Patent Application
20210032790
The present disclosure is directed to sewing devices, and more particularly to imaging systems for use with sewing devices and related imaging methods.
Throughout American history, quilting has become a popular pastime. The craft today has experienced resurgence in popularity and enjoys significant participation by hobbyists in quilting shows, magazines, newsletters, clubs, societies, and the like. Although traditional quilt making may be at the root of this resurgence, the development of modern textiles, machinery, and labor saving sewing devices can be contributing to this resurgence, as many activities compete for the time of the average hobbyist or crafts person.
Quilting typically involves stitching together multiple layers of fabric to form a fabric assembly. A quilt typically includes at least an upper fabric layer, a lower fabric layer, and a layer of batting positioned between the upper and lower layers. Quilts can be created in various shapes, sizes, and can be used in many different ways such as to cover beds or mounting on walls.
Designs and patterns can be sewn or stitched into a quilt by hand or with a sewing machine, thereby adding an artistic element to the craft of quilt making. Some designs or patterns can be elaborate, thus requiring a high degree of skill and dexterity at the part of the crafts person. In some cases, sewing machines can be equipped with pre-programmed stitching patterns to assist in performing these tasks more accurately and with a greater degree of intricacy than when quilting by hand. More importantly, quilting can require hours of time if performed manually even by the most skilled crafts person.
Due to the significant time requirements to manually create a quilt, industrial quilting machines or quilting assemblies have been developed for use in producing quilts in high quantities. These types of industrial quilting assemblies typically include heavy-duty, bulky sewing machines disposed in a stationary position wherein the quilt, mounted on a quilting frame, is moved relative to the sewing machine. One disadvantage with these types of industrial quilting assemblies is the significant work area required to move and position the quilting frame relative to the sewing machine.
Household sewing machines have resulted in both significant time savings and quality improvements over traditional hand sewing methods and industrial style sewing machines. Nevertheless, manipulating large pieces of cloth, such as a quilt, with respect to stationary sewing machines is typically cumbersome and a laborious process. Long arm quilting machines have been developed in part to address the problems associated with manipulating large quilts while stitching together multiple layers of cloth. Long arm quilting machines make it possible to move the sewing machine relative to the quilting frame typically in two degrees of motion: along a longitudinal axis across a width dimension of the quilt, and a lateral axis along the length dimension of the quilt.
When using a long arm quilting machine, the long arm quilting machine is typically mounted to a quilting table. The quilting table typically has a width dimension of about 8-14 feet and includes multiple rollers upon which the quilt is mounted. Some of the rollers usually hold that portion of the quilt that is unstitched (e.g., different layers of cloth and batting) and the other roller holds the stitched portion of the quilt. When the quilt is mounted to the rollers, the rollers are spaced apart a distance typically about 18 to 24 inches. That portion of the quilt extending between the rollers is available for stitching by the long arm quilting machine. One of the rollers is positioned within a throat cutout portion of the quilting machine and the other rollers are positioned outside of the quilting machine. The operator can create stitches on the exposed part of the quilt by moving the quilting machine in the longitudinal and traverse directions relative to the rollers and fabric mounted to the rollers.
When creating stitches on the quilt with the quilting machine the operator can typically see only the top surface of the quilt where the stitches are being formed. Only after later rolling up a stitched portion of the quilt onto one of the rollers is the bottom side of the quilt positioned such that the operator can see the stitched pattern on the bottom side of the quilt. Any defects in the stitching on the quilt typically have to be removed by hand. The unstitching process can be extremely time-consuming. Some common stitching defects when quilting include poor thread tension, loops in the thread, tucks in the fabric, and incorrect pattern of the stitches.
Over the years, various camera systems have been developed as an aid in monitoring the stitching on the bottom surface of a quilt during the quilting process, such as that described in U.S. Pat. Nos. 8,633,982 and 9,076,194 (assigned to Quilter's Eye Inc.). Although such systems provide a view of the bottom surface of the quilt, such systems can be cumbersome to install as they typically include a monitor, which must be fixedly coupled to the sewing machine. Further, such systems tend to gather lint and other fabric particles over time (particularly where the imaging module takes on a static charge), which can accumulate on the lens and negatively interfere with the image quality. The present disclosure addresses these concerns.
Embodiments of the present disclosure provide an imaging system and method for use with sewing devices, such as a long arm sewing machine. In particular, the disclosed system and method are particularly adept at examining the underside of the quilt while it is still mounted on the sewing device. The imaging system can include one or more cameras selectively positioned beneath the quilting plane of a long arm sewing machine, thereby enabling a capture of images and/or video of a quality of the stitching on the underside of a quilt during construction.
