U.S. patent application number 13/371995 was filed with the patent office on 2012-09-06 for sewing machine, stitch data generating device and stitch data generating program.
This patent application is currently assigned to BROTHER KOGYO KABUSHIKI KAISHA. Invention is credited to Satoko HISHIDA, Masayuki HORI, Chiyo KOGA.
Application Number | 20120222602 13/371995 |
Document ID | / |
Family ID | 46752489 |
Filed Date | 2012-09-06 |
United States Patent
Application |
20120222602 |
Kind Code |
A1 |
HISHIDA; Satoko ; et
al. |
September 6, 2012 |
SEWING MACHINE, STITCH DATA GENERATING DEVICE AND STITCH DATA
GENERATING PROGRAM
Abstract
A sewing machine which forms stitches on a first object to be
sewn based on stitch data, includes an imaging unit which images an
outline of an upper cloth as the first object onto a lower cloth as
a second object, obtaining image data, an outline calculation unit
which calculates the outline of the upper cloth from the image data
obtained by the imaging unit, a determination unit which determines
a stitch-forming region for sewing the upper cloth onto the lower
cloth based on the outline of the upper cloth calculated by the
outline calculation unit, and a stitch data generating unit which
generates stitch data for the stitch-forming region determined by
the determination unit.
Inventors: |
HISHIDA; Satoko;
(Nagoya-shi, JP) ; KOGA; Chiyo; (Nagoya-shi,
JP) ; HORI; Masayuki; (Gifu-shi, JP) |
Assignee: |
BROTHER KOGYO KABUSHIKI
KAISHA
Nagoya-shi
JP
|
Family ID: |
46752489 |
Appl. No.: |
13/371995 |
Filed: |
February 13, 2012 |
Current U.S.
Class: |
112/470.05 ;
112/470.09 |
Current CPC
Class: |
D05B 23/00 20130101;
D05B 19/08 20130101 |
Class at
Publication: |
112/470.05 ;
112/470.09 |
International
Class: |
D05B 19/08 20060101
D05B019/08 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 1, 2011 |
JP |
2011-043953 |
Claims
1. A sewing machine which forms stitches on a first object to be
sewn based on stitch data, comprising: an imaging unit which images
an outline of an upper cloth as the first object onto a lower cloth
as a second object, thereby obtaining image data; an outline
calculation unit which calculates the outline of the upper cloth
from the image data obtained by the imaging unit; a determination
unit which determines a stitch-forming region for sewing the upper
cloth onto the lower cloth based on the outline of the upper cloth
calculated by the outline calculation unit; and a stitch data
generating unit which generates stitch data for the stitch-forming
region determined by the determination unit.
2. The machine according to claim 1, wherein the upper cloth is a
pocket cloth and the determination unit determines a region of the
outline of the pocket cloth other than a region defining a pocket
opening, as the stitch-forming region out of the outline of the
pocket cloth, and the stitch data generating unit generates the
stitch data according to the outline of the pocket cloth in the
stitch generating region determined by the determination unit.
3. The machine according to claim 2, wherein the stitch data
generating unit includes a reinforcement stitch data generating
unit which generates reinforcement stitch data for forming
reinforcement stitches on ends of the region defining the pocket
opening.
4. The machine according to claim 3, further comprising a storage
unit which stores a plurality of types of patterns as the
reinforcement stitch data, wherein the reinforcement stitch data
generating unit includes a setting unit which sets one of the types
of patterns stored on the storage unit, said one type of pattern
being desired by the user.
5. A stitch data generating device which generates stitch data for
a sewing machine which forms stitches on a first object to be sewn
based on stitch data, the device comprising: an imaging unit which
images an outline of an upper cloth as the first object to be sewn
onto a lower cloth serving as a second object, thereby obtaining
image data; an outline calculation unit which calculates the
outline of the upper cloth from the image data obtained by the
imaging unit; a determination unit which determines a
stitch-forming region for sewing the upper cloth onto the lower
cloth based on the outline of the upper cloth calculated by the
outline calculation unit; and a stitch data generating unit which
generates stitch data for the stitch-forming region determined by
the determination unit.
6. The device according to claim 5, wherein the upper cloth is a
pocket cloth and the determination unit determines a region of the
outline of the pocket cloth other than a region of a pocket opening
as the stitch-forming region out of the outline of the pocket
cloth, and the stitch data generating unit generates the stitch
data along the outline of the pocket cloth in the stitch generating
region determined by the determination unit.
7. The device according to claim 6, wherein the stitch data
generating unit includes a reinforcement stitch data generating
unit which generates reinforcement stitch data for forming a
reinforcement stitch on ends of the region defining the pocket
opening.
8. The device according to claim 7, further comprising a storage
unit which stores a plurality of types of patterns as the
reinforcement stitch data, wherein the reinforcement stitch data
generating unit includes a setting unit which sets one of the types
of patterns stored on the storage unit, said one type of pattern
being desired by the user.
