U.S. patent application number 11/870703 was filed with the patent office on 2008-04-17 for sequin feeder apparatus and sewing machine capable of sewing sequins.
This patent application is currently assigned to TOKAI KOGYO MISHIN KABUSHIKI KAISHA. Invention is credited to Aisuke Murase.
Application Number | 20080087206 11/870703 |
Document ID | / |
Family ID | 39277842 |
Filed Date | 2008-04-17 |
United States Patent
Application |
20080087206 |
Kind Code |
A1 |
Murase; Aisuke |
April 17, 2008 |
SEQUIN FEEDER APPARATUS AND SEWING MACHINE CAPABLE OF SEWING
SEQUINS
Abstract
Sequin feeder apparatus includes at least two sequin feed units
each including a sequin feed mechanism for feeding a continuous
sequin strip toward a predetermined cutting position and a
sequin-cutting cutter section located in the predetermined cutting
position. One of the sequin feed units is selected and positioned
in a predetermined sewing operation position, and driving force of
a feeding drive mechanism is transmitted to the sequin feed
mechanism to feed out a sequin. Respective cutting positions of the
cutter sections of the feed units are adjustable independently of
each other.
Inventors: |
Murase; Aisuke;
(Kasugai-shi, JP) |
Correspondence
Address: |
ROSSI, KIMMS & McDOWELL LLP.
P.O. BOX 826
ASHBURN
VA
20146-0826
US
|
Assignee: |
TOKAI KOGYO MISHIN KABUSHIKI
KAISHA
Kasugai-shi
JP
|
Family ID: |
39277842 |
Appl. No.: |
11/870703 |
Filed: |
October 11, 2007 |
Current U.S.
Class: |
112/106 ;
112/99 |
Current CPC
Class: |
D05C 7/08 20130101; D05B
3/12 20130101 |
Class at
Publication: |
112/106 ;
112/99 |
International
Class: |
D05B 3/12 20060101
D05B003/12 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 13, 2006 |
JP |
2006-280396 |
Sep 20, 2007 |
JP |
2007-244083 |
Claims
1. A sequin feeder apparatus comprising: at least two sequin feed
units each including a sequin feed mechanism for feeding a
continuous sequin strip toward a predetermined cutting position and
a sequin-cutting cutter section located in the predetermined
cutting position; a sequin selection mechanism for selecting one of
said at least two sequin feed units and positioning the selected
one sequin feed unit in a predetermined sewing operation position;
and a drive mechanism for engaging with said sequin feed mechanism
of said one sequin feed unit, positioned in the predetermined
sewing operation position, and thereby driving, in response to a
sewing operation, the engaged sequin feed mechanism to feed the
continuous sequin strip toward the predetermined cutting position,
wherein the predetermined cutting position in each of said sequin
feed units is adjustable independently of the predetermined cutting
position in other of said sequin feed units, and said cutter
section is driven, in response to the sewing operation, to cut a
sequin off from the continuous sequin strip having been fed to the
predetermined cutting position.
2. A sequin feeder apparatus as claimed in claim 1 wherein each of
said sequin feed units includes an adjustment mechanism for
adjusting a position, relative to a position of a sewing needle, of
said cutter section of the sequin feed unit independently of the
other of said sequin feed units.
3. A sequin feeder apparatus as claimed in claim 2 wherein said
adjustment mechanism of each of said sequin feed units adjusts the
cutting position, where said cutter section cuts the sequin off
from the sequin strip, by linearly displacing a whole of the sequin
feed unit.
4. A sequin feeder apparatus as claimed in claim 2 wherein each of
said sequin feed units includes a support plate for supporting
thereon the continuous sequin strip to be fed toward the cutting
position, and said cutter section of the sequin feed unit is
provided at a distal end of said support plate, and said adjustment
mechanism of each of said sequin feed units adjusts the cutting
position, where said cutter section cuts the sequin off from the
sequin strip, by linearly displacing said support plate of the
sequin feed unit.
5. A sequin feeder apparatus as claimed in claim 3 wherein said
adjustment mechanism of each of said sequin feed units includes a
mechanism for linearly displacing the whole of said sequin feed
unit.
6. A sequin feeder apparatus as claimed in claim 5 wherein said
mechanism for linearly displacing the whole of the sequin feed unit
includes a mechanism for converting rotation of an adjustment screw
into linear displacement of the sequin feed unit.
7. A sequin feeder apparatus as claimed in claim 1 wherein said
cutter section of each of said sequin feed units includes a fixed
cutter blade and movable cutter blade that operate independently of
the fixed cutter blade and movable cutter blade of the other sequin
feed unit.
8. A sequin feeder apparatus as claimed in claim 1 wherein said
sequin feed mechanism of each of said sequin feed units is capable
of setting a sequin feed amount independently of the sequin feed
mechanism of the other sequin feed unit.
9. A sequin feeder apparatus as claimed in claim 8 wherein said
drive mechanism drives said sequin feed mechanism of the one sequin
feed unit, currently positioned in the predetermined sewing
operation position, with a drive amount corresponding to the sequin
feed amount set by said sequin feed mechanism of the one sequin
feed unit.
10. A sequin feeder apparatus as claimed in claim 1 wherein said at
least two sequin feed units are disposed side by side in such a
manner that said sequin feed units are slidable together, and said
sequin selection mechanism positions one of said at least two
sequin feed units in the predetermined sewing operation position by
sliding said at least two sequin feed units together.
11. A sequin feeder apparatus as claimed in claim 1 wherein said
drive mechanism includes: an engagement portion for engaging with
said sequin feed mechanism of the one sequin feed unit positioned
in the predetermined sewing operation position; a motor drivable in
interlocked relation to the sewing operation; and a link mechanism
for transmitting motion of said motor to said engagement portion,
and wherein said sequin feed mechanism of the one sequin feed unit
positioned in the predetermined sewing operation position is caused
to operate, in response to the motion of said motor and via said
link mechanism and said engagement portion, to thereby feed the
continuous sequin strip toward the predetermined cutting
position.
12. A sequin feeder apparatus as claimed in claim 1 wherein said
cutter section of the one sequin feed unit positioned in the
predetermined sewing operation position is driven, in response to
movement of a needle bar during the sewing operation, to thereby
cut a sequin off from the continuous sequin strip.
13. A sequin feeder apparatus as claimed in claim 1 which further
comprises a detection device for detecting whether or not a supply
of the continuous sequin strip from a sequin strip supply source to
any of said sequin feed units has run out.
14. A sequin feeder apparatus as claimed in claim 1 wherein each of
said sequin feed units is detachably attached to a base section of
said sequin selection mechanism.
15. A sewing machine comprising the sequin feeder apparatus,
recited in claim 1, in association with a sewing head.
16. A sewing machine as claimed in claim 15 wherein different
continuous sequin strips of at least two types are supplied from
the sequin strip supply sources to the at least two sequin feed
units, and which further comprises a control device that, on the
basis of sewing pattern data of a desired sequin pattern that uses
at least two types of sequins in combination, controls the sequin
selection mechanism to select any one of said at least two sequin
feed units at a particular sewing position where the sequin to be
used is to be changed from one type to another, said control device
then performing control such that sequin sewing is performed using
the selected sequin feed unit.
17. A sewing machine as claimed in claim 16 wherein the desired
sequin pattern comprises a pattern to be made by alternately
selecting and sewing the at least two types of sequins.
18. A sewing machine as claimed in claim 16 wherein the desired
sequin pattern comprises a pattern to be made by alternately
selecting and sewing the at least two types of sequins in
overlapped relation to each other.
19. A sequin feeder apparatus comprising: a sequin feed unit
including a sequin feed mechanism for feeding a continuous sequin
strip toward a predetermined cutting position and a sequin-cutting
cutter section located in the predetermined cutting position; a
drive mechanism for driving, in response to a sewing operation, the
sequin feed mechanism to feed the continuous sequin strip toward
the predetermined cutting position, the cutter section being
driven, in response to the sewing operation, to cut a sequin off
from the continuous sequin strip having been fed to the
predetermined cutting position; a displacement member provided
between a sequin strip supply source and the sequin feed unit and
displaceable between a first position and a second position, said
first position being where said displacement member is held
stationary in abutting contact with the continuous sequin strip
supplied from the sequin strip supply source to the sequin feed
unit, said second position being where, due to absence of the
continuous sequin strip, said displacement member is located past
said first position without abutting against the continuous sequin
strip; and a detection device for detecting that said displacement
member has shifted from said first position to said second
position, wherein that a supply of the continuous sequin strip has
run out is detected on the basis of an output of said detection
device.
Description
BACKGROUND
[0001] The present invention relates generally to sequin feeder
apparatus for use in sewing machines which sew a sequin onto a
sewing workpiece while severing the sequin from a ribbon or strip
of continuously-connected sequins. More particularly, the present
invention relates to a sequin feeder apparatus which is capable of
changing the sequin to be sewn from one type to another in the
middle of sewing, as well as a sewing machine suited to sew sequins
of different pitches in combination.
[0002] Example of the conventional sequin feeder apparatus is known
from German Utility Model Registration No. G9209764.2, U.S. Pat.
No. 5,755,168 or German Patent No. DE19538084 (corresponding to
U.S. Pat. No. 5,755,168 above). Such a known sequin feeder
apparatus includes a feed mechanism, which causes a strip of a
multiplicity of continuously-connected sequins (or spangles)
(hereinafter referred to as "continuous sequin strip") to be let
out or paid out from a reel, having the continuous sequin strip
wound thereon, onto a support plate and then, through predetermined
forward and rearward (i.e., advancing and retracting) movement of a
feed lever, feeds the continuous sequin strip at a predetermined
pitch corresponding to the size of each sequin of the strip. One
sequin is sewn at a time onto a sewing workpiece while being
severed or cut off from the continuous sequin strip having been fed
in interlocked relation to a sewing operation by a needle bar of
the sewing machine.
[0003] Further, Japanese Patent Application Laid-open Publication
No. 2004-167097 discloses an embroidery sewing machine including a
sequin feeder apparatus attached to a sewing head so that sequins
can be sewn onto a sewing workpiece, such as an embroidering
fabric.
[0004] Furthermore, Korean Patent Application Laid-open Publication
No. 10-2006-68405 and Korean Patent Publication No. 10-614630
(corresponding to the No. 10-2006-68405 laid-open publication)
disclose an apparatus capable of changing or switching the sequin
to be sewn to from one type to another in the middle of sewing. The
disclosed apparatus includes two sequin reels each having wound
thereon a different strip of continuously-connected sequins of a
predetermined shape and color, and feeding rods for individually
feeding out the respective continuous sequin strips, paid out from
the reels, to a needle entry point. By selecting the feeding-out
operation by any one of the feeding rods on the basis of a control
signal, the disclosed apparatus can successively perform sequin
sewing while switching between the continuous sequin strips to be
fed toward the needle entry point. However, the disclosed apparatus
is provided with only one, common cutter section for cutting a
sequin off from any one of the sequin strips; namely, a sequin of
one of the continuous sequin strips, which has been fed out by the
corresponding feeding rod, is cut off by the common cutter section.
Therefore, although sequins can be made different in size between
two continuous sequin strips to be set on the reels, the sequin
sizes can no longer be changed freely once continuous sequin strips
having sequins of predetermined sizes are set. Because, the common
cutter section, shared between the two continuous sequin strips,
comprises a movable cutter blade having a predetermined stepped
structure and a fixed cutter blade (or die) having a similar
predetermined stepped structure, and the stepped structures of
these movable and fixed cutter blades have to be mechanically
fixed. Namely, if the apparatus is constructed so that continuous
sequin strips of different sequin sizes are set on the two reels,
the mechanically-fixed structures of the common cutter section can
not deal with the different sequin sizes.
