This application is a U. S. National Phase Application of PCT International Application PCT/JP2004/017013 filed on Nov. 16, 2004.
The present invention relates generally to sewing machines of a type which sews a string material, such as a tape or cord, to a fabric through lock switching. More particularly, the present invention relates to an improved sewing machine in which a bobbin having a string material wound thereon is disposed above a needle bar so that it can have an increased size, and which allows the string material to be smoothly paid out from the bobbin by positively rotating the bobbin as necessary when the string material is to be sewn to a fabric.
There have been known sewing machines of a type which includes a vertically driven needle bar, a sewing needle fixed to a lower end portion of the needle bar, a rotary member mounted concentrically with the needle bar and freely rotatable about the axis and a guide fixed to the rotary member for guiding the string material (i.e., string-shaped embroidering member, such as a tape or cord) to a sewing position of the sewing needle. The sewing machines of the type operate to sew the string material to a fabric through lock stitching, by the rotation of the rotary member being appropriately controlled in accordance with a moving direction of a fabric based on embroidery data and by the orientation of the guide being appropriately varied to optimize the direction in which the string material is guided to the sewing position of the sewing needle. One example of such sewing machines is known from Japanese Patent Application Laid-open Publication No. HEI-3-286797. The No. HEI-3-286797 publication discloses a sewing machine of the above-mentioned type, where a bobbin having a string material wound thereon has an increased size by being disposed in a space above the needle bar. The bobbin having the string material wound thereon is mounted on a bobbin shaft supported at its opposite ends by a pair of support members fixed to a machine frame, and the bobbin is supported at its opposite end portions by a pair of retaining members mounted on the bobbin shaft. First guide roller for winding the string material from the bobbin to invert upwardly the feed direction of the string material is rotatably provided beneath a substantial middle region of the bobbin. Roller support frame is rotatably mounted at its proximal end portion to the pair of support members, and a second guide roller for winding thereon the string material, inverted by the first guide roller, and further inverting downward the direction of the string material is rotatably mounted to a portion of the roller support frame corresponding in position to the substantial middle region of the bobbin. Coil spring is provided on the roller support frame for normally biasing the roller support frame in the upward direction, and a brake member is also provided on the roller support frame in such a manner that it can be brought to frictional contact with the retaining members when necessary.
The string material paid out from the bobbin is guided to the sewing position via the first guide roller and second guide roller. As the second guide roller is pulled by the string material in accordance with a progression of sewing of the string material, the roller support frame is caused to pivot downward and the bobbin is rotated by being pulled by the string material so that the string material is paid out from the bobbin. As the tension of the string material decreases by the paying-out of the string material, the roller support frame is caused to pivot upward by the biasing force of the coil spring. Once the roller support frame is caused to pivot further upward by the string material being paid out sufficiently, the brake member is brought to frictional contact with the retaining members, which terminates the rotation of the bobbin and thereby inhibits inertial rotation (overrun) of the bobbin. In such a sewing machine, where the bobbin having the string material wound thereon is located above the needle bar, the bobbin can have an increased size so that an increased amount of the string material can be wound on the bobbin.
In the conventionally-known sewing machines like the one disclosed in the HEI-3-286797 publication, as the string material is paid out from the bobbin and sewn onto a fabric, the bobbin is rotated by being pulled by the string material, in accordance with a progression of the sewing operation, so that the string material is further paid out from the bobbin, as set forth above. However, because the large-size bobbin having an increased amount of the string material wound thereon would have an increased overall weight, an extremely great force would be required to rotate the bobbin in order to pay out the string material. Thus, if the bobbin is very heavy in weight, the rotation of the bobbin tends to be slow so that the paying-out of the string material is delayed behind the sewing operation, and the bobbin tends to start rotating rapidly so that the string material may be paid out more than necessary. Further, depending on the weights of the bobbin and string material, the bobbin may fail to rotate even when it is pulled by the string material being sewn, in which case the string material may not be paid out at all. Thus, the convention sewing machines would suffer from the inconveniences that the string material can not be paid out smoothly, the string material can not be sewn accurately and beautifully or aesthetically and the sewing of the string material is undesirably halted.
It is an object of the present invention to provide an improved sewing machine which allows a sewn material (string material) to be smoothly paid out from a bobbin even if the bobbin has an increased size so that an increased amount of sewn material (string material) can be wound thereon and the bobbin is heavy in weight.
The present invention provides a sewing machine including: a reciprocally-driven needle bar; a sewing needle fixed to the distal end of the needle bar; a rotary member provided concentrically with the needle bar for rotation about the axis of the needle bar; a rotary holder member having an elongated sewn material wound thereon; and a guide for guiding the sewn material, paid out from the rotary holder member, to a sewing position of the sewing needle, the guide being provided for rotation together with the rotary member, the sewing machine sewing the sewn material onto an object of sewing while appropriately adjusting the orientation of the guide by controlling the rotation of the rotary member. The sewing machine comprises: a tension detector that detects tension acting on the sewn material paid out from the rotary holder member; and a drive device that drives the rotary holder member to rotate, and the driving operation of the drive device is controlled on the basis of detection, by the tension detector, of the tension.
