Patent Grant
12152327
The present application claims priority under 35 U.S.C. ยง 119 to Japanese Patent Application No. 2018-012301, filed Jan. 29, 2018. The contents of this application are incorporated herein by reference in their entirety.
The present invention relates to a sewing system for controlling a sewing operation, a sewing machine, and a management device.
In the related art, a sewing system in which a sewing machine and a computer are connected to each other via a network are known as a sewing system (refer to JP-A-2012-200265). In the sewing system described in JP-A-2012-200265, a sewing machine reads various pieces of data such as an embroidery pattern from the computer, and a pattern is formed on a work cloth while referring to the various pieces of data. In this case, the sewing machine is provided with an operation panel, and the embroidery patterns are displayed as thumbnails on a display of the operation panel. By selecting the embroidery pattern on the operation panel of the sewing machine, the sewing machine accesses the computer and a sewing operation corresponding to the selected embroidery pattern is executed.
However, in the sewing system described in JP-A-2012-200265, it has been necessary to take various pieces of data from the sewing machine side to the computer by operating the operation panel. In addition, in general, as an operator adjusts sewing machines one by one after confirming work contents or a product cloth, it becomes necessary to take a long time to operate a plurality of sewing machines, and it is a burden work for the operator. Further, there was a risk that setting mistakes occur due to carelessness of the operator.
An aspect of the present invention provides a sewing system, a sewing machine, and a management device which can improve a work efficiency of an operator and prevent setting mistakes by the operator.
A sewing system includes a plurality of sewing machines and a management device which manages the plurality of sewing machines. Each of the plurality of sewing machines including a memory which stores parameter data obtained by digitizing an adjustment amount of an adjustment function of a seam, and an adjustment unit which adjusts the adjustment function of the seam by the adjustment amount corresponding to the parameter data in the memory. The management device including a management unit which separately manages the parameter data of the plurality of sewing machines, and a delivery unit which simultaneously delivers the parameter data to each of the plurality of sewing machines.
A sewing machine managed by a management device includes a memory that stores parameter data obtained by digitizing an adjustment amount of an adjustment function of a seam, and an adjustment unit that adjusts the adjustment function of the seam with an adjustment amount corresponding to the parameter data in the memory. The parameter data of a plurality of the sewing machines separately managed by the management device is simultaneously delivered. Each of the parameter data of the plurality of the sewing machines is stored in each of the memory of the plurality of sewing machines. Each of the adjustment function of the seam of the plurality of the sewing machines is adjusted by the parameter data in the memory.
A management device that manages a plurality of sewing machines, includes a management unit that separately manages parameter data of the plurality of sewing machines obtained by digitizing an adjustment amount of an adjustment function of a seam, and a delivery unit that simultaneously delivers the parameter data to each sewing machine. The adjustment function of the seam is adjusted by the adjustment amount corresponding to the parameter data with respect to the plurality of sewing machines by simultaneously delivering the parameter data.
According to the configurations, the parameter data is simultaneously delivered to the plurality of sewing machines from the management device, and the adjustment function of the seam of each sewing machine is automatically adjusted by an appropriate adjustment amount. For each sewing machine, the operator does not need to manually adjust the adjustment function of the seam, and the operator does not need to operate the sewing machine to obtain the parameter data. Accordingly, even when the plurality of sewing machines are installed in the sewing line, it is possible to shorten the work time of the adjustment work of the plurality of sewing machines, and to improve the work efficiency, and it is possible to prevent the setting mistakes due to carelessness of the operator.
The management device may include a collection unit that collects current parameter data from each of the plurality of sewing machines, and manages the current parameter data of each of the plurality of sewing machines. According to the configuration, the current parameters collected from each sewing machine can be used for the next production for each sewing machine.
The management unit may manage the parameter data of the plurality of sewing machines for each step in a sewing line including a plurality of steps. The delivery unit may deliver the parameter data simultaneously to the sewing machine in each step. According to the configuration, it is possible to adjust the adjustment function of the seam by the adjustment amount appropriate for each step.