SUMMARY OF THE INVENTION
[0005] In view of the foregoing, it is an object of the present
invention to provide an improved sequin feeder apparatus which
includes a plurality of sequin feed units such that the sequin to
be sewn can be changed from one type to another in the middle of
sewing and which allows a sequin feed amount of each of the sequin
feed units to be changed as desired. It is another object of the
present invention to provide an improved sewing machine which is
suited to sew sequins of desired different feed pitches in
combination using such an improved sequin feeder apparatus.
[0006] According to one aspect of the present invention, there is
provided a sequin feeder apparatus, which comprises: at least two
sequin feed units each including a sequin feed mechanism for
feeding a continuous sequin strip toward a predetermined cutting
position and a sequin-cutting cutter section located in the
predetermined cutting position; a sequin selection mechanism for
selecting one of the at least two sequin feed units and positioning
the selected one sequin feed unit in a predetermined sewing
operation position; and a drive mechanism for engaging with the
sequin feed mechanism of the one sequin feed unit, positioned in
the predetermined sewing operation position, and thereby driving,
in response to a sewing operation, the engaged sequin feed
mechanism to feed the continuous sequin strip toward the
predetermined cutting position. Here, the predetermined cutting
position in each of the sequin feed units is adjustable
independently of the predetermined cutting position in the other
sequin feed unit, and the cutter section is driven, in response to
the sewing operation, to cut a sequin off from the continuous
sequin strip having been fed to the predetermined cutting
position.
[0007] According to another aspect of the present invention, there
is provided a sewing machine where the aforementioned sequin feeder
apparatus of the present invention is provided in association with
a sewing head.
[0008] Each of the sequin feed units includes its own sequin feed
mechanism and sequin-cutting cutter section, and the predetermined
cutting position in each of the sequin feed units is adjustable
independently of the predetermined cutting position in the other
sequin feed unit. Thus, in each of the sequin feed units, the
cutting position, where the cutter section cuts a sequin off from
the sequin strip, can be adjusted as desired independently of the
cutting position in the other sequin feed unit; thus, the sequin
feed units can respectively handle sequins of desired feed sizes.
Because the present invention thus arranged allows a sequin feed
amount of the continuous sequin strip in each of the feed units to
be changed as desired independently of the sequin feed amount in
the other feed unit, the sewing machine, to which is applied the
sequin feeder apparatus of the present invention, can perform
sequin sewing while combining sequins of desired different feed
pitches.
[0009] The following will describe embodiments of the present
invention, but it should be appreciated that the present invention
is not limited to the described embodiments and various
modifications of the invention are possible without departing from
the basic principles. The scope of the present invention is
therefore to be determined solely by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view showing a general outer
appearance of an embroidery sewing machine to which is applied a
sequin feeder apparatus of the present invention;
[0011] FIG. 2 is a right side view showing a first embodiment of
the sequin feeder apparatus of the present invention, which
particularly shows the sequin feeder apparatus held in a lowered
position;
[0012] FIG. 3 is a left side view of the first embodiment of the
sequin feeder apparatus;
[0013] FIG. 4 is a front view of the first embodiment of the sequin
feeder apparatus;
[0014] FIG. 5 is a right side view of the first embodiment of the
sequin feeder apparatus, which particularly shows the sequin feeder
apparatus held in an evacuated position;
[0015] FIG. 6 is a left side view of the first embodiment of the
sequin feeder apparatus, which shows the sequin feeder apparatus
held in the evacuated position;
[0016] FIG. 7 is a rear perspective view showing in enlarged scale
parts of sequin feed units, sequin selection mechanism and feeding
drive mechanism in the first embodiment of the sequin feeder
apparatus;
[0017] FIG. 8 is a rear view of the first embodiment of the sequin
feeder apparatus;
[0018] FIG. 9 is a sectional view taken along the I-I line of FIG.
8;
[0019] FIG. 10 is a plan view showing a manner in which a leading
sequin is cut off from a continuous sequin strip held on a support
plate in one of the sequin feed units in the first embodiment;
[0020] FIG. 11 is a front view showing in enlarged scale parts of
the sequin feed units and sequin selection mechanism when where the
first sequin feed unit is selected;
[0021] FIG. 12 is a front view showing in enlarged scale parts of
the sequin feed units and sequin selection mechanism when the
second sequin feed unit is being selected;
[0022] FIG. 13 is a perspective view similar to FIG. 7, which shows
parts of the sequin feed units, sequin selection mechanism and
feeding drive mechanism when the second sequin feed unit is
selected;
[0023] FIG. 14 is a side view of a supporting plate of the second
sequin feed unit taken from a side opposite a side where the sequin
feed mechanism is disposed;
[0024] FIG. 15 is a sectional plan view showing a manner in which
respective cutting positions of the first and second feed units are
adjusted in accordance with sequin sizes of continuous sequin
strips set on the feed units;
[0025] FIG. 16 is a right side view of a second embodiment of the
sequin feeder apparatus;
[0026] FIG. 17 is a right side view showing in enlarged scale a
detection device employed in the second embodiment;
[0027] FIG. 18 is a view taken in a direction of arrow A of FIG.
17;
[0028] FIG. 19 is a sectional view taken along the B-B line of FIG.
17;
[0029] FIG. 20 is a view showing a state where a supply of one of
continuous sequin strips has run out;
[0030] FIG. 21 is a view showing an example of a sequin pattern to
be made by alternately sewing sequins of different types to a
workpiece;
[0031] FIG. 22 is a view showing another example of the sequin
pattern to be made by alternately sewing sequins of different types
to a workpiece;
[0032] FIG. 23 is a side view showing a state where a previous-sewn
stitch position has got into under the sequin feed unit;
[0033] FIG. 24 is a view showing an example of a sequin pattern to
be by alternately sewing sequins of different types to a workpiece
in overlapped relation to each other;
[0034] FIG. 25 is a view showing an example sequence of operations
for sewing the sequin pattern, comprising two sequins of different
types, to the workpiece in overlapped relation to each other;
and
[0035] FIG. 26 is an exploded rear perspective view of a sequin
feeder apparatus in accordance with another embodiment of the
present invention.
DETAILED DESCRIPTION
[0036] FIG. 1 shows a four-head embroidery sewing machine equipped
with four sewing machine heads H. Needle bar cases 2 are provided
in corresponding relation to the sewing machine heads H, and a
needle plate 70 is disposed under each of the needle bar cases 2.
Sequin feeder apparatus 1 is attached to the left side and/or right
side of each of the needle bar cases 2; in the instant embodiment,
the sequin feeder apparatus 1 is attached to only the left side of
each of the needle bar cases 2. Each of the needle bar cases 2
comprises a multi-needle structure, and, in the case where the
sequin feeder apparatus 1 is attached to the left side of the
associated needle bar case 2 as in the illustrated example, the
leftmost needle bar in the needle bar case 2 is used as a sequin
sewing needle bar (or sequin needle bar). As conventionally known
in the art, an embroidery frame 80 is driven in left-right (X) and
front-rear (Y) horizontal directions in accordance with
predetermined sewing data.
First Embodiment
[0037] First, a description will be given about a first embodiment
of the sequin feeder apparatus 1.
[0038] FIG. 2 is a right side view showing in enlarged scale a part
of one of the sequin feeder apparatus 1, FIG. 3 is a left side view
of the sequin feeder apparatus 1, and FIG. 4 is a front view of the
sequin feeder apparatus 1. The sequin feeder apparatus 1 includes a
fixed base 3 fixed to the left side surface of the needle bar case
2 for attaching the feeder apparatus 1 to the machine head H, and a
mounting base 4 mounted on the fixed base 3 in such a manner that
it can ascend and descend relative to the fixed base 3. Two guide
rods 5 are fixed to the base 3, and a screw shaft 6 is pivotally
mounted on the base 3; note that, in FIG. 3, only one of the guide
rods 5 is shown with the other guide rod 5 located behind the screw
shaft 6 and thus invisible in FIG. 3. The screw shaft 6 is
connected to the shaft of a motor 7 fixed to the base 3. Moving
member 8 slidably fitted on the two guide rods 5 is fixed to the
mounting base 4. Nut member 9 screwed on the screw shaft 6 is fixed
to the moving member 8. Thus, as the screw shaft 6 rotates by being
driven via the motor 7, the mounting base 4 is vertically movable,
along the guide rods 5, between a lowered position in which the
sequin feeder apparatus 1 performs a sequin sewing operation and an
evacuated position in which the sequin feeder apparatus 1 does not
perform a sequin sewing operation. FIGS. 2 and 3 show a state of
the apparatus when the sequin feeder apparatus 1 is in the lowered
position, and FIGS. 5 and 6 show a state of the apparatus when the
sequin feeder apparatus 1 is in the evacuated position. Further, a
positioning block 12 is fixed to the mounting base 4, and, when the
mounting base 4 is in the lowered position, this positioning block
12 fits between two positioning plates 11 having respective distal
end portions that project along and are fixed to left and right
surfaces of the base 3. With the positioning block 12 fitting
between the two positioning plates 11, the mounting base 4 in the
lowered position is positioned in the left-right horizontal
direction.
[0039] Each of the sequin feeder apparatus 1 generally comprises:
two sequin feed units 20 and 21; a sequin selection mechanism
(composed of components 44-50, 60-67 and the like that will be
later described with reference to FIG. 7 etc.) for selecting any
one of the two sequin feed units 20 and 21 and positioning the
selected sequin feed unit 20 or 21 in a predetermined sewing
operation position; and a feeding drive mechanism (composed of
components 51-59 and the like that will be later described with
reference to FIG. 7 etc.) for engaging with a sequin feed mechanism
19 of the one sequin feed unit 20 or 21 positioned in the
predetermined sewing operation position. These two sequin feed
units 20 and 21, sequin selection mechanism (44-50, 60-67 and the
like) and feeding drive mechanism (composed of components 51-59 and
the like) are mounted on the above-mentioned mounting base 4 so
that they are vertically movable (ascendable and descendable)
between an evacuated position for not performing sequin sewing and
a lowered position for performing sequin sewing.
[0040] Further, each of the sequin feed units 20 and 21 includes
the sequin feed mechanism 19 for feeding a continuous sequin strip
13 toward a predetermined cutting position, and a sequin-cutting
cutter section (composed of components 36 and 23b that will be
later described with reference to FIG. 7 etc.) located in the
predetermined cutting position. As shown in FIG. 4, two reels
(sequin holder sections or sequin strip supply sources) 14, each
having a desired continuous sequin strip 13 wound thereon, are
provided, in corresponding relation to the sequin feed units 20 and
21, for feeding the continuous sequin strips 13 to the
corresponding sequin feed units 20 and 21. Each of the reels 14
corresponding to the sequin feed units 20 and 21 holds, i.e. has
wound thereon, the continuous sequin strip 13 comprising a
multiplicity of continuously-connected sequins each having a
desired shape, color and size (i.e., feed size corresponding to a
dimension from the needle-passing hole to the outer periphery of
the sequin). Namely, the instant embodiment is capable of using one
sequin feeder apparatus 1 to sew a combination of two different
types of sequins as sequins to be sewn to make an embroidery
pattern. Two reels (sequin strip supply sources) 14 holding two
different types of sequins, suiting such a combined sequin-sewing
design, are set in a manner as shown in FIG. 4. In the illustrated
example of FIG. 4, the left reel 14 corresponds to the left sequin
feed unit 20, while the right reel 14 corresponds to the right
sequin feed unit 21.