In some embodiments, the one or more cameras are wireless and/or battery-powered. In other embodiments, the one or more cameras can be powered directly or indirectly via an outlet on the long arm sewing machine. In one embodiment, the one or more wireless cameras are selectively positioned beneath the quilting plane via magnets or an adhesive configured to adhere to a surface of the long arm sewing machine, thereby enabling the one or more cameras to be easily removed and/or repositioned as desired. In one embodiment, the imaging system includes two cameras configured to be positioned on opposing sides of the sewing head, thereby enabling visibility of the stitch quality on the underside of the quilt, regardless of the direction that the quilt moves during stitching operations. In one embodiment, the one or more wireless cameras further include a magnifying lens, which can be removably coupled to the camera, thereby enabling selective removal of the magnifying lens as desired.
The one or more cameras can be in wireless communication with one or more mobile di splays (e.g., a cell phone, laptop, electronic tablet, personal electronic device, etc.). Accordingly, systems methods of the present disclosure do not require a monitor or display to be installed on the sewing machine itself. Rather, the display is mobile, thereby enabling a user to freely move around the machine while continuing to monitor the underside of the quilt, as well as to continue monitoring the underside of the quilt remotely, for example where a number of sewing machines are being operated by the user simultaneously. In one embodiment, multiple views from different cameras can be displayed on the display simultaneously, thereby enabling the simultaneous viewing of the stitching from various angles. By touching the display in a particular way, any of the images can be made larger or smaller, thereby enabling a zoom in/zoom out feature.
One embodiment of the present disclosure provides a stitch monitoring system configured to provide one or more real-time views of stitching applied to a quilt during construction of the quilt on a long arm sewing machine the stitch monitoring system can include a camera module and a user interface. The camera module can include a housing, power module, imaging module, compound macro lens assembly, and wireless transceiver module. The housing can include an adhesive, double sided tape or one or more magnets configured to selectively couple the camera module to an exterior of a long arm sewing machine to selectively position the camera module relative to stitching applied to a quilt by the long arm sewing machine during construction of the quilt. The power module can be configured to receive a supply of electrical power from an external source. The imaging module can include a complementary metal oxide semiconductor sensor configured to convert photons to electrons for digital processing. The compound macro lens assembly can include a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens, wherein the second magnification is greater than the first magnification, the first lens and the second lens having a combined fixed focal length, the spacer element having a length substantially equal to the combined fixed focal length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens. The wireless transceiver module can be configured to wirelessly transmit data gathered by the imaging module via a wireless network. The user interface can be configured to receive the data transmitted by the wireless transceiver module to display real-time views of stitching applied to the quilt by the long arm sewing machine, as captured by the imaging module.
In one embodiment, the stitch monitoring system can include a first camera module and a second camera module. In one embodiment, the first camera module can be positioned below a quilting plane, and the second camera module can be positioned above the quilting plane. In one embodiment, the first camera module and the second camera module can be configured to transmit views of stitching applied to the quilt to the user interface to enable a user to simultaneously view the stitching from multiple angles. In one embodiment, the first camera module can be selectively coupled to a first long arm sewing machine, and the second camera module can be selectively coupled to a second long arm sewing machine to enable a user to simultaneously view the stitching from two separate long arm sewing machines.
Another embodiment of the present disclosure provides a camera module configured to provide views of stitching applied to a quilt during construction of the quilt on a sewing machine. The camera module can include a housing, imaging module, compound macro lens assembly, and wireless transceiver module. The housing can be configured to selectively adhere to an exterior of a sewing machine to position the camera module relative to stitching applied to a quilt by the sewing machine during construction of the quilt. The imaging module can be configured to convert photons to electrons for digital processing. The compound macro lens assembly can include a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens, wherein the second magnification is greater than the first magnification, and the spacer element has a length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens. The wireless transceiver module can be configured to wirelessly transmit data gathered by the imaging module via a wireless network to display real-time views of stitching applied to the quilt by the sewing machine, as captured by the imaging module.
In one embodiment, the imaging module can include a complementary metal oxide semiconductor sensor. In one embodiment, the imaging module can have a resolution output of about 1920 pixels by about 1080 pixels. In one embodiment, the compound macro lens assembly can be at least one of magnetically or adhesively adhered to an exterior of the housing. In one embodiment, the housing can be configured to selectively adhere to an exterior of the sewing machine via at least one of a magnetic or an adhesive. In one embodiment, the spacer element can be constructed of at least one of an opaque or translucent material to reduce glare and distribute light evenly. In one embodiment, the spacer element can be constructed of a frosted acrylic material. In one embodiment, the camera module can further include a light assembly configured to provide illumination in proximity to the compound macro lens assembly. In one embodiment, the light assembly can include a one or more LEDs. In one embodiment, the camera module can be configured to be positioned at least one of below a quilting plane or above the quilting plane. In one embodiment, the wireless transceiver module can be configured to transmit data gathered by the imaging module to a remotely located user interface.