The management unit may manage the parameter data of the plurality of sewing machines for each item number. The delivery unit may deliver the parameter data simultaneously to each of the sewing machines according to the item number. According to the configuration, it is possible to adjust the adjustment function of the seam by the adjustment amount appropriate for each item number.
The sewing system may further includes a reading unit that reads the item number from a sewing target carried into the sewing machine. The management device may deliver the parameter data separately to each of the plurality of sewing machines by the delivery unit according to the item number read by the reading unit. According to the configuration, since the parameter data is separately delivered to the sewing machine each time the item number is changed, it is possible to make the real-time adjustment function of the seam variable according to the item number of the sewing target carried into the sewing machine.
The management unit may manage the parameter data of the plurality of sewing machines for each operator. The delivery unit may deliver the parameter data simultaneously to each of the sewing machines according to operator identification information for identifying the operator of each of the sewing machines. According to the configuration, it is possible to adjust the adjustment function of the seam by the adjustment amount corresponding to the skill of the operator.
In addition to the parameter data, the delivery unit may deliver at least one of vector pattern data indicating an embroidery pattern, a memory switch indicating a sewing machine control option, continuous stitch data for controlling automatic sewing of a continuous sewing, cycle stitch data for controlling an automatic sewing of a pattern seamer, and firmware, to the plurality of sewing machines. According to the configuration, it is possible to further improve the working efficiency by simultaneously delivering at least one of vector pattern data, memory switch, continuous sewing data, cycle sewing data, and firmware, in addition to parameter data, to a plurality of sewing machines. More specifically, each of the plurality of sewing machines are connected to a respective terminal such that said terminal is connected to the management device, and such that the plurality of sewing machines are capable of communicating bidirectionally. Each terminal includes a reading unit that reads the item number from a sewing target carried into the sewing machine and that reads operator identification information of an operator of the sewing machine. The delivery unit delivers according to the operator identification information for identifying the operator of each of the sewing machines as read out by each reading unit.
According to the present invention, by simultaneously delivering the parameter data from the management device to the plurality of sewing machines, it is possible to improve the working efficiency and to prevent the setting mistakes by the operator.
Hereinafter, a sewing system of an embodiment will be described with reference to the attached drawings.
As illustrated in
A plurality of sewing machines 20 are arranged in the sewing facility 10D to form a sewing line. The sewing line is made up of a plurality (four in the embodiment) of steps A to D for each stitching location of the parts 42, and the various parts 42 go through each of the steps A to D of the sewing line to produce the workpiece 43. The plurality of sewing machines 20 are connected to the management device 30 via a terminal 25, and the plurality of sewing machines 20 are managed by the management device 30. In addition, an automatic guided vehicle (AGV) (not illustrated) is provided in the sewing factory, the AGV makes it possible to perform unmanned conveyance between each of the facilities 10A to 10G or unmanned conveyance between each of the steps A to D of the sewing line.
Incidentally, when adjusting the seam with an analog sewing machine, an operator has to manually adjust an adjustment function of the seam, such as feed dog height, feed pitch, feed trajectory, pressing pressure, or thread tension. The adjustment of the sewing machine is largely influenced by the work contents of each step or the material or the thickness of the cloth, and sufficient skill is required for the operator. For example, it is necessary to change the pressing pressure for a slippery cloth and a non-slip cloth, and it is necessary to change the thread tension for a soft cloth and a hard cloth. In particular, since there is a slight difference in the pressing pressure and the like for each sewing machine, even when the work contents or the cloth are the same, the adjustment amount should be finely adjusted for each sewing machine.