[0041] These two reels 14 are coaxially mounted side by side, or
juxtaposed, on a same mounting shaft provided on the fixed base 3.
Further, pairs of first, second and third rollers 15, 16 and 17 for
guiding portions of the continuous sequin strips 13 paid out from
the reels 14 are supported on the fixed base 3, and fourth rollers
18 are supported on the mounting base 4; each of the pairs of the
rollers 15, 16, 17 and 18 is also composed of two rollers coaxially
mounted side by side. Further, two tension rollers 10 are provided
between the first rollers 15 and the second rollers 16, and these
tension rollers 10 are supported on tension bases 72 and 73
rotatably mounted on the shafts of the first and second rollers 15
and 16, respectively. Torsion springs (not shown) are mounted on
the shafts of the first and second rollers 15 and 16, so that the
tension base 72 is normally urged in a clockwise direction of FIG.
2 while the tension base 73 is normally urged in a counterclockwise
direction of FIG. 2 and these bases 72 and 73 are normally held in
abutting engagement with stoppers 74 secured to the fixed base
3.
[0042] Portion of the continuous sequin strip 14 paid out from each
of the reels 14 is directed to and supported on the first roller
15, tension roller 10, second roller 16, third roller 17 and fourth
roller 18 in the mentioned order as shown in FIG. 2, and then
guided to the sequin feed mechanism 19 provided on the mounting
base 4. Thus, as the mounting base 4 is moved to the evacuated
position, the continuous sequin strip 13 is appropriately pulled by
the fourth roller 18, so that the sequin strip 13 can be prevented
from greatly slackening during the movement of the mounting base 4
to the evacuated position.
[0043] FIG. 7 is a rear perspective view showing in further
enlarged scale parts of the sequin feed units 20 and 21, sequin
selection mechanism (44-50, 60-67, etc.) and feeding drive
mechanism (51-59, etc.), FIG. 8 is a rear view of the sequin
selection mechanism and feeding drive mechanism, and FIG. 9 is a
sectional view taken along the I-I line of FIG. 8. As apparent from
these figures, the two sequin feed units 20 and 21 are provided on
the mounting base 4 in opposed relation to each other and
horizontally slidable relative to the mounting base 4 along sliding
rods 47 and 48 provided on the mounting base 4. Such sliding
movement of the sequin feed units 20 and 21 is effected by the
sequin selection mechanism (44-50, 60-67, etc.); more specifically,
the sequin selection mechanism selects and connects any one of the
feed units 20 or 21 to the feeding drive mechanism (51-59, etc.),
and thus, a sequin is fed out from the selected sequin feed unit 20
or 21 by a driving force of the feeding drive mechanism (51-59,
etc.) being transmitted to the selected sequin feed unit 20 or
21.
[0044] Although the two sequin feed units 20 and 21 provided in
opposed relation to each other are constructed of same mechanical
components (i.e., mechanically constructed in the same manner), the
feed units 20 and 21 are arranged and shaped in symmetrical
relation to each other. Thus, details of the mechanical components
of only one of the sequin feed units 20 will be described
representatively with reference to FIG. 9. The sequin feed unit 20
generally comprises a supporting plate 22; a support plate 23
provided horizontally at the lower end of the supporting plate 22;
the sequin feed mechanism 19 composed of various components
(indicated by 24-35 etc.) mounted on the supporting plate 22; and
the cutter section (including fixed cutter blade 23b and movable
cutter blade 36) located in the predetermined cutting position at
the distal end of the support plate 23. Portion of the continuous
sequin strip paid out from the corresponding reel 14 is directed
onto the support plate 23 and then sent toward the cutting position
or cutter section by means of the sequin feed mechanism 19. The
support plate 23 has a slit 23a (see FIG. 10) having an appropriate
dimension in the front-rear or Y direction. The slit 8a is provided
to allow entry therein of an engaging claw 33a of a lock lever 33
of the sequin feed mechanism 19 as will be later described.
[0045] First, details of the sequin feed mechanism 19 will be
described. Link arm 25 is fixed to the shaft 24 supported on the
supporting plate 22, and a link pin having a slanted distal end
surface is fixed to a free end portion of the link arm 25. Feed
lever 29, having an engaging portion 29a at its distal end, is
pivotably supported, via a shaft 30, on a free end portion of the
pivot arm or lever 27. Torsion spring (not shown) for normally
urging the feed lever 29 in the clockwise direction is fitted on
the shaft 30, by which the distal end portion of the feed lever 29
is normally urged toward the support plate 23. With the feed lever
29 urged in the clockwise direction, the pivot lever 27 is normally
urged in a direction where it abuts against a stopper 31. The
stopper 31 is in the form of a threaded rod screwed to a bracket 32
secured to the supporting plate 22, and the stopper 31 is locked by
screwing up of a nut. The pivot lever 27 abuts against the rear end
of the stopper 31. The lock lever 33 is provided over the feed
lever 29. The lock lever 33 has an engaging claw (or engaging
projection) 33a at its one end and a stopper portion 33b at its
other end. Intermediate portion of the lock lever 33 is pivotably
supported, via a pin 35, on a support block 34 that is in turn
fixed to the supporting plate 22. The engaging claw 33a of the lock
lever 33 is inserted through a through-hole 29b formed in the feed
lever 29. Torsion spring (not shown) is provided on the pin 35
fixed to the support block 34, and the lock lever 33 is normally
biased, by that torsion spring, in the counterclockwise direction.
With the lock lever 33 normally biased in the counterclockwise
direction like this, the lock lever 33 in its free state abuts
against a stopper portion 34a of the support block 34, and thus,
the lock lever 33 is held in a posture or position where the end of
the engaging claw 33a projects into the slit 23a of the support
plate 23. The engaging claw 33a of the lock lever 33 held in this
posture engages the sewing hole Sa of one of the sequins S of the
continuous sequin strip 13 led onto the support plate 23 to thereby
immovably lock the continuous sequin strip 13 during sequin sewing
(cutting).
[0046] The following lines describe details of the cutter section
comprising the fixed cutter blade 23b and movable cutter blade 36.
Such movable cutter blade 36 is pivotably supported via a pin 37 on
a distal end portion of the support plate 23 and is normally held,
via a torsion spring 38, in a retracted or evacuated posture or
position where it is spaced upward from the fixed cutter blade 23b.
The movable cutter blade 36 is depressed by a needle clamp 40,
provided at the lower end of a needle bar 39, as the needle bar 39
descends. Such depression by the needle clamp 40 causes the movable
cutter blade 36 to pivot downward against the resilient biasing
force of the torsion spring 38, so that the movable cutter blade 36
cuts the continuous sequin strip 13 across a connecting portion Sb
(see FIG. 10) of the leading sequin S in conjunction with the fixed
cutter blade 23b. As the needle clamp 40 ascends together with the
needle bar 39, the movable cutter blade 36 returns to its evacuated
position by the restoring or resilient force of the torsion spring
38.
[0047] Next, with reference to FIG. 9, a description will be given
about a guide mechanism for guiding a portion of the continuous
sequin strip 13, paid out from the reel 14, to the sequin feed unit
20 or 21. Bracket 41 is fixed to the supporting plate 22, and a
guide section 42 for directing the continuous sequin strip 13 onto
the support plate 23 is provided on the bracket 41. The guide
section 42 is replaceable with another one depending on the width
of the continuous sequin strip 13 to be set on the sequin feeder
apparatus. Holding member 43, which is in the form of a resilient
plate such as a spring steel plate, is fixed to the bracket 41. The
holding member 43 has its free end portion resiliently abutted
against the upper surface of the support plate 23, and the portion
of the continuous sequin strip 13, delivered via the guide section
42 onto the support plate 23, is passed between the support plate
23 and the holding member 43.
[0048] The following lines describe the sequin selection mechanism
(44-50, 60-67 and the like). As illustrated in FIG. 7, the sequin
feed units 20 and 21 constructed in the aforementioned manner are
secured to a slide plate 45 via the respective fixed brackets 44.
Slide members 46 are fixed to left and right end portions of the
slide plate 45. The two slide members 46 are slidably supported on
a first rod 47 that is in turn fixed to the mounting base 4. Second
rod 48 is secured at opposite ends to and extends between the two
fixed brackets 44; more specifically, the second rod 48 is slidably
supported on support sections 49a of a support member 49. The
support member 49 is fixed to a bracket 50 that is in turn fixed to
the mounting base 4 via a bearing member 51.
[0049] FIG. 7 shows a state of the apparatus when one of the sequin
feed units 20 (hereinafter referred to as "first sequin feed unit
20") is selected. FIG. 11 is a front view showing in further
enlarged scale the sequin feed units 20 and 21 and sequin selection
mechanism in the state of FIG. 7. FIG. 12 is a front view similar
to FIG. 11, but shows a state of the apparatus when the other
sequin feed unit 21 (hereinafter referred to as "second sequin feed
unit 21") is selected. Further, FIG. 13 is a perspective view
similar to FIG. 7, but shows the state of the apparatus when the
other or second sequin feed unit 21 is selected.
[0050] As clear from FIG. 11, a connecting arm 60 is pivotably
connected at one end to the slide plate 45 and connected at the
other end to one end of a pivot lever 62 that is in turn pivotably
supported on a motor base 61 fixed to the mounting base 4. Drive
arm 64 is fixed to the shaft of a motor 63 fixed to the motor base
61, and the drive arm 64 is connected at its free end to the other
end of the pivot lever 62 via a connecting member 65. Thus, as the
motor 63 is reciprocatively driven, the two sequin feed units 20
and 21 together slide in the left-right horizontal (i.e., X)
direction. Limiting members 66 for defining limits of a slidable
range of the sequin feed units 20 and 21 are provided on the first
rod 47 at left and right sides of the left slide member 46. As
shown in FIG. 11, when the left slide member 46 is in a slide
position where it abuts against the right limiting member 66 via a
shock-absorbing member 67, it means that the first sequin feed unit
20 has been selected and positioned in the predetermined sewing
operation position. FIG. 8 also shows the state of the apparatus
when the first sequin feed unit 20 is selected. In such a state of
the apparatus when the first sequin feed unit 20 is selected and
positioned in the sewing operation position, not only a link pin 26
of the link arm 25 of the first sequin feed unit 20 engages with an
engagement portion 54a of a transmission lever 54 of the feeding
drive mechanism (51-59 etc.) but also the sewing hole Sa of a
sequin S to be fed out by the first sequin feed unit 20 is
positioned in vertical alignment with a needle drop position (i.e.,
position of a needle-passing hole 71 of) of the needle plate 70, as
shown in FIG. 8.
[0051] On the other hand, when the left slide member 46 is in a
slide position where it abuts against the left limiting member 66
via a shock-absorbing member 67, it means that the second sequin
feed unit 21 has been selected and positioned in the sewing
operation position, as shown in FIG. 12. In this state, not only a
link pin 26 of the link arm 25 of the second sequin feed unit 20
engages with the engagement portion 54a of the transmission lever
54 of the feeding drive mechanism (51-59 etc.) (see FIG. 13) but
also the sewing hole Sa of a sequin S to be fed out by the second
sequin feed unit 21 is positioned in vertical alignment with the
needle drop position (i.e., position of the needle passing hole 71
of) of the needle plate 70. Namely, by causing the two sequin feed
units 20 and 21 to slide together, any one of the units 20 and 21
can be selectively positioned in the predetermined sewing operation
position. Then, sequin sewing is performed using the selected
sequin feed unit 20 or 21, as will be later described. As a
modification of the present invention, any one of the two sequin
feed units 20 and 21 may be selectively positioned in the
predetermined sewing operation position by selectively moving the
one sequin feed unit 20 or 21 instead of causing the two sequin
feed units 20 and 21 to slide together.