According to the present invention, the tension detector detects the tension acting on the sewn material (e.g., string material) paid out from the rotary holder member (bobbin), the drive device drives the rotary holder member, and the driving operation of the drive device is controlled on the basis of the tension detection by the tension detector. Thus, when the sewn material (e.g., string material) is to be paid out from the rotary holder member (bobbin) and sewn onto the object of sewing (fabric), the drive device can be activated to drive or rotate the rotary holder member (bobbin) once the tension acting on the sewn material has increased due to the weight of the rotary holder member (bobbin) and other causes, which thereby allows the sewn material (e.g., string material) to be paid out smoothly. For example, once the sewn material (e.g., string material) has been paid out sufficiently to decrease the tension, the driving operation of the drive device is terminated to stop the paying-out of the string material. By positively rotating the bobbin in accordance with the tension acting on the string material in the aforementioned manner, the string material can be paid out smoothly, with the result that the string material can be sewn accurately and beautifully or aesthetically.
Further, according to the present invention, the rotary holder member (bobbin) having the sewn material (string material) wound thereon is positioned in a space above the needle bar. Thus, the invention is particularly useful in a case where the rotary holder member (bobbin) is constructed into a large size such that an increased amount of sewn material can be wound thereon. Namely, in the present invention, the rotary holder member (bobbin) is positively rotated by the drive device in accordance with the tension acting on the string material, and thus, even where the large-size rotary holder member (bobbin) is heavy in overall weight with a great amount of the sewn material (string material) wound thereon, the present invention achieves the superior benefit that the sewn material (string material) can be paid out appropriately and sewn onto the object of sewing accurately and beautifully.
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At respective predetermined positions beneath the bobbin 10, there are provided a first guide roller 19 for winding therearound and inverting upward the direction of the string material A paid out from the bobbin 10 and a second guide roller 20 for winding therearound and inverting downward the direction of the string material A inverted by the first roller 19. Here, the first guide roller 19 is rotatably mounted on a distal end portion of a support arm 21 fixed to the support member 1b located in a right side area in
The pivot arm 22 is pivotally supported by a base member 24 fixed to the support member 1b, and an actuating piece 25 is fixed to a surface, opposite from the base member 24, of a proximal end portion of the pivot arm 22. The pivot arm 22 is caused to pivot, by tension applied to or acting on the string material A, about the axis of the base member 24. As the pivot arm 22 pivots, the actuating piece 25 pivots together with the pivot arm 22. As seen from
Holder 30 is fixed via a bracket 29 to a front surface (i.e., a surface closer to the reader of
As shown in
Now, an example detailed construction of the machine head H will be described with primary reference to
Engagement member 47 is fixed to the rotary bush 42 and extends downward therefrom, and the engaging member 47 has, at its distal end, an engagement section 47a engaged in a grove 41a formed vertically in the fabric holder 41. Thus, the fabric holder 41 is vertically movable along and rotatable about the axis of the needle bar 45 together with the rotary bush 42. Interlocking member 48 is provided along the outer periphery of the rotary bush 42 in such a manner that it is vertically movable and rotatable together with the rotary bush 42. Ring 49 vertically movable via a not-shown drive source is provided in a groove formed in the outer periphery of the interlocking member 48. Further, a guide lever 50 (e.g., zigzag swing lever) is rotatably provided on the outer peripheral surface of the rotary bush 42. The guide lever 50 is connected with the interlocking member 48 so as to pivot in response to the vertical movement of the interlocking member 48, and a pipe-shaped guide 51 for guiding the string material A to the sewing position of the sewing needle 34 is fixed to the lower end of the guide lever 50.
The following paragraphs describe how the above-described embroidering sewing machine operates to sew a string material A, such as a tape, to a fabric (not shown) by lock switching.
First, the string material A wound on the bobbin 10 is paid out and guided to the sewing position of the sewing needle 34 via the first guide roller 10, second guide roller 20, first tube 31, second tube 32 and guide 51, as explained above. Then, control is performed, on the basis of embroidery data, such that the not-shown fabric is moved in X- and Y-axis directions and the needle bar 35 is vertically driven to perform the well-known lock stitching by the sewing needle 34 in conjunction with a not-shown rotary hook. During that time, the fabric holder 41 is driven vertically, at predetermined timing relative to the vertical movement of the needle bar 35, to perform the fabric holding function, as well known in the art. Further, the ring 49 is driven vertically, at predetermined timing relative to the vertical movement of the needle bar 35, in response to which the interlocking member 48 is vertically moved to cause the guide lever 50 to pivot. As a consequence, the string material A, having been guided to the sewing position of the sewing needle 35 by the guide 51 fixed to the lower end of the guide lever 50, is swung to the left and right of the sewing position, for example, per vertical reciprocation (i.e., per stitch) of the needle bar 35. In this way, the string material A can be sequentially sewn onto the fabric by so-called “zigzag switching”.