Therefore, depending on the intuition or experience of the operator, the operator who is inexperienced has variations in the adjustment for each sewing machine, and further, there is a risk that the adjustment mistakes occur due to carelessness of the operator. In this regard, when a digital sewing machine is employed, it is possible to digitize and store feed dog height, feed pitch, feed trajectory, pressing pressure, thread tension, and the like, as numerical values. Therefore, it is possible to faithfully realize the previous adjustment contents for each sewing machine, and to adjust each sewing machine during a short period of time without relying on the intuition or experience of the operator similar to the analog sewing machine.
However, even with a digital sewing machine, it is not possible to recognize the work contents or the type of the carried-in cloth in the sewing line. In general, the operator adjusts the sewing machines one by one after confirming the work contents or the cloth of the product, and it becomes necessary to take a long time to operate the plurality of sewing machines. Here, in the embodiment, the plurality of sewing machines 20 are separately managed by the management device 30, the parameter data obtained by digitizing the adjustment amount of the adjustment function of the seam is simultaneously delivered from the management device 30 to the plurality of sewing machines 20, and the work efficiency is improved and the setting mistakes by the operator are prevented.
Hereinafter, with reference to
As illustrated in
In addition, the terminal 25 is not limited as long as the terminal connects the sewing machine 20 and the management device 30 to each other, and may be configured, for example, by a tablet terminal or an operation panel of the sewing machine 20. Further, the terminal 25 transfers various pieces of arrived data without delay, and in a case where a transfer destination is busy, it is possible to buffer a certain amount of data. In a case where the data is not transferred to the limit of the buffer, an error is displayed on the display and the operator is informed of the data loss. Furthermore, the terminal 25 displays a connection status with the sewing machine 20 on the display and is informed to the operator.
The plurality of sewing machines 20 are provided with a memory 21 and an adjustment unit 22. In the memory 21, sewing machine data, such as vector pattern data indicating an embroidery pattern, a memory switch indicating a sewing machine control option, continuous stitch data for controlling automatic sewing of the continuous sewing, cycle stitch data for controlling the automatic sewing of a pattern seamer, and firmware, are stored in addition to the parameter data obtained by digitizing the adjustment amount of the adjustment function of the seam. By storing the sewing machine data in the memory 21 of the sewing machine 20, the setting contents necessary for the production of the workpiece 43 in the sewing line are reflected on the sewing machine 20.
In the adjustment unit 22, the adjustment function of the seam is adjusted by the adjustment amount corresponding to the parameter data in the memory 21. For example, the adjustment function of the seam includes a feed dog height adjustment function, a feed pitch adjustment function, a feed trajectory adjustment function, a pressing pressure adjustment function, a thread tension adjustment mechanism. By adjusting the adjustment functions by the digitized adjustment values, the sewing operation of the sewing machine 20 is adjusted in accordance with the work contents of the step or the condition of the material and the like of the cloth. In addition, the sewing machine 20 is not limited to a general industrial sewing machine, but may be a robot sewing machine in which the sewing machine is attached to a tip end of a robot arm, in addition to an automatic machine in which multiple steps are fully automated.
The management device 30 is provided with a management unit 31, a delivery unit 32, a collection unit 33, and a transmitting and receiving unit 34. In the management unit 31, the sewing machine data of the plurality of sewing machines 20 are separately managed. In the management unit 31, parameter data, vector pattern data, continuous sewing data, and cycle sewing data for each sewing machine 20 are managed. In addition, in the management unit 31, the memory switch or the firmware is managed for each type of the sewing machine 20. In the management unit 31, a management table for managing the parameter data and the like for each sewing machine, and a management table for managing memory switches and the like for each type are prepared.
For example, the management unit 31 may create, as a management table for the parameter data, at least one of the management table for managing the parameter data for each sewing machine, the management table for managing the parameter data for each step, the management table for managing the parameter data for each item number, and the management table for managing the parameter data for each operator (refer to
In the delivery unit 32, sewing machine data is simultaneously delivered to each sewing machine 20. In this case, the sewing machine data is selected for each sewing machine 20 from each management table of the management unit 31, and delivered as delivery data from the delivery unit 32 to each sewing machine 20. In the collection unit 33, current sewing machine data is collected from each sewing machine 20. In this case, the current sewing machine data set in the memory 21 is uploaded as uplink data from each sewing machine 20 to the collection unit 33 according to the request simultaneously notified to each sewing machine 20 from the collection unit 33.