[0052] Note that the sliding movement for selecting the sequin feed
unit 20 or 21 in order to change the sequin to be sewn to from one
type to another in the middle of a series of sequin pattern sewing
operations is performed by the sequin selection mechanism (44-50,
60-67 and the like) while the needle bar 39 is in a raised or upper
position. In this way, it is possible to eliminate a need for
temporarily stopping the vertical movement of the needle bar 39
(i.e., effecting so-called "jumping" of the needle bar 39) in order
to switch between the sequin types, so that the sewing efficiency
can be enhanced.
[0053] The following lines describe the feeding drive mechanism
(51-59 etc.). Referring to FIG. 7 or 9, a pivot shaft 52 is
pivotably supported on the bearing member 51 mounted on the
mounting base 4, and a driven lever 53 and the transmission lever
54 are fixed to the pivot shaft 52. The transmission lever 54 has,
in its free end, an engagement portion 54a in the form of a
U-shaped recess that engages with the link pin 26 of the link arm
25 of each of the sequin feed units 20 and 21. As each of the units
20 and 21 is caused to slide horizontally, the engagement portion
54a in the form of a U-shaped recess allows the link pin 26 of each
of the sequin feed units 20 and 21 to move horizontally relative to
the engagement portion 54a, so that only the link arm 26 of the
selected one sequin feed unit 20 or 21 engages with the engagement
portion 54a. Each of the link pins 26 may have a slanted distal end
surface to permit smooth engagement with the engagement portion
54a. Note that such a slanted surface may be formed on the
engagement portion 54a of the transmission lever 54 rather than on
each of the link pins 26, or on both the link pins 26 and the
engagement portion 54a.
[0054] The driven lever 53 has its free end portion connected to a
free end portion of a driving lever 56 via a connecting link 55,
and the driving lever 56 is fixed to the shaft of a motor 57
secured to the left side surface of the mounting base 4. Torsion
spring 58 is provided on the pivot shaft 52, which normally urges
the driven lever 53 and transmission lever 54 in the clockwise
direction of FIG. 9 so that an abutting piece 56a of the driving
lever 56 normally abuts against a stopper 59. To feed out a sequin,
the motor 57 performs one reciprocative stroke driving; that is,
the motor 57 is caused to pivot through a predetermined angle in
the counterclockwise direction of FIG. 9 and then rotated back
(returned) through a predetermined angle in the clockwise
direction.
[0055] Next, sequin feeding operation by the sequin feed mechanism
19 will be described. First, in response to counterclockwise
rotational driving (i.e., forward driving operation) of the motor
57, the driving lever 56 is caused to pivot through a predetermined
angle in the counterclockwise direction so that a connection
between the lower end of the connecting link 55 and the free end of
the driven lever 53 is caused to pivot downward through a
predetermined angle in the counterclockwise direction. Thus, the
pivot shaft 52 is caused to pivot through a predetermined angle in
the counterclockwise direction, so that the engagement portion 54a
at the lower end of the transmission lever 54 is driven rearwardly
(rightward or counterclockwise in FIG. 9). As the engagement
portion 54a is driven rearward, the link pin 26 of the sequin feed
mechanism 19 of one of the sequin feed units 20 or 21, currently
engaging with the engagement portion 54a, moves rearward together
with the engagement portion 54a. In the sequin feed mechanism 19 of
one of the sequin feed units 20 or 21, the link arm 25 and pivot
lever 27 are caused to pivot about the shaft 24 in the
counterclockwise direction of FIG. 9 in response to the movement of
the link pin 26, so that the feed lever 29 supported at the free
end (lower end) of the pivot lever 27 is moved forward (leftward in
FIG. 9). After that, in response to clockwise rotational driving
(i.e., rearward driving operation) of the motor 57, each of the
relevant components is moved in a direction opposite the
aforementioned, so that the feed lever 29 supported at the free end
(lower end) of the pivot lever 27 is moved forward (rightward in
FIG. 9, i.e. toward the predetermined cutting position).
[0056] One stroke length of the feed lever 29 in the forward or
rearward movement generally corresponds to a one-pitch feed amount
of the continuous sequin strip 13. As detailed in the
above-discussed No. 2004-167097 laid-open publication, the sequin
feeding operation is carried out upon completion of sewing of the
leading sequin S (and cutting of the continuous sequin strip across
the connecting portion Sb immediately following the leading sequin
S) shown in FIG. 10. By that time, the engaging portion 29a at the
distal end of the feed lever 29 has engaged with the sewing hole of
the next sequin S1, and the engaging claw 33a of the lock lever 33
has engaged with the sewing hole of some subsequent (e.g., second
sequin) of the next sequin S1.
[0057] The sequin feeding operation in the instant embodiment,
which is generally the same as disclosed in the above-discussed No.
2004-167097 laid-open publication, will be described briefly below.
As the feed lever 29 is moved forward (leftward in FIG. 9 or 10),
the engaging portion 29a of the feed lever 29 gets out of the
sewing hole of the sequin S1; at that time, however, the engaging
claw 33a of the lock lever 33 still remains engaging with the
sewing hole of the subsequent sequin, and thus, the continuous
sequin strip 13 can be reliably prevented from being undesirably
displaced by impact produced when the engaging portion 29a of the
feed lever 29 gets out of the sewing hole of the sequin S1. As the
feed lever 29 is moved further forward (further leftward in FIG. 9
or 10) in this state, the lock lever 33 pivots in the clockwise
direction of FIG. 9 against the biasing force of the torsion spring
through engagement with the edge of the through-hole 29b of the
feed lever 29, so that the engaging claw 33a of the lock lever 33
moves upward away from the sequin out of the engagement with the
sewing hole of the sequin. Then, at the end of the forward stroke,
the engaging portion 29a of the feed lever 29 is positioned a
little ahead (leftward in FIG. 9 or 10) of the sewing hole of
another sequin immediately following the sequin S1 (namely, the
engaging portion 29a has not yet engaged with the sewing hole of
the immediately-following sequin), and the lock lever 33 is still
located over the sequin strip. As a modification, arrangements may
be made to cause the engaging portion 29a of the feed lever 29 to
engage with the sewing hole of the sequin immediately following the
sequin S1 at the end of the forward stroke. Note that, during the
forward stroke, the continuous sequin strip 13, having disengaged
from the engaging claw 33a of the lock lever 33, is held by the
spring resiliency of the holding member 43 and thus will not move
with the movement of the feed lever 29.
[0058] As the feed lever 29 is moved rearward (rightward in FIG. 9
or 10), the engaging portion 29a of the feed lever 29 engages with
the sewing hole of the sequin immediately following the sequin S1.
By the engagement of the engaging portion 29a with the sewing hole
of the immediately-following sequin, the feed lever 29 feeds the
continuous sequin strip 13 toward the predetermined cutting
position (i.e., rightward in FIG. 9 or 10). The edge of the
through-hole 29b of the feed lever 29 gets out of the engagement
with the lock lever 33 during the rearward movement of the feed
lever 29, so that the lock lever 33 is caused to pivot in the
counterclockwise direction by the resiliency of the torsion spring
fitted on the pin 35. Thus, the engaging claw 33a of the lock lever
33 resiliently contacts the upper surface of the sequin strip 13
and slides along the strip's upper surface relative thereto. At the
end of the rearward stroke, the current leading sequin S1 reaches
the predetermined cutting position (i.e., sewing position) in a
similar manner to the leading sequin S shown in FIG. 10. Then, the
engaging claw 33a of the lock lever 33 engages with the sewing hole
of a predetermined sequin of the sequin strip 13 in the manner as
note above.
[0059] Next, an adjustment mechanism (68, 69) for variably
adjusting the cutting position (position relative to a sewing
needle 77) in each of the sequin feed units 20 and 21. FIG. 14 is a
side view of the supporting plate 22 of one of the sequin feed
units 20 or 21 taken from a side opposite the side where the sequin
feed mechanism 19 is provided. As shown in FIG. 14, the supporting
plate 22 is secured to a fixed bracket 44 via screws 68 passed
through an elongated hole 44a formed in the fixed bracket 44.
Adjustment screw (or bolt) 69, having a distal end portion screwed
to a threaded hole formed in the supporting plate 22, is provided
on the fixed bracket 44 in such a manner that it is rotatable about
its axis but can not move in an axial direction thereof. By
loosening the screw 68 fixing the supporting plate 22 and rotating
the adjustment screw 69 clockwise or counterclockwise, the
supporting plate 22 is moved linearly forward or rearward relative
to the fixed bracket 44 so that its position in the front-rear
direction can be adjusted. Once the supporting plate 22 has been
adjusted to a desired position in the front-rear direction, the
screw 68 is tightened to fix the supporting plate 22 to the fixed
bracket 44.
[0060] However, as the supporting plate 22 is adjusted in position
as noted above, the link pin 26 of the link arm 25 is also
displaced in the front-rear direction so that positional
relationship between the link pin 26 and the engagement portion 54a
of the transmission lever 54 in the returned position would go
wrong. But, if the link arm 25 is placed in a freely movable state
by loosening in advance a screw 81 (see FIG. 8), fixing the link
arm 25 to the shaft 24, at the time of positional adjustment of the
plate 22, the transmission lever 54 in the returned position can be
prevented from undesirably pivoting as the supporting plate 22 is
moved; after completion of the positional adjustment of the
supporting plate 22, it is only necessary to again fix the link arm
25 to the shaft 24 by tightening the screw 81.
[0061] Through the positional adjustment of the supporting plate
22, the sequin feed unit 21 is adjusted in position in the
front-rear direction. Because the sewing needle 77 attached to the
needle bar 39 of the machine head is relatively fixed in position
(horizontal position), the aforementioned front-rear positional
adjustment of the sequin feed unit 21 can adjust the position of
the cutter section (36 and 23b) relative to the sewing needle 77,
i.e. cutting position (or horizontal distance between the axis of
the vertical movement of the sewing needle 77 and the fixed cutter
blade 23b). The cutting position is adjusted in accordance with the
size of each sequin (i.e., distance from the sewing hole Sa to the
connecting portion Sb of the sequin as shown in FIG. 10) of a
continuous sequin strip 13 to be set on the sequin feed unit 21.
Thus, such adjustment of the cutting position is performed when the
reel (sequin holder) 14 holding a continuous sequin strip 13 of one
sequin size (or one sequin feed size) and mounted in correspondence
with the sequin feed unit 21 is to be replaced with another reel
(sequin holder) 14 holding a continuous sequin strip 13 of another
sequin size (or another sequin feed size). More specifically, when
a reel 14 holding a continuous sequin strip 13 of one sequin size
has been newly set, for example, a portion of the continuous sequin
strip 13 is paid out and placed onto the support plate 23, then the
leading sequin S is positioned a little ahead of the fixed cutter
blade 23b so that the connecting portion Sb of the leading sequin S
aligns with the fixed cutter blade 23b as illustrated in FIG. 10,
and thence the adjustment screw 69 is rotated clockwise or
counterclockwise to thereby adjust the front-rear position of the
sequin feed unit 21.