Another embodiment of the present disclosure provides a method of monitoring stitching applied to a quilt during construction of the quilt on a long arm sewing machine, the stitch monitoring system comprising: providing a first camera module comprising an imaging module configured to convert photons to electrons for digital processing and a compound macro lens assembly comprising a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens, wherein the second magnification is greater than the first magnification, and the spacer element having a length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens; and transmitting data gathered by the imaging module to a user interface via a wireless network to display real-time views of stitching applied to the quilt by the long arm sewing machine, as captured by the imaging module.
In one embodiment, the method further comprises providing a second camera module, and transmitting data gathered by the second camera module to the user interface via the wireless network. In one embodiment, the first camera module and the second camera module are configured to transmit views of stitching applied to the quilt to the user interface to enable a user to simultaneously view the stitching from multiple angles. In one embodiment, the first camera module is adhered to a first long arm sewing machine, and the second camera module is adhered to a second long arm sewing machine to enable a user to simultaneously view the stitching from two separate long arm sewing machines.
The summary above is not intended to describe each illustrated embodiment or every implementation of the present disclosure. The figures and the detailed description that follow more particularly exemplify these embodiments.
The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which:
While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.
Referring to
The embodiments described herein have a wide application to a number of sewing machine applications, beyond the long arm sewing machine applications emphasized herein. While wide applications to different sewing machines in the sewing environment are possible, emphasis is placed on the application of the stitch monitoring system 100 for long arm sewing machines in the production of quilts, as that particular application is particularly benefited from the embodiments described herein with reference to the attached figures.
As depicted in
In some embodiments, the quilting table assembly 220 can include one or more rollers 222A/B upon which a portion of the quilt 204 can be wound. For example, in some embodiments an unstitched portion of the quilt 204 can be wound on a first roller 222A, while a stitched portion of the quilt 204 can be wound on a second roller 222B, or vice versa. In some embodiments, the quilting table assembly 220 can further include a carriage assembly (not depicted) configured to support the sewing machine 202. The carriage assembly can include a set of lateral rails configured to permit movement of the sewing machine 202 along an x-axis (e.g., laterally relative to the quilting table assembly 220), and a set of longitudinal rails configured to permit movement of the sewing machine 202 along a y-axis (longitudinally relative to the quilting table assembly 220), thereby permitting movement of the sewing machine 202 relative to the quilting table assembly 220 during the construction of a quilt 204.
With additional reference to
As depicted in
In some embodiments, the one or more camera modules 102 can be selectively positioned beneath the sewing machine 202 via one or more magnets or adhesive 108 configured to selectively couple to an exterior surface of the sewing machine 202, thereby enabling the one or more camera modules 102 to be easily removed and/or repositioned as desired. In other embodiments, the one or more camera modules 102 can be fixedly coupled to the sewing machine 202 in a more semi-permanent manner, for example via an adhesive or other coupling method. In some embodiments, a light assembly 110 (e.g., a plurality of LEDs) can be positioned in proximity to the one or more wireless camera modules 102 for improved lighting and visibility during image capture. In some embodiments, the one or more wireless camera modules 102 can include an outlet power port 134 configured to provide power for an optional light assembly 110.
With additional reference to
In some embodiments, the power module 112 can be configured to receive a supply of electrical power to power other components of the camera module 102. For example, in some embodiments, the power module 112 can be configured to receive a 120 or 220 VAC power supply, or other electrical power supply (e.g., via an electrical outlet on the sewing machine 202). In other embodiments, the power module 112 can be a battery pack or other electrical storage device. In some embodiments, the power module 112 can include a power converter configured to reduce or otherwise convert the incoming electrical power supplied to a usable voltage and/or current. In some embodiments, the power supply 112 can include an electrical output 134, for example in the form of a USB port, to selectively provide a reduced power output (e.g., 5 VDC/1000 mA) to optional accessories, such as a light assembly 110.