During that time, the rotary bush 42 is rotated by the motor 44 via the driving pulley 45, timing belt 46 and timing pulley 43, in response to which the guide 51 is controlled to be positioned forward in a direction of relative movement of the machine head H based on the movement of the fabric. In this way, the string material A can be appropriately guided to the sewing position of the sewing needle 34. If the rotary bush 42 is rotated more than 360 degrees, the second tube 32 might get undesirably entwined around the machine head H; thus, it is necessary that the embroidery data be made so as not to rotate the rotary bush 42 more than 360 degrees.
As the string material A is sequentially sewn onto the fabric in the above-described manner, the second guide roller 20 is pulled by the string material A so that the pivot arm 22 is caused to pivot downward. Then, the actuating piece 25 fixed to the proximal end portion of the pivot arm 22 pivots in a counterclockwise direction (of
In the embodiment of the embroidery sewing machine, as described above, the bobbin 10 is located above the machine head H, and thus, the bobbin 10 can have an increased size so that an increased amount of the string material A can be wound on the bobbin 10. Further, with the arrangement that the bobbin 10 is driven to rotate by the drive motor 14, the embodiment of the invention allows the string material A to be smoothly paid out from the bobbin 10 by positively rotating the bobbin 10 in accordance with the tension of the string material A, even where the bobbin 10 has an increased weight due to a great amount of the string material A wound thereon. Namely, in sewing the string material A, the embodiment allows the bobbin 10 to rotate and stop rotating in accordance with a paid-out amount of the string material A. Because the string material A can be paid out smoothly in this way, the string material A can be sewn to the fabric accurately and beautifully.
Note that the drive motor 41 for rotating the bobbin 10 may be arranged to directly rotate the rotary pulley 18 or directly rotate the bobbin shaft 4.
Further, whereas the embodiment of the invention has been described as sewing the string material A onto the fabric by so-called zigzag stitching, the present invention is, of course, not so limited.
Furthermore, the tension of the string material A may be detected, via a sensor or the like, so that the drive motor 14 is controlled on the basis of the detected tension to pay out the string material A.
Note that the terms “string material” used in connection with the present invention embrace all kinds of elongated sewn materials, not to mention tapes and cords, as long as the elongated sewn materials has flexibility such that they can be wound and held on the bobbin (i.e., rotary holder member). Furthermore, the object of sewing, onto which the sewn material is to be sewn, may be other than a fabric. Furthermore, the object of sewing need not be of a web, sheet or planar shape and may be of a curved shape or other shape having a curved surface, or a fragment. Furthermore, the present invention is not limited to the type of embroidery sewing machine where an embroidery frame having the object of sewing (fabric) held thereon is moved in accordance with sewing data, and is also applicable to another type of embroidery sewing machine where a needle drop position is moved in accordance with sewing data.
The bobbin (rotary holder member) may be driven by the motor in any other suitable manner than that described above in relation to the preferred embodiment. For example, the sewn material (string material A) may normally be paid out, in response to a drawing or pulling force produced in accordance with a progression of the sewing operation, from the bobbin (rotary holder member) through free rotation of the bobbin, and, upon detection of tension mote than a predetermined level, the motor may be activated to assist the bobbin (rotary holder member) in the free rotation (i.e., rotation as a follower).
Number | Date | Country | Kind |
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2003-389795 | Nov 2003 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2004/017013 | 11/16/2004 | WO | 00 | 7/5/2006 |
Publishing Document | Publishing Date | Country | Kind |
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WO2005/049907 | 6/2/2005 | WO | A |
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523522 | Haas et al. | Jul 1894 | A |
740654 | Hochstrasser | Oct 1903 | A |
797308 | Nassberg | Aug 1905 | A |
1004912 | Russell | Oct 1911 | A |
1356762 | Groebli | Oct 1920 | A |
4009674 | Ladd | Mar 1977 | A |
5029543 | Trojan | Jul 1991 | A |
5178081 | von-Hagen et al. | Jan 1993 | A |
5404824 | Hiraoka et al. | Apr 1995 | A |
5615628 | Tajima et al. | Apr 1997 | A |
Number | Date | Country |
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3-286797 | Dec 1991 | JP |
2003-320189 | Nov 2003 | JP |
Number | Date | Country | |
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20070137540 A1 | Jun 2007 | US |