[0062] The instant embodiment is not limited to the aforementioned
"following" adjustment; for example, the cutting position of the
sequin feed unit 21 may be adjusted by measuring a distance from
the center of the sewing needle 77 to the fixed cutter blade 23b on
the basis of data indicative of the distance from the sewing hole
Sa to the fixed cutter blade 23b and adjusting the measured
distance to equal the distance indicated by the data.
Alternatively, such adjustment based on the measured distance data
and copying adjustment may be used in combination. Further, a
suitable scale may be provided in relation to the adjustment screw
69 so that correspondency between the current setting of the
adjustment screw 69 and the cutting position (or distance from the
center of the sewing needle 77 to the fixed cutter blade 23b) can
be grasped on the basis of the scale. The adjustment mechanism is
not limited to one using the adjustment screw 69 as set forth above
and may be one using another linear displacement mechanism. In an
alternative, the adjustment screw 69 may be omitted, in which case
the supporting plate 22 may be adjusted in its front-rear position
by the human operator holding and moving the supporting plate 22
with his or her hand with the supporting-plate adjusting screw 68
loosened in advance. In another alternative, the cutting position
may be variably adjusted by automatically linearly displacing the
corresponding sequin feed unit 20 or 21 using a drive means, such
as a linear motor.
[0063] The mechanism for adjusting the cutting position of the
other sequin feed unit 20 is constructed in the same manner as the
aforementioned cutting-position adjusting mechanism of the sequin
feed unit 21. However, it should be noted that, in the instant
embodiment of the present invention, the cutting position, i.e.
position of the cutter section (36 and 23b) relative to the sewing
needle 77, of each of the sequin feed units 20 and 21 can be
adjusted independently of the cutting position of the other sequin
feed unit. Namely, whereas each of the sequin feed units 20 and 21
is slidable in the left-right horizontal direction integrally with
the fixed bracket 44 in response to the movement of the
above-mentioned slide plate 45, the cutting positions of the sequin
feed units 20 and 21 can be adjusted independently of each other
because the feed units 20 and 21 are independently adjustable in
position in the front-rear direction relative to the fixed bracket
44. Thus, if the respective cutting positions of the sequin fced
units 20 and 21 are adjusted in accordance with the sequin sizes
(i.e., distances from the sewing hole Sa to the connecting portion
Sb) of continuous sequin strips set on the units 20 and 21, and if
the sequin sizes are different from each other, the position, in
the front-rear direction, of the support plate 23, i.e. the
position of the cutter section (36 and 23b), will differ between
the units 20 and 21.
[0064] The following lines describe variable setting of the sequin
feed amount (feed pitch) of the sequin feed mechanism 19 in each of
the sequin feed units 20 and 21. When a reel 14 holding a
continuous sequin strip 13 requiring sequin feed pitch adjustment
has been newly set on any one of the sequin feed units 20 and 21,
the sequin feed amount (feed pitch) of the sequin feed mechanism 19
in the unit 20 or 21 is first adjusted in the following manner.
First, the screw 28 (see FIG. 9) fixing the pivot lever 27 is
loosened to allow the human operator to readily rotate the pivot
lever 27 with a hand relative to the pivot shaft 24. Further, the
nut of the stopper 31 is loosened to cancel the locking by the
stopper, and a portion of the continuous sequin strip 13 is paid
out from the reel 14 onto the support plate 23 until the leading
sequin S is positioned a little ahead of the fixed cutter blade
23b, so that the connecting portion Sb aligns with the fixed cutter
blade 23b as illustrated in FIG. 10. Such a state corresponds to a
"feed-out completed position" where one-pitch sequin feeding has
been completed by the sequin feed mechanism 19. In this "feed-out
completed position", the pivot lever 27 and feed lever 29 are
manually moved to cause the engaging portion 29a of the feed lever
29 to engage with the sewing hole of the second sequin S1 from the
leading end of the strip 13. Namely, the pivot lever 27 and feed
lever 29 are caused to follow the "one-pitch-feed-out completed
position". Then, the nut of the stopper 31 is again tightened for
locking the stopper 31, and the screw 28 is tightened to fix the
pivot lever 27 relative to the pivot shaft 24.
[0065] Then, the locked condition of the support block 34 of the
lock lever 33 is canceled, and the lock lever 33 is adjusted with
the pivot arm or lever 27, feed lever 29 and continuous sequin
strip 13, lying on the support plate 23, held in the "feed-out
completed position". Then, with the stopper portion 33b at the
upper end of the lock lever 33 abutted against the stopper portion
34a of the support block 34, the lock lever 33 is adjusted in
position by manually adjusting the position, in the front-rear
position, of the support block 34 so that the engaging claw 33a of
the lock lever 33 engages with the sewing hole of a predetermined
sequin of the continuous sequin strip 13 lying on the support plate
23; the predetermined sequin is several sequins after (e.g., second
sequins from) the sequin S1 engaged by the engaging portion 29a of
the feed lever 29. The support block 34 is locked with the lock
lever 33 adjusted in position in the aforementioned manner.
[0066] In variably setting the sequin feed amount (feed pitch) of
the sequin feed mechanism, the "feed-out completed position", i.e.
start position (=end position) of the reciprocative stroke for
effecting one-pitch sequin feeding, is set/adjusted through
mechanical positional adjustment of the pivot lever 27, feed lever
29 and lock lever 33. Then, the end position (=start position) of
the reciprocative stroke for effecting one-pitch sequin feeding is
set/adjusted by setting data indicative of a rotational range of
the motor 57, which effects one-pitch sequin feeding driving, to a
value corresponding to a one-pitch feed amount of the feed lever
29. Such data indicative of a rotational range of the motor 57 may
be set by human operator's manual setting operation on an operation
panel 90 (FIG. 1) of the sewing machine, or may be incorporated in
advance in embroidery sewing data as sequin-feed-amount setting
data. Needless to say, data setting for setting a one-pitch feed
amount is performed independently for each of the sequin feed units
20 and 21. Namely, although the same or common motor 57 is used for
sequin feeding driving, when the motor 57 should perform sequin
feeding driving for the first sequin feed unit 20, the driving by
the motor 57 is controlled in accordance with a feeding driving
amount (rotational range) set for the feed unit 20, but, when the
motor 57 should perform sequin feeding driving for the second
sequin feed unit 21, the driving by the motor 57 is controlled in
accordance with a feeding driving amount (rotational range) set for
the feed unit 21.
[0067] Basically, the feeding may be performed using, as one feed
pitch, the size (i.e., diameter) of a sequin to be fed out; in
practice, however, a value slightly greater than the sequin size
(i.e., diameter) is set as a one-pitch feed amount of the feed
lever 29, in order to allow feed-out of the sequin strip 13 to be
effected with an increased reliability. For example, in the case of
a sequin having a 6 mm diameter, the one-pitch feed amount is set
at about 7 mm, or in the case of a sequin having a 4 mm diameter,
the one-pitch feed amount is set at about 5 mm. Namely, by setting
the one-pitch feed amount of the feed lever 29 to a value slightly
greater than the sequin size (i.e., diameter), the engaging portion
29a of the feed lever 29 is positioned a little ahead (leftward in
FIG. 9 or 10) of the sewing hole of another sequin immediately
following the leading sequin S1 (namely, the engaging portion 29a
has not yet engaged with the sewing hole of the
immediately-following sequin) at the end of the forward stroke.
Once the rearward stroke starts in this state, the engaging portion
29a of the feed lever 29 enters and engages with the sewing hole of
the sequin immediately following the leading sequin S1, so that the
continuous sequin strip 13 can be fed toward the cutting position.
The one-pitch feed amount of the feed lever 29 may be set at the
same value as the sequin size (diameter) in principle, in which
case, however, the engaging portion 29a of the feed lever 29 might
stop short of the sewing hole of the sequin immediately following
the leading sequin S1, instead of entering the sewing hole of the
immediately-following sequin, due to an error at the end of the
forward stroke of the feed lever 29. Thus, even when the feed lever
29 then starts the rearward stroke, the engaging portion 29a of the
feed lever 29 does not engage with the sewing hole of the sequin,
so that the feed lever 29 will not perform feeding of the
continuous sequin strip 13. In order to forestall such an
inconvenience, it is preferable to set the one-pitch feed amount of
the feed lever 29 to a value slightly greater than the sequin size
(i.e., diameter) as noted above.
[0068] The following paragraphs describe an example of the sequin
sewing operation using the aforementioned sequin feeder apparatus
1. In the case where sequin sewing is to be performed using the
machine head H having the sequin feeder apparatus 1 set thereon,
two different types of sequins can be sewn as desired by using the
two sequin feed units 20 and 21 during sewing of an embroidery
pattern while switching between the units 20 and 21. According to
the present invention, as set forth above, each of the sequin feed
units 20 and 21 is capable of setting/changing its sequin feed
pitch as desired, and thus, the "two different types of sequins"
may differ in any of not only shape and color but also size
(diameter). Further, even the same sequin feeder apparatus 1 can
sew sequins of any desired size (diameter), i.e. any desired feed
pitch, in accordance with a desired sequin sewing design. Note that
sewing control to be described below is implemented by a not-shown
control device (e.g., computer) executing a sewing control program,
containing a sequence of operations to be explained below, on the
basis of desired sequin-design sewing pattern data related to
two-sequin-combined embroidery. Although a flow chart of the
sewing-controlling operational sequence is not shown here, such a
flow chart may be readily realized on the basis of the following
description of the sewing-controlling operational sequence.
[0069] First, two reels 14 holding, i.e. having wound thereon,
continuous sequin strips 13 differing in sequin shape, color and/or
size are prepared in accordance with a two-type-sequin-combined
embroidering design and then set on the base 3 side by side in
correspondence with the two sequin feed units 20 and 21 Portions of
the sequin strips 13 are paid out from the two reels 14, then
directed to and supported on the first rollers 15, tension rollers
10, second rollers 16, third rollers 17 and fourth rollers 18 in
the mentioned order and then guided to the feed units 20 and 21.
The portion of the continuous sequin strip 13 paid out from the
right reel 14 in FIG. 4 is directed to the support plate 23 of the
right feed unit 21, while the portion of the continuous sequin
strip 13 paid out from the left reel 14 in FIG. 4 is directed to
the support plate 23 of the left feed unit 20, The guide sections
42 (FIG. 9) corresponding to the sequin feed units 20 and 21 are
replaced, if necessary, in accordance with the widths of the sequin
strips 13. Then, various adjustment, such as adjustment of the
"cutting position" and "feed amount" is also performed in the
above-described manner in accordance with the sequin sizes of the
set continuous sequin strips 13; such adjustment may be performed
in suitable order.
[0070] After completion of predetermined adjustment and setting,
the operation of the sewing machine is started, upon which sequin
embroidery sewing is carried out under the control of the control
device and on the basis of desired sequin-pattern sewing pattern
data using a combination of at least two types of sequins. For
example, the desired sequin sewing pattern data are embroidery
sewing data of a format programmed to realize a desired sewing
pattern and include data for driving the embroidery frame along the
X and Y axes in accordance with the desired sewing pattern. The
sewing pattern data also include data for selecting sequins to be
used for sewing in correspondence with an initial stitch and groups
of desired one or a plurality of stitches. First, which one of the
sequin feed units 20 and 21 should be used is instructed on the
basis of the data for selecting a sequin in correspondence with the
initial stitch. If use of the first sequin feed unit 20 has been
instructed, the motor 63 is driven to position the first sequin
feed unit 20 in the sewing operation position as shown in FIG. 11.