In some embodiments, the wireless transceiver module 116 can be configured to transmit and receive data from the user interface 104, for example via a wireless network. In some embodiments, the user interface 104 can be provided via a mobile computing device 224, such as a cellular telephone, electronic tablet, laptop, personal electronic device, etc.), thereby enabling a user to view a live stream of stitching being performed by the sewing machine 202 in real-time. Moreover, in some embodiments, the user interface 104 can be configured to enable the monitoring of the stitching from multiple angles (e.g., above the quilting plane, below the quilting plane, from the left side, from the right side, from the front, from the back, etc.) and on multiple sewing machines 202, remotely, thereby enabling the user to perform other tasks (separated from the sewing machine 202 by some distance), while the one or more sewing machines 202 execute programmed stitching operations. Accordingly, in some embodiments, the stitch monitoring system 100 can serve as a useful tool to improve productivity in the quilting process, particularly where multiple sewing machines 202 are employed.
Accordingly, systems methods of the present disclosure do not require a monitor or display to be installed on the sewing machine itself. Rather, the display can be mobile and remote, thereby enabling a user to freely move around the machine (and even away from the machine) while continuing to monitor the quality of the stitching, for example where a number of sewing machines are being operated by the user simultaneously. As depicted in
In some embodiments, the imaging module 114 can be a digital camera configured to convert optical images to pixelated data. For example, in one embodiment, the imaging module 114 can include a complementary metal oxide semiconductor (CMOS) sensor configured to convert photons to electrons for digital processing. In some embodiments, the imaging module 114 can be configured to reduce high definition quality figures, having a resolution output of about 1920 pixels (width) by about 1080 pixels (height); although other pixel counts are also contemplated. In some embodiments, the imaging module 114 can be configured to capture video. In other embodiments, the imaging module 114 can be configured to capture a series of still images to provide a time lapse video.
With additional reference to
In some embodiments, the first lens 120 can have a first magnification. For example, in one embodiment, the first lens 120 (alone) can include structure configured to enable a viewing angle of about 110 degrees with a focal length of about 2.8 mm. In some embodiments, the second lens 122 can have a second magnification, wherein the second magnification is greater than the first magnification (e.g., objects viewed through the second lens 122 alone appear larger than the same objects viewed through the first lens 120 alone). In some embodiments, the first lens 120 can be housed within the housing 118, while the second lens 122 can be adhered to an exterior of the housing 118. In some embodiments, the second lens 122 can be operably coupled to the housing 118 via one or more magnets or an adhesive, thereby enabling the second magnifying lens 122 to be rapidly coupled and decoupled to the camera module 102 as desired. In other embodiments, the lens compound macro lens assembly 132 (or components thereof) can be at least partially secured within the housing 118. Other methods of securing be second lens 122 in position relative to the first lens 120 are also contemplated. In some embodiments, the first lens 120 and the second lens 122 can have a combined fixed focal length, for example in the range of between about 20 mm to about 100 mm.
The third lens 130 can be a clear plane, with no magnification. For example, in some embodiments, the third lens 130 can be constructed of a substantially flat plane of glass or plastic. In some embodiments, the third lens 130 can be well adapted to inhibiting lint, and other cloth debris from accumulating on the first and second lenses 120, 122 during operation. As depicted in
In some embodiments, the spacer element 126 can be positioned between the second lens 122 and the third lens 130, to provide a desired distance between the second lens 122 and the third lens 130. In some embodiments, the spacer element 126 can have a length substantially equal to the combined fixed focal length of the combined first lens 120 and the second lens 122, thereby enabling a sharp image of objects positioned adjacent to the third lens 130. Further, in some embodiments. Further, in some embodiments the spacer element 126 can be constructed of an opaque or translucent material to reduce glare and distribute light evenly. For example, in some embodiments, the tube portion 126 can be constructed of a frosted acrylic; although other construction materials are also contemplated.
Accordingly, in some embodiments the length of the spacer element 126 can be adjusted to match the focal length of the combination of lenses, such that an object positioned at a distal end 128 of the spacer element 126 (e.g., fabric including stitching) is positioned at an ideal focal distance from the imaging module 114 to ensure that images captured by the imaging module 114 of the object continuously remain in focus. Accordingly, in some embodiments, the one or more camera modules 102 can be positioned such that the clear cover 130 presses slightly against the surface of the quilt 204 during the quilting process, such that the fabric of the quilt slides over the clear cover 130 to ensure that fabric containing the stitching continuously remains at within the ideal focal range, thereby enabling a sharp view of the stitching at all times, particularly where stitching, creases, and/or bends in the fabric would otherwise cause the applied stitching to move in and out of focus.
Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.
Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.
Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.
Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.
For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.
This application claims the benefit of U.S. Provisional Application No. 62/882,284, filed Aug. 2, 2019, the contents of which are fully incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62882284 | Aug 2019 | US |