The transmitting and receiving unit 34 of the management device 30 is connected to the transmitting and receiving unit 26 of the terminal 25, and various processing, such as modulation and demodulation processing, are applied to the delivered data (downlink data) and uplink data by the transmitting and receiving units 34 and 26. The transmitting and receiving units 34 and 26 are configured of, for example, a transmission and reception circuit, an antenna, an amplifier circuit, and the like. Further, the control configuration of the management device 30, the terminal 25, and the sewing machine 20 is configured of a processor, a memory, or the like that execute various processing. The memory is configured of one or a plurality of storage media, such as read only memory (ROM), random access memory (RAM), and the like, and stores various programs according to the application.
Subsequently, data management using the management table will be described with reference to
As illustrated in
As illustrated in
As illustrated in
In a case where the item number is to be switched, the parameter data can be delivered to each of the sewing machines 20 as an administrator specifies the item number. In addition, instead of specifying the item number, it is also possible to read the item number from a workpiece RF tag on the sewing machine 20 side, and to separately deliver the parameter data to each of the sewing machines 20. Accordingly, it is possible to make the adjustment function of the seam variable according to the item number of the sewing target carried into the sewing machine 20. In addition, the parameter data may not be unified for each item number. For example, the parameter data 1 may be allocated to the item number 1 of the serial number S1, and the parameter data 3 may be allocated to the item number 1 of the serial number S2, respectively.
As illustrated in
In a case where the operator is to be switched, the parameter data can be delivered to each sewing machine 20 as the administrator specifies the operator. In addition, instead of specifying the operator, it is also possible to read the operator identification information from the RF tag, such as an employee ID card of the operator on the sewing machine 20 side, and to separately deliver the parameter data to each sewing machine 20. Accordingly, it is possible to appropriately make the adjustment function of the seam variable according to the switching of the operator.
As illustrated in
In a case where the operator is to be switched, the intrinsic installation value can be delivered to each of the sewing machines 20 as the administrator specifies the operator. In addition, instead of specifying the operator, it is also possible to read the operator identification information from the RF tag of the employee ID card of the operator on the sewing machine 20 side, and to separately deliver the intrinsic installation value to each of the sewing machines 20. Accordingly, it is possible to appropriately make the intrinsic setting value, such as the maximum stitch speed of the sewing machine 20, variable according to the switching of the operator.
As illustrated in
Therefore, when producing the item number 1, the parameter data 1 to 6 that correspond to the serial numbers S1 to S6 are simultaneously delivered to the sewing machine 20 in steps A to D from the management device 30. In addition, when producing the item number 2, the parameter data 7 to 12 that correspond to the serial numbers S1 to S6 are simultaneously delivered to the sewing machine 20 in steps E to H from the management device 30. Accordingly, it is possible to adjust the adjustment function of the seam by the adjustment amount appropriate for each of the item numbers 1 and 2 and each of the steps A to D. In a case where the item number is to be switched, the parameter data can be delivered to each of the sewing machines 20 as the administrator specifies the item number. In addition, instead of specifying the item number, it is also possible to read the item number from the workpiece RF tag on the sewing machine 20 side, and to separately deliver the parameter data to each of the sewing machines 20.
In addition, in the above-described management table, in addition to managing the parameter data as the sewing machine data, vector pattern data, continuous sewing data, and cycle sewing data may also be managed. As the parameter data, parameters, such as feed dog height, feed pitch, feed trajectory, pressing pressure, and thread tension adjusted for each sewing machine 20 are included, and considering the individuality of each sewing machine 20, the adjustment function of the seam is separately managed. Embroidery patterns and automatic sewing data are included as vector pattern data, continuous sewing data, and cycle sewing data, and the sewing functions necessary for the sewing machine 20 are managed.