In this state, the motor 57 is driven, per sewing operation, to
cause the pivot lever 27 of the first sequin feed unit 20 to pivot
and thereby feed the continuous sequin strip 13. The leading sequin
S of the thus-fed continuous sequin strip 13 is sewn onto a fabric,
held taut on the embroidery frame 80, by means of the sewing needle
77, and the movable cutter blade 36 is driven downward by the
needle clamp 40 of the needle bar 39 lowered simultaneously with
the sewing needle 77. The leading sequin S thus sewn is cut off
from the sequin strip 13. In the aforementioned manner, sequins fed
by the first sequin feed unit 20 can be sewn to the fabric.
[0071] Once a stitch at which a sequin change or switch from one
type to another is to be effected arrives as the sequin sewing
progresses, use of the second sequin feed unit 21, for example, is
instructed on the basis of the embroidery sewing data. Then, while
the needle bar 39 is in its raised position, the motor 63 is driven
to position the second sequin feed unit 21 in the sewing operation
position as illustrated in FIG. 12. Thus, after that, the driving
force of the motor 57 is transmitted to the pivot lever 27 of the
second sequin feed unit 21, so that the continuous sequin strip 13
of the second sequin feed unit 21 is fed to the cutting position.
In order that the sequin-changing (i.e., sequin-switching) slide
and sequin feed-out operations may be performed while the needle
bar 39 is in its raised position during one up-down movement cycle,
the sequin-changing slide operation is performed first, and then
the one-reciprocative-stroke driving for sequin feed-out is
performed by the motor 57. In this manner, sequins fed by the
second sequin feed unit 21 can be sewn to the fabric. Then, the
sequin feed unit to be used for the sewing can be changed or
switched to the other as needed.
[0072] In the aforementioned manner, the first embodiment of the
invention can change the sequin to be sewn from one type to another
without stopping the rotation of the sewing machine and without
jumping the needle bar 39. Of course, the manner of the sequin
change control in the instant embodiment is not limited to the
aforementioned, and the needle bar 39 may be jumped throughout the
sequin-changing slide operation.
[0073] Note that the present invention is not limited to the case
where the embroidery sewing data include sequin-selecting
(changing) data only in correspondence with a stitch at which a
sequin change is to be effected as noted above; the embroidery
sewing data may include sequin-selecting (changing) data per
stitch.
[0074] In an alternative, the sequin-changing slide control may be
automatically performed on the basis of a predetermined sequin
changing pattern or may be manually performed as necessary in
response to operation, by the human operator, of the operation
panel 90, instead of being performed on the basis of embroidery
sewing data as set forth above. For example, the "predetermined
sequin changing pattern" may be one in accordance with which a
predetermined number n of sequins of the first sequin feed unit 20
are sewn in succession and then a predetermined number m of sequins
of the second sequin feed unit 21 are sewn in succession; thus, the
sequin to be sewn can be changed from one type to another through
repletion of the pattern. In such a case, it is preferable that the
"n" and "m" values may be manually set/changed as desired by the
human operator operating the operation panel 90. In still another
alternative, a plurality of different sequin changing patterns may
be prepared in advance so that the human operator can select, as
necessary, any desired one of the sequin changing patterns by
operating the operation panel 90.
[0075] In the above-described embodiment, the two sequin feed units
20 and 21 symmetrically arranged and substantially identically
constructed are provided in opposed relation to each other.
Alternatively, such identically-constructed sequin feed units 20
and 21 may be provided side by side in a same orientation. In such
a case, the shape of the link arm 25, fixing the link pin 26, is
modified so that the link arm 25 can move without interfering with
the transmission lever 54 during the sliding movement of the feed
units 20 and 21. In the case where the link arm 25 is modified in
shape and construction as noted above, three or more sequin feed
units, rather than the two sequin feed units 20 and 21, can be
provided side by side in such a manner that any desired one of the
feed units can be selected through the sliding movement. Thus,
switching can be made among three or more types of sequins
[0076] The first embodiment has been described above as constructed
to adjust the cutting position of each of the sequin feed units 20
and 21 through positional adjustment of the supporting plate 22
(i.e., the whole of the sequin feed unit in question).
Alternatively, the support plate 23 may be made adjustable in
position relative to the supporting plate 22 so that desired
adjustment of the cutting position can be performed through
positional adjustment of the support plate 23 alone. In such a
case, the mechanism for linearly displacing the support plate 23
may employ a rotation-to-linear-displacement conversion mechanism,
such as the above-mentioned adjustment screw 69, linear motor, or
the like.
Second Embodiment
[0077] With reference to FIGS. 16-20, the following paragraphs
describe a sequin feeder apparatus 100 in accordance with a second
embodiment of the present invention.
[0078] FIG. 16 is a right side view of the sequin feeder apparatus
100, which is provided with a detection device 101 for detecting
that the entirety of a continuous sequin strip 13 has been supplied
from the reel 14. Namely, the detection device 101 is provided for
detecting whether the supply from any of the supply sources (reels)
14 to the respective sequin feed units 20 and 21 has stopped. The
sequin feeder apparatus 100 according to the second embodiment is
slightly different, in installed position of the rollers for
guiding the sequins strips 13 paid out from the reels 14, from the
sequin feeder apparatus 1 because of the provision of the detection
device 101, but, the two embodiments are identical to each other in
the other structural features.
[0079] FIGS. 17-20 are views showing in enlarged scale an example
construction of the detection device 101. More specifically, FIG.
17 is a side view of the detection device 101, FIG. 18 is a view
taken in a direction of arrow A of FIG. 17, and FIG. 19 is a
sectional view taken along the B-B line of FIG. 17. Mounting
bracket 102 of the detection device 101 includes a mounting section
102a mounted on the fixed base 3, and a first base plate 102b bent
at a right angle from the mounting section 102a. As shown in FIG.
18, the first base plate 102b has a projection 103 of an inverted T
shape formed integrally with the lower edge thereof, and guiding
portions 103a and 103b for guiding the respective continuous sequin
strips 13 extend leftward and rightward from the projection 103.
Second base plate 104, having a similar shape to the first base
plate 102b, is secured, by means of a stud 105, to the mounting
bracket 102 in parallel with the first base plate 102b. Namely, the
second base plate 104 has guiding portions 104a and 104b similar to
the guiding portions 103a and 103b of the first base plate 102b.
Thus, as shown in FIG. 19, the two continuous sequin strips 13,
hanging down from above, are guided by the left and right guiding
portions 103a, 103b and 104a, 104b with each of the continuous
sequin strips 13 supported at two points by a pair of the preceding
and succeeding guiding portions 103a and 104a (103b and 104b).
Between the first and second base plates 102b and 104, right and
left levers 106 and 107 are rotatably mounted via a pin provided on
the projection 103. The right and left levers 106 and 107 has
respective arms 106a and 107a capable of abutting against the
corresponding continuous sequin strips 13 supported by the
preceding and succeeding (i.e., upper and lower) guiding portions
103a, 104a and 103b, 104b, and detecting portions (made of metal)
106b and 107b extending from the right and left levers 106 and 107,
respectively. Knobs 108 are provided at the respective ends of the
levers 106 and 107.
[0080] Each of the right and left levers 106 and 107 functions as a
displacement member displaceable between first and second
positions. The "first position" is where the displacement member
(lever 106 or 107) is held in abutting contact with the
corresponding continuous sequin strip 13, while the "second
position" is where the displacement member (lever 106 or 107) is
located past the first position, without abutting against the
corresponding continuous sequin strip 13, due to a stoppage (i.e.,
runout) of the supply of the continuous sequin strip 13.
[0081] FIG. 18 shows where the two continuous sequin strips 13
supported by pairs of the preceding and succeeding guiding portions
103a, 104a and 103b, 104b. In this state, the arms 106a and 107a of
the right and left levers 106 and 107, having pivoted downward by
the weights of the respective knobs 108, are in abutting contact
with the corresponding continuous sequin strips 13 from above;
hardly, the right and left levers 106 and 107 are each held in the
first position. On the other hand, when the continuous sequin strip
13 is not being supported by the guiding portions 103a, 103b (104a,
104b), i.e., when the supply of the continuous sequin strip 13 has
run out as shown in FIG. 20, the right lever 106 pivots in the
clockwise direction by the weight of the knob 108 to pass between
the guiding portions 103a and 104a, so that the lever 106 takes a
posture where the corresponding knob 108 is oriented vertically;
namely, the lever 106 takes the second position.
[0082] Magnetic sensor 109 is provided on the upper surface of the
second base plate 104 and on pivoting trajectories of the detecting
portions 106b and 107b, and a permanent magnet 110 is provided on
the lower surface of the first base plate 102b. When none of the
detecting portions 106b and 107b is located between the magnetic
sensor 109 and the permanent sensor 110 as shown in FIG. 18, the
magnetic sensor 109 is kept in an ON state. But, as the right lever
106 pivots, from the position of FIG. 18, in the clockwise
direction (i.e., shifts from the first position to the second
position) due to a stoppage (runout) of the supply of the right
(-side) continuous sequin strip 13 as shown in FIG. 20, the
detecting portion 106b passes transversely between the magnetic
sensor 109 and the permanent sensor 110 and thereby temporarily
blocks out the magnetism of the permanent magnet, so that the
magnetic sensor 109 is shifted to an OFF state. In this way, it is
possible to detect that the supply of the continuous sequin strip
13, so far has been paid out or supplied from the reel 14, has run
out.
[0083] The detection device 101 in the second embodiment operates
as follows at the time of sequin sewing. First, as in the first
embodiment, two reels 14 holding, or having wound thereon,
continuous sequin strips 13 differing in shape and/or size, are set
side by side on the fixed base 4. Portions of the continuous sequin
strips 13, paid out from the reels 14, are passed to and engaged
with the individual rollers and detection device 101 and then
directed to the corresponding sequin feed units 20 and 21. In the
detection device 101, the continuous sequin strips 13 are set on
the guiding portions 103a, 104a and 103b, 104b, respectively. When
a continuous sequin strip 13 is set relative to the right side of
the detection device 101, for example, the following operation
takes place. As long as no continuous sequin strip 13 is set on the
right side of the detection device 101, the right lever 106 is held
in the second position where the knob 108 is oriented vertically
downward as shown in FIG. 20. Thus, the human operator holds the
knob 108 of the right lever 106 to cause the right lever 106 to
pivot from the second position in the counterclockwise direction
until the arm 106a of the right lever 106 is located above the
first position shown in FIG. 18, after which the operator inserts
and sets the right-side continuous sequin strip 13 between the arm
106a and the guiding portions 103a, 104a. In this manner, the right
lever 106 is held in the first position where the arm 106a is held
horizontally with the right lever 106 supported by the upper
surface of the continuous sequin strip 13 that is in turn supported
at two points thereof by the preceding and succeeding guiding
portions 103a and 104a. Left-side continuous sequin strip 13 can be
set relative to the left side of the detection device 101 in
generally the same manner as the right-side continuous sequin strip
13.
[0084] When sequin sewing is started after the continuous sequin
strips 13 have been properly set in place in the aforementioned
manner, the two levers 106 and 107 are held in the first position
as shown in FIG. 18 and the magnetic sensor 109 is kept in the ON
state detecting the magnetism of the permanent magnet 110, as long
as there exist the sequin strips 13 on the detection device 101.
