position.

Because the loop taker is mounted at the tip of the loop taker module, by pivoting the loop taker module into its retracted position, the edge of the loop taker module is exposed to the user. Sufficient space to expose the end of the loop taker module can be secured. Therefore, replacement of the bobbins and correction of problems in the vicinity of the shuttle can be easily performed.

The mechanism for enabling minute adjustment of the loop taker module in the axial direction of the principal shaft can be manually driven or driven by a pulse motor. By minutely adjusting the loop taker module in the principal shaft direction, minute adjustment in the positional relationship between the loop seizing beak of the shuttle and the sewing needle can be made. Therefore, stitches will not be skipped. Also, adjustment can be made easily according to the thickness of the sewing needle and thickness of the needle thread. Further, in a two-needle sewing machine, the distance between the pair of loop takers can be adjusted when distance between two needles is adjusted.

When a thread cutting mechanism is provided, the needle thread and the bobbin thread can both be automatically cut at the end of sewing operations.

An example of a mechanism for supplying oil includes an oil tank and a wick for introducing oil from the oil tank to sliding portions along the drive shaft. Another example includes an oil tank and an oil pump for supplying oil from the oil tank to sliding portions of the drive shaft via an introduction tube. Because an oil supply mechanism is provided in the loop taker module, there is no need to supply oil to the loop taker module from an external source. This enables producing the loop taker module in a completely isolated unit.

Claims

1. A sewing machine comprising:

a head portion for mounting a needle with a needle thread;

a needle drive means for driving the needle;

a bed portion; and

a loop taker module detachably fixed to the bed portion and including:

a loop taker for catching a thread loop of the needle thread of the needle; and

a loop taker drive means for driving the loop taker, wherein the loop taker drive means in the loop taker module drives the loop taker independently from drive of the needle by the needle drive means, and wherein the loop taker module further includes a thread cutting mechanism near the loop taker and for cutting the needle thread and a bobbin thread.

2. A sewing machine as claimed in claim 1, wherein the loop taker is an oscillating loop taker.

3. A sewing machine as claimed in claim 2, further comprising a position switching mechanism for switching the loop taker module from a usage position in confrontation with the head portion and a retracted position retracted away from the head portion compared with the usage position.

4. A sewing machine as claimed in claim 3, wherein the loop taker module further includes a thread cutting mechanism near the loop taker and for cutting the needle thread and a bobbin thread.

5. A sewing machine as claimed in claim 4, wherein the loop taker module includes an oil supply means for supplying oil to sliding portions of a drive shaft of at least the loop taker drive means.

6. A sewing machine as claimed in claim 1, wherein the loop taker is a rotary hook.

7. A sewing machine as claimed in claim 6, further comprising a position switching mechanism for switching the loop taker module from a usage position in confrontation with the head portion and a retracted position retracted away from the head portion compared with the usage position.

8. A sewing machine as claimed in claim 7, wherein the loop taker module further includes a thread cutting mechanism near the loop taker and for cutting the needle thread and a bobbin thread.

9. A sewing machine as claimed in claim 8, wherein the loop taker module includes an oil supply means for supplying oil to sliding portions of a drive shaft of at least the loop taker drive means.

10. A sewing machine as claimed in claim 1, wherein the loop taker is a looper.

11. A sewing machine as claimed in claim 1, further comprising a position switching mechanism for switching the loop taker module from a usage position in confrontation with the head portion and a retracted position retracted away from the head portion compared with the usage position.

12. A sewing machine as claimed in claim 11, wherein the position switching mechanism includes:

a pivot frame extending horizontally from a lower surface of the bed portion and to which a lower surface of the loop taker module is detachably fixed; and

an upright shaft horizontally pivotally attaching the pivot frame to the bed main portion.

13. A sewing machine as claimed in claim 1, wherein the needle drive means drives the needle via a sewing machine principal shaft extending in a principal shaft direction and further comprising an axial position adjustment mechanism enabling minute adjustments in position of the loop taker module with respect to the principal shaft direction.

14. A sewing machine as claimed in claim 13, wherein the axial position adjustment mechanism includes:

a pulse motor fixed to one of the loop taker module and the bed portion;

a ball screw shaft rotatably driven by the pulse motor and rotatably supported by the bed portion;

a ball screw nut in screwing engagement with the ball screw shaft and connected with the loop taker module to move reciprocally therewith.

15. A sewing device as claimed in claim 1, wherein the thread cutting mechanism includes:

a movable blade; and

a thread cutting operation lever connected to the movable blade and extending through the bed portion.

16. A sewing machine as claimed in claim 1, wherein the loop taker module further includes:

a loop taker shaft for transmitting drive force from the loop taker drive means to the loop taker; and

an oil supply means for supplying oil to sliding portions of at least the loop taker shaft.

17. A sewing machine as claimed in claim 16, wherein the loop taker module further includes a sleeve body fitted around the loop taker shaft, and wherein the oil supply means includes:

an oil tank filled with oil; and

a wick for supplying oil from the oil tank to sliding portions between the sleeve body and the loop taker shaft and extending from the oil tank to the loop taker shaft.