As illustrated in
Next, bidirectional communication of the sewing system will be described with reference to
As illustrated in
In this manner, since the management device 30 manages each sewing machine 20 for each step and item number in the management table, it is possible to recognize the parameter data uploaded from the sewing machine 20 is the parameter data of the sewing machine 20 for which item number in which step. Accordingly, it is not necessary to give the identification information indicating the step or the item number to the parameter data on the sewing machine 20 side and to notify the management device 30. In addition, the current parameter data of each sewing machine 20 is managed for each step and item number by the management unit 31 such that the same parameter data is used again for each sewing machine 20 at the same step as the current step and at the next production of the item number (step S04).
In addition, in the uploading of the parameter data, the parameter data adjusted by sample sewing of each sewing machine 20 may be uploaded to the management device 30. In a case where different sewing machines 20 are used for sample sewing for the actual operation, the parameter data adjusted by the sample sewing is uploaded to the management device 30, and the parameter data may be applied to the sewing machine 20 for the actual operation. In the parameter data of the sample sewing, in a case where the adjustment of the sewing machine 20 for the actual operation is insufficient, the parameter data adjusted again by the sewing machine 20 for the actual operation is uploaded to the management device 30 and registered in the management table for each step and item number.
As illustrated in
Accordingly, in order to simultaneously switch the production item number in a specific sewing line or a plurality of sewing lines, it is possible to automatically adjust the management function of the seam with respect to the plurality of sewing machines 20 on the management device 30 side. Accordingly, it is possible to start operating the plurality of sewing machines 20 during a short period of time, and it is possible to reduce the work burden of the operator. In addition, it is possible to appropriately adjust the sewing machines one by one independently of the skill of the operator, and it is also possible to prevent setting mistakes by the operator. By managing the parameter data of each sewing machine 20 for each step and item number, each sewing machine 20 can be adjusted to a condition appropriate for the step and the item number.
In addition, as illustrated in
In addition, when the parameter data is received by the terminal 25, the parameter data is transferred from the terminal 25 to the sewing machine 20 (step S25), and the parameter data is set in the memory 21 of the sewing machine 20 (step S26). In this manner, the delivery unit 32 can not only simultaneously deliver the parameter data to the plurality of sewing machines 20, but also separately deliver the parameter data to the plurality of sewing machines 20 according to the item number. Accordingly, since the parameter data is separately delivered to the sewing machine 20 each time the item number is changed, it is possible to make the real-time adjustment function of the seam variable according to the item number of the sewing target 43 carried into the sewing machine 20.
As described above, in the sewing system 11 according to the embodiment, the parameter data is simultaneously delivered to the plurality of sewing machines 20 from the management device 30, and the adjustment function of the seam of each sewing machine 20 is automatically adjusted by an appropriate adjustment amount. For each sewing machine 20, the operator does not need to manually adjust the adjustment function of the seam, and the operator does not need to operate the sewing machine 20 to obtain the parameter data. Accordingly, even when the plurality of sewing machines 20 are installed in the sewing line, it is possible to shorten the work time of the adjustment work of the plurality of sewing machines 20, and to improve the work efficiency, and it is possible to prevent the setting mistakes due to carelessness of the operator.
In addition, in the embodiment, the management unit is configured to manage the parameter data of the plurality of sewing machines for each step, each item number, each operator, each step and item number, but the configuration is not limited thereto. The management unit may be configured to separately manage the parameter data of the sewing machine, and the parameter data may be managed by appropriately combining the step, the item number, and the operator.
Further, in the embodiment, the sewing machine and the management device are configured to communicate with each other via the terminal connected to the sewing machine, but the configuration is not limited thereto. The sewing machine and the management device may communicate with each other by using the transmitting and receiving function of the tablet, the operation panel and the like connected to the sewing machine, and the sewing machine and the management device may communicate with each other by the transmitting and receiving function embedded in the sewing machine.