Then, once the supply of one of the continuous sequin strips (e.g.,
right-side continuous sequin strip) 13 runs out and the right-side
continuous sequin strip 13 is no longer present at the guiding
portions 103a and 104a, the right lever 106 pivots downward to the
second position shown in FIG. 20. At that time, the detecting
portion 106b of the right lever 106 passes transversely between the
magnetic sensor 109 and the permanent magnet 109, so that the
magnetism of the permanent magnet 21 is temporarily blocked out and
thus the magnetic sensor 109 is temporarily placed in the OFF state
and then returns to the ON state. Output of the magnetic sensor 109
is supplied to a not-shown control device. When the control device
detects that the output of the magnetic sensor 109 has switched to
the OFF state, it determines that the supply of the continuous
sequin strip 13 has run out, so that it automatically deactivates
the sewing machine and informs, via suitable visible and/or audible
means, the human operator that the supply of the continuous sequin
strip 13 has run out.
[0085] In the aforementioned detection device 101, the magnetic
sensor 109 is kept in the ON state while the lever 106 or 107 is
held in the second position. Thus, when sequin sewing is to be
performed with a continuous sequin strip 13 set only on one of the
two sequin feed units (i.e., with no sequin color change to be
effect), there is no need to make an arrangement for preventing a
state of the other sequin feed unit, where no continuous sequin
strip 13 is set, from being detected, e.g. by evacuating the lever
106 or 107 of the other sequin feed unit. Because the lever 106 or
107 of the other sequin feed unit, where no continuous sequin strip
13 is set, is held in such a manner that the corresponding knob 108
is oriented vertically downward by its own weight alone, the lever
106 or 107 of the other sequin feed unit might undesirably pivot if
the embroidery sewing machine vibrates greatly, which tends to
result in a false detection. To avoid such an inconvenience,
holding members, such as leaf springs, may be provided to restrict
movement the levers 106 and 107 such that, when any one of the
levers 106 or 107 is in the second position (where the knob 108 is
oriented vertically downward), the lever 106 or 107 can be reliably
prevented from undesirably pivoting due to vibration. Alternatively
biasing members, such as torsion springs, for normally urging the
levers 106 and 107 to the second position (i.e., position where the
knob 108 is oriented vertically downward), in which case it is
preferable to provide stoppers for holding the thus-urged levers
106 and 107 in the second position.
[0086] Note that, in the above-described second embodiment, the
detection device 101 only detects that any one of the two
continuous sequin strips 13 has run out and does not specifically
detect which one of the two continuous sequin strips 13 has run
out. This is because the second embodiment can achieve necessary
and sufficient functions by automatic deactivation of the sewing
machine or information to the human operator based on the mere
detection that any one of the two continuous sequin strips 13 has
run out. However, the present invention is not so limited, and two
detection devices of the aforementioned construction may be
provided, in correspondence with two continuous sequin strips 13 to
be set, so as to specifically detect which one of the two
continuous sequin strips 13 has run out.
[0087] Note that the detection device 101 for detecting that a
continuous sequin strip 13 has run out is also applicable to sequin
feeder apparatus of the conventionally-known type where only one
continuous sequin strip is set and fed, instead of being limited to
the sequin feeder apparatus 1 of the type where two or more
continuous sequin strips 13 are set side by side to permit sequin
selection or change as desired. In such a case, the construction of
the detection device 101 shown in FIGS. 17-20 may be used as-is,
and the continuous sequin strip 13 only has to be guided by the
left- or right-side guiding portions 103a and 104a (or 103b and
104b). Alternatively, the construction of the detection device 101
shown in FIGS. 17-20 may be modified; for example, there may be
provided only the left- or right-side 103a and 104a (or 103b and
104b) and the corresponding lever 106 (or 107).
[0088] Further, the detection device 101 may comprise any suitable
detection means, such as an optical sensor or mechanical sensor,
rather than a magnetic sensor.
Other Improvements or Modifications
[0089] According to the present invention, spring members for
holding the two reels 14 sideways against excessive rotation are
provided at positions where the reels 14 are set side by side.
Thus, some force would act on the two juxtaposed reels 14 such that
the reels 14 tend to rotate together; consequently, as one of the
reels 14, which is currently involved in sequin sewing, rotates,
the other reel 14, which is not currently involved in the sequin
sewing, may undesirably rotate together with the one reel 14 and
slacken to have adverse influences on the sequin sewing. To avoid
such adverse influences, it is desirable to take some measure to
prevent the two reels 14 from rotating together. As an example of
such a measure, a key groove may be formed in the mounting shaft
supporting the reels 14, and a washer having a key formed, on its
inner periphery, for fitting engagement with the key groove may be
provided between the two reels 14. Alternatively, a part of the
mounting shaft may be formed into a substantial D sectional shape,
and a washer having a hole corresponding in sectional shape to that
part may be provided between the two reels 14. In this way, the two
reels 14 can be reliably prevented from rotating together, and,
besides, the holding force applied sideways effectively acts on
both of the reels 14.
[0090] Further, the mounting base 4 may be constructed so that it
can also be stopped and held in an intermediate position between
the lowered position and the evacuated position. For example, when
the sequin sewing operation is to be switched to the embroidery
operation by the sequin needle bar, it has been conventional to
hold the mounting base in the lowered position in order to reduce
the necessary working time; however, according to the modification
of the present invention, the mounting base 4 is raised from the
lowered position to the intermediate position without the sewing
machine being deactivated. With such a modification, it is possible
to avoid the inconveniences that the movable cutter blade 36 is
easily damaged by being unnecessarily hit by the needle clamp 40.
Furthermore, the modification can reduce the time required for
ascending and descending of the mounting base 4, and, because the
sewing machine is not deactivated, it can effectively reduce the
loss of the operating time as compared to the case where the
switching from the sequin sewing operation to the embroidery
operation is effected with by the base 4 held in the lower
position. Alternatively, the needle bar may be held in the jumping
state, in which case too the loss of the operating time can be
considerably reduced. Note that the "intermediate position" of the
mounting base 4 may be any suitable position where the movable
cutter blade 36 is not hit by the needle bar 40. Also note that, in
the case where the mounting base 4 is constructed to be able to be
stopped and held in the intermediate position as noted above, the
mounting base 4 may be evacuated from the intermediate position to
the evacuated position upon deactivation of the sewing machine.
Further, the human operator may set individually whether the
mounting base 4 should be held in the lowered position or should be
raised to the intermediate position or to evacuated position in
various predetermined states, such as when the thread is to be cut
and when a thread breakage has been detected.
[0091] In the case where the sequin feeder apparatus 1 is attached
to the left side of the needle bar case 2 as shown in FIG. 1, a
state or position where the right-side sequin feed unit 21 of the
two sequin feed units 20 and 21 is in the sewing operation position
may be set as a "reference position"; namely, when the sequin
sewing operation is not to be performed, the right-side sequin feed
unit 21 may be positioned in the sewing operation position. Thus,
in an operation for threading a needle bar located immediately to
the right of the sequin needle bar, for example, the threading can
be performed with ease without being interfered with by the sequin
feeder apparatus 1. In the case where the sequin feeder apparatus 1
is attached to the right side of the needle bar case 2, on the
other hand, a state or position where the left-side sequin feed
unit 20 is in the sewing operation position may be set as the
"reference position".
[0092] Furthermore, for each of the sequin feeder apparatus 1,
there may be provided a feeding switch operable to instruct an
operation for feeding a continuous sequin strip 13, a switching
switch operable to instruct that the sequin feed unit to be used
for feeding the continuous sequin strip 13 be changed or switched
over to the left or right sequin feed unit 20 or 21, an
ascending/descending switch operable to instruct that the sequin
feeder apparatus 1 be caused to ascend or descend, and other
switches, so that any desired operation can be instructed by the
human operator manually operating a corresponding one of the
switches.
[0093] During operation of the sewing machine, embroidery sewing
data corresponding to several stitches may be pre-read so that
sequin changing (switching) can be effected at a stitch preceding
the sewing of the several stitches. More specifically, once a
particular stitch at which a sequin change is to be effected is
identified through pre-reading of the embroidery sewing data, a
determination is made as to whether or not the sequin change is
possible at a stitch preceding the particular stitch. If the
preceding stitch is a stitch at which a sequin is not to be fed
out, then it is determined that the sequin change is possible at
the preceding stitch. If, on the other hand, the preceding stitch
is a stitch at which a sequin is to be fed out, then it is
determined that the sequin change is impossible at the preceding
stitch, and jump stitch data is inserted for jumping the needle bar
between needle stitches so that a sequin change can be effected
during the jumping of the needle bar.
[0094] Such a sequin change will be described in more detail below
in relation to a case where sequin patterns shown in FIGS. 21 and
22 are to be sewn. The sequin patterns shown in FIGS. 21 and 22
each comprise a pattern to be made by alternately sewing sequins of
different sizes, and let it be assumed here that, of the sequin
patterns, the large-size sequins A are sewn via the sequin feed
unit 21 while the small-size sequins B are sewn via the other
sequin feed unit 20. In each of FIGS. 21 and 22, P1 represents a
first "sewing stitch" formed by a first "needle stitch", P2 a
second sewing stitch formed by a second needle stitch, P3 a third
sewing stitch formed by a third needle stitch, P4 a fourth sewing
stitch by a fourth needle stitch, and so on. In the sequin pattern
shown in FIG. 21, there are provided, between the large-size
sequins A and the small-size sequins B, "no sequin" stitches where
no sequin is sewn, while, in the sequin pattern shown in FIG. 22,
the different-size sequins A and B are sewn successively stitch by
stitch, i.e. with no "no-sequin stitch".
[0095] The following lines describe a sequence of operations
performed by the control device (e.g., computer) for sewing the
sequin pattern shown in FIG. 21. First, the sequin feed unit 21 is
positioned in the sewing operation position in correspondence with
the first large-size sequin A to be first sewn to a workpiece, and
then the first sewing stitch P1 corresponding to the first needle
stitch is formed with no sequin sewn. Then, the sequin A is fed out
via the sequin feed unit 21 and sewn to the workpiece by the second
sewing stitch P2. Then, sewing of the first small-size sequin B at
the fourth needle stitch is identified by pre-reading of embroidery
sewing data, and a determination is made as to whether or not a
sequin change is possible at the third needle stitch preceding the
fourth needle stitch. Because the third needle stitch is where no
sequin is to be fed out, it is determined that the sequin change is
possible at the third needle stitch. Thus, the control device
decides to effect the sequin change at the third needle stitch, on
the basis of which the sequin feed unit 20 is positioned in the
sewing operation position in correspondence with the small-size
sequin B to be next sewn. Then, the third sewing stitch is formed
with no sequin sewn, at which time the sequin feed unit to be
positioned in the sewing operation position is switched while the
needle bar is raised between the second and third needle stitches.
Then, the small-size sequin B is fed out via the sequin feed unit
20, currently positioned in the sewing operation position, and sewn
to the workpiece by the fourth sewing stitch P4. Then, in a similar
manner to the aforementioned, the sequin feed unit 21 corresponding
to the second large-size sequin A is positioned in the sewing
operation position, and thence the fifth sewing stitch P5 is formed
with no sequin sewn. After that, the aforementioned operations are
repeated, so that the sequin pattern shown in FIG. 21 is sewn to
the workpiece.
[0096] The following lines describe a sequence of operations
performed by the control device (e.g., computer) for sewing the
sequin pattern shown in FIG. 22. First, the sequin feed unit 21 is
positioned in the sewing operation position in correspondence with
the first large-size sequin A to be first sewn to a workpiece, and
then the first sewing stitch P1 corresponding to the first needle
stitch is formed. Then, the sequin A is fed out via the sequin feed
unit 21 and sewn to the workpiece by the second sewing stitch P2.