In addition, in the embodiment, feed dog height, feed pitch, feed trajectory, pressing pressure, and thread tension are described as examples of the adjustment function of the seam, but the configuration is not limited thereto. The adjustment function of the seam may be any function as long as the function is used for the adjustment of the seam. In addition, the adjustment function of the seam is adjusted by operating the adjustment mechanism of each part of the sewing machine.
Further, in the embodiment, a configuration has been described in which the sewing machine data is simultaneously delivered from the management device to the plurality of sewing machines and the sewing machine data is uploaded from each sewing machine to the management device, but the configuration is not limited to thereto. The sewing system may be configured such that the sewing machine data is simultaneously delivered at least from the management device to the plurality of sewing machines.
In addition, in the embodiment, parameter data, vector pattern data, memory switch, continuous stitch data, cycle sewing data, and firmware are described as examples of the sewing machine data, but the configuration is not limited thereto. The sewing machine data may be any data as long as the data is set to each sewing machine.
Further, in the embodiment, it is not necessary for the delivery unit to deliver all sewing machine data, but only the parameter data may be delivered, and in addition to the parameter data, at least one of vector pattern data, memory switch, continuous sewing data, cycle sewing data, and firmware may be delivered. In addition, the delivery timing of each sewing machine data may be the same, or may be different for each sewing machine data.
In addition, in the embodiment, the RF tag is described as an example of the tag used for the real-time delivery of the parameter data, but the configuration is not limited thereto. The tag may be any tag as long as the tag can specify the item number of the sewing target, for example, a two-dimensional code or the like. Further, instead of providing the tag in the sewing target, image processing or the like may be performed on the sewing target to specify the item number.
Further, in the embodiment, the sewing line is not limited to the line for producing the clothes. The sewing line may be any line as long as the line is for producing the workpiece, for example, shoes, bags, futons, small items, and the like may be produced.
Further, the program of the embodiment may be stored in a storage medium. The storage medium is not particularly limited, but may be a non-transitory recording medium, such as an optical disk, a magneto-optical disk, a flash memory, or the like.
Further, although the embodiment and the modification example of the invention have been described, as another embodiment of the invention, the above-described embodiment and the modification example may be combined in whole or in part.
Further, the embodiment of the invention is not limited to the above-described embodiment and the modification example, and various modifications, substitutions, and changes may be made without departing from the spirit of the technical idea of the present invention. Furthermore, when the technical idea of the present invention can be realized in another manner by the advancement of technology or another derivative technology, the invention may be realized using the method. Therefore, the range of the claims covers the entire embodiment that can be included in the scope of the technical idea.
Furthermore, in the above-described embodiment, there is provided a sewing system in which a plurality of sewing machines are managed by a management device, in which the plurality of sewing machines include a memory for storing parameter data obtained by digitizing an adjustment amount of an adjustment function of a seam, and an adjustment unit that adjusts the adjustment function of the seam by the adjustment amount corresponding to the parameter data in the memory, and in which the management device includes a management unit that separately manages the parameter data of the plurality of sewing machines, and a delivery unit that simultaneously delivers the parameter data to each of sewing machines. According to the configuration, the parameter data is simultaneously delivered to the plurality of sewing machines from the management device, and the adjustment function of the seam of each sewing machine is automatically adjusted by an appropriate adjustment amount. For each sewing machine, the operator does not need to manually adjust the adjustment function of the seam, and the operator does not need to operate the sewing machine to obtain the parameter data. Accordingly, even when the plurality of sewing machines are installed in the sewing line, it is possible to shorten the work time of the adjustment work of the plurality of sewing machines, and to improve the work efficiency, and it is possible to prevent the setting mistakes due to carelessness of the operator.
As described above, the present invention has an effect that it is possible to improve the working efficiency and to prevent the setting mistakes by the operator, and is particularly useful for the sewing system, the sewing machine, and the management device for sewing clothes.
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