Then, sewing of the first small-size sequin B at the third needle
stitch is identified by pre-reading of embroidery sewing data, and
a determination is made as to whether or not a sequin change is
possible at the second needle stitch preceding the third needle
stitch. Because the second needle stitch is where the large-size
sequin A is to be sewn, it is determined that the sequin change is
impossible at the second needle stitch, jump stitch data is
inserted for jumping the needle bar between the second and third
needle stitches. Thus, the needle bar is jumped with a jump stitch,
and the sequin feed unit 20 is positioned in the sewing operation
position in correspondence with the small-size sequin B to be next
sewn. Then, the small-size sequin B is fed out via the sequin feed
unit 20 and sewn to the workpiece by the third sewing stitch P3
corresponding to the third needle stitch. Then, in a similar manner
to the aforementioned, jump stitch data is inserted, the needle bar
is jumped, and the sequin feed unit 21 is positioned in the sewing
operation position in correspondence with the first large-size
sequin A. Then, the sequin A is fed out via the sequin feed unit 21
and sewn to the workpiece by the fourth sewing stitch P4
corresponding to the fourth needle stitch. After that, the
aforementioned operations are repeated, so that the sequin pattern
shown in FIG. 22 is sewn to the workpiece. Namely, a change or
switch from a sequin of one type to a sequin of the other type and
feeding of the sequin of the other type may be performed at
different stitches, by effecting the sequin change at a stitch
preceding the stitch at which the sequin is to be sewn.
[0097] Note that, even where a stitch at which no sequin is to be
fed is present before a stitch at which a sequin is to be sewn as
in the sequin pattern of FIG. 21, it may be determined that no
sequin change is possible if the embroidery frame 80 is to be moved
rearward. This is because, if the embroidery frame 80 is moved
rearward, a previously-sewn stitch position will get into under the
sequin feed units 20 and 21, and thus, an upper thread (or needle
thread) T may contact the distal or lower end (movable cutter blade
36) of the sequin feed unit 20 or 21 as shown in FIG. 23. Thus, if
the sequin feed units 20 and 21 differ in position in the
front-rear direction, for example, depending on the sizes of the
sequins set thereon as illustrated in FIG. 15, and if switching is
made from the sequin feed unit 21 to the sequin feed unit 20, the
upper thread T may enter the cutter section (36, 23b) of the sequin
feed unit 20. If the upper thread T has entered the cutter section
(36, 23b), not only the sewing is adversely influenced, but also
the upper thread T is undesirably cut by the cutter section (36,
23b) during sewing of a sequin. Thus, in the case where a sequin
change at a point when the embroidery frame 80 is to be moved
rearward has been determined to be impossible, a further
determination may be made as to whether a sequin change is possible
at a further preceding stitch that precedes the aforementioned
preceding stitch. If the further preceding stitch is a stitch at
which no sequin is to be fed out, and if the embroidery frame 80 is
to be moved rearward, the desired sequin change is effected at the
further preceding stitch. If, on the other hand, no sequin change
is impossible at the further preceding stitch too, thenjump stitch
data is inserted. Note that, in order to prevent the upper thread T
from entering the cutter section (36, 23b) with an increased
reliability, the sequin feed units 20 and 21 may each be provided
with a guide member for guiding the upper thread T so as not to
enter the cutter section (36, 23b). Furthermore, by pre-reading the
embroidery sewing data, the sewing speed of the sewing machine may
start to be lowered several stitches before a stitch at which a
sequin change is to be effected; the sewing speed may be returned
to a normal speed when no sequin change is to be effected between
given stitches.
[0098] The following lines describe an example manner in which a
sequin pattern is created using the basic principles of the present
invention. Sequin pattern, comprising a heretofore-unachievable,
novel pattern structure, can be created by using the sequin feeder
apparatus 1 of the present invention to sew two sequins C and D of
different types to a workpiece in an overlapped relation to each
other as shown in FIG. 24. Now, with reference to FIG. 25, a
description will be given about an example sequence of operations
performed by the control device (e.g., computer) for creating such
a novel sequin pattern. First, one of the sequin feed units 20 or
21 to be used for sewing of the sequin C to a workpiece is
positioned in the sewing operation position, and then a first
sewing stitch P1 corresponding to a first needle stitch shown in
(a) of FIG. 25 is formed. Next, the sequin C is fed out and sewn to
the workpiece by a second sewing stitch P2 corresponding to a
second needle stitch. After that, the other sequin feed units 21 or
20 to be used for sewing of the sequin D to the workpiece is
positioned in the sewing operation position, and then a third
sewing stitch P3 corresponding to a third needle stitch is formed.
Then, the sequin C is fed out and sewn to the workpiece by a fourth
sewing stitch P4 corresponding to a fourth needle stitch. After
that, sewing stitches P5, P6 and P7 corresponding to fifth, sixth
and seventh needle stitches are sequentially formed as shown in (c)
of FIG. 25. In the meantime, the sequin feed unit 20 or 21 to be
used for sewing of the next sequin C to the workpiece is positioned
in the sewing operation position, and the next sequin C is sewn to
the workpiece by an eighth sewing stitch corresponding to an eighth
needle stitch. Afterward, the aforementioned operations at the
third to eighth needle stitches are repeated, so that the sequin
pattern shown in FIG. 24 is sewn to the workpiece. In the
aforementioned sewing, some places where two or more sewing
stitches overlap occur on the workpiece; in each of these places,
the sewing stitches may be formed either at the same position or at
positions slightly displaced from each other.
Other Embodiment of Sequin Feeder Apparatus of the Invention
[0099] FIG. 26 is an exploded rear perspective view of a sequin
feeder apparatus 120 in accordance with another embodiment of the
present invention. FIG. 26 shows in enlarged scale parts of a
feeding drive mechanism 121, sequin selection mechanism 122,
left-side sequin feed unit 123 and right-side sequin feed unit 124.
In this sequin feeder apparatus 120, each of the sequin feed units
123 and 124 includes an adjustment mechanism for variably adjusting
a cutting position (position relative to a sewing needle 77) in the
feed unit 123 or 124. As detailed later, the sequin feeder
apparatus 120 is constructed in such a manner that, in each of the
sequin feed units 123 and 124, the cutting position, adjusted in
each of the sequin feed units 123 and 124 in accordance with a
sequin size of a continuous sequin strip set on the unit, can be
maintained even after detachment of the feed unit from the
apparatus 120, and that the sequin feed units 123 and 124 can be
accurately attached to the feeder apparatus 120 by being fixedly
positioned at respective predetermined positions.
[0100] The following lines describe constructions of the sequin
feed units 123 and 124 and mounting sections thereof. For mounting
of the sequin feed units 123 and 124, the sequin selection
mechanism 122 includes base members 125 on its left and right
sides. Each of the sequin feed units 123 and 124 includes a
mounting bracket 126 having a mounting groove 126a and hole 126b.
Each of the sequin feed units 123 and 124 can be detachably fixed
to the corresponding bracket 125 by means of two stepped screws
132, and the height of the groove 126a and diameter of the hole
126b of the mounting bracket 126 are appropriately chosen such that
shaft portions 132a of the stepped screws 132 can be fitted in the
groove 126a and hole 126b with no wobbling or backlash. In this
way, the mounting brackets 126 can always be positioned in same
positions relative to the corresponding base members 125.
[0101] Each of the mounting brackets 126 is fixed to a
corresponding supporting plate 127 by means of two fastening screws
128. The mounting bracket 126 includes a mounting section for each
of the fastening screws 128, which has a stepped shape having a
through-hole for passage therethrough a threaded portion of the
fastening screw 128 and an increased-diameter portion for fitting
engagement therein of a head portion of the fastening screw 128.
The through-hole and increased-diameter portion of the mounting
section together constitute an elongated hole extending in the
front-rear direction of the sequin feeder apparatus. Further, each
of the mounting brackets 126 has a guide hole 126c extending in the
front-rear direction of the sequin feeder apparatus so that one of
guide pins 129 fixed to the supporting plate 127 can be slidably
fitted therein. In each of the mounting brackets 126, an adjustment
screw 130 is supported by a support section 126d, bent at a right
angle from the body of the bracket 126, in such a manner that the
screw 130 is rotatable about its axis but immovable in the axial
direction thereof, and the adjustment screw 130 has a distal end
portion screwed into a threaded hole of a support member 131 that
is in turn fixed to the supporting plate 127. Thus, in response to
rotation of the adjustment screw 130, the support member 131 having
the threaded hole and the supporting plate 127 are linearly
displaced without the adjustment screw 130 being linearly
displaced. Thus, as the adjustment screw 126 is rotated clockwise
or counterclockwise, the supporting plate 127 is linearly displaced
in the forward or rearward direction so that its position in the
front-rear direction can be adjusted. The other structural elements
of the sequin feeder apparatus 120 than the above-described will
not be described here because they are similar in function to those
of the sequin feeder apparatus 1 according to the first embodiment
of the invention although slightly different from the latter in
terms of shapes and positions of some of the component parts.
[0102] When some adjustment has to be made for at least one of the
sequin feed unit 123 and 124 in the sequin feeder apparatus 120 in
accordance with the size of sequins to be sewn, the sequin feed
unit 123 or 124, requiring the adjustment, is detached from the
body of the sequin feeder apparatus 120, and the sequin feed amount
(i.e., positional adjustment of the pivot lever and lock lever) of
the detached sequin feed unit 123 or 124 is adjusted. After that,
the sequin feed unit 123 or 124 is re-attached to the body of the
sequin feeder apparatus 120, and then the cutting position
(position relative to a sewing needle 77) is adjusted by rotating
the adjustment screw 130 clockwise or counterclockwise to move the
supporting plate 127 in the front-rear direction. Then, the
rotational range of the sequin-feeding drive motor is set, as
necessary, to a value corresponding to a one-pitch sequin feed
amount. Namely, the desired adjustment can be made with ease by
detaching the sequin feed unit 123 or 124, requiring the
adjustment, from the body of the sequin feeder apparatus 120 as
noted above.
[0103] Further, because each of the mounting brackets 126 can
always be positioned in the same position relative to the
corresponding base members 125, the cutting position in the sequin
feed unit 123 or 124 will not vary even though the feed unit 123 or
124 is detached and attached after the supporting plate 127 is
positioned in position according to the sequin size. Therefore, if
some scale means indicative of adjusted positions of the supporting
plate 127 corresponding to various sequin sizes is provided, and if
arrangements are made for permitting the cutting position
adjustment while the feed unit 123 or 124 is detached from the body
of the sequin feeder apparatus 120, the desired adjustment can be
made with ease. Further, such arrangements permit novel usage of
the sequin feeder apparatus, in accordance with which sequin feed
units adjusted according to various sequin sizes are prepared in
advance and switching is made to one of such prepared sequin feed
units, which corresponds to the size of a sequin to be used,
without making various adjustments in accordance with the size of
the sequin to be used.
[0104] Note that, whereas the structure for sliding the sequin
selection mechanism in each of the above-described embodiments has
been described above as comprising the two rods and member slidably
supported on the rods, the present invention is not limited to such
a structure and any other desired sliding structure comprising a
linear rail may be employed.
[0105] This application is based on, and claims priority to, JP PA
2006-280396 filed on 13 Oct. 2006. The disclosure of the priority
application, in its entirety, including the drawings, claims, and
the specification thereof, is incorporated herein by reference.
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