9. A computer-readable medium storing a stitch data generating
program on which a computer executes processing for generating
stitch data for a sewing machine which forms stitches on a first
object to be sewn based on stitch data, the program comprising: an
imaging routine of imaging, by an imaging unit, an outline of an
upper cloth as the first object to be sewn onto a lower cloth as a
second object, thereby obtaining image data; a calculation routine
of calculating the outline of the upper cloth from the image data
obtained by the imaging unit; a determination routine for
determining a stitch-forming region for sewing the upper cloth onto
the lower cloth based on the outline of the upper cloth calculated
by the outline calculation unit; and a stitch data generating
routine for generating stitch data for the stitch-forming region
determined by the determination unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of
priority from the prior Japanese Patent Application No. 2011-043953
filed on Mar. 1, 2011, the entire contents of which are
incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to a sewing machine which
forms stitches on an object to be sewn, such as a workpiece cloth,
based on stitch data, a stitch data generating device which
generates the stitch data and a computer-readable medium which
stores a stitch data generating program.
[0004] 2. Related Art
[0005] There has conventionally been known a sewing machine which
can perform embroidery sewing and which is provided with a stitch
forming mechanism including a needle, a transfer mechanism for
moving an embroidery frame holding a workpiece cloth in X and Y
directions on a sewing bed, and a control device which controls the
stitch forming mechanism and the transfer mechanism. The control
device controls the stitch forming mechanism and the transfer
mechanism based on embroidery data indicative of amounts of
movement of the embroidery frame in the X and Y directions for
every stitch, so that an embroidery pattern according to the
embroidery data is sewn onto the workpiece cloth.
[0006] On the other hand, a sewing machine has also been provided
which sews, onto a lower cloth, an upper cloth such as a label or
patch with the use of the above-described sewing machine. The
sewing machine comprises a CCD camera which images the upper cloth
temporarily tacked on the lower cloth. The sewing machine
identifies an outline of the cloth from an image obtained by the
CCD camera and generates stitch data for forming stitches along the
outline. The control device then controls the stitch generating
device and the transfer mechanism according to the stitch data
thereby to execute an operation of sewing the upper cloth onto the
lower cloth.
[0007] There is sometimes a case where a pocket is desired to be
formed on a front of clothes such as Western-style clothes when the
clothes are sewn by the use of a sewing machine. In this case, a
sewing operation is executed so that stitches are formed along an
outline of the pocket cloth after the pocket cloth (or an upper
cloth) has been temporarily tacked on the front (or a lower cloth)
of the clothes. The user carries out the sewing while changing a
sewing direction by turning or moving the front of the clothes with
the temporarily tacked pocket cloth relative to a needle bar (a
needle) of the sewing machine. However, a user unfamiliar with the
sewing machine would have a difficulty in sewing the pocket cloth
onto the front of the clothes.
[0008] In view of the problem, the above-described conventional
sewing machine has been considered to be applied to the sewing of
pocket cloth. In this case, the pocket cloth needs to be sewn onto
the clothes except for a part thereof serving as a pocket opening.
However, the above-described conventional sewing machine has been
found unsuitable for the sewing of the pocket cloth since the part
of the pocket opening is also sewn as well as the other part of the
pocket cloth.
SUMMARY
[0009] Therefore, an object of the disclosure is to provide a
sewing machine which can automatically execute a work of sewing the
upper cloth onto the lower cloth based on stitch data and can
determine a region of the upper cloth to be sewn. Another object of
the disclosure is to provide a stitch data generating device which
can generate stitch data for the sewing machine and a
computer-readable medium which stores a stitch data generating
program for the stitch data generating device.
[0010] The present disclosure provides a sewing machine which forms
stitches on a first object to be sewn based on stitch data,
comprising an imaging unit which images an outline of an upper
cloth as the first object onto a lower cloth as a second object,
thereby obtaining image data; an outline calculation unit which
calculates the outline of the upper cloth from the image data
obtained by the imaging unit; a determination unit which determines
a stitch-forming region for sewing the upper cloth onto the lower
cloth based on the outline of the upper cloth calculated by the
outline calculation unit; and a stitch data generating unit which
generates stitch data for the stitch-forming region determined by
the determination unit.
[0011] The disclosure also provides a stitch data generating device
which generates stitch data for a sewing machine which forms
stitches on a first object to be sewn based on stitch data, the
device comprising an imaging unit which images an outline of an
upper cloth as the first object to be sewn onto a lower cloth
serving as a second object, thereby obtaining image data; an
outline calculation unit which calculates the outline of the upper
cloth from the image data obtained by the imaging unit; a
determination unit which determines a stitch-forming region for
sewing the upper cloth onto the lower cloth based on the outline of
the upper cloth calculated by the outline calculation unit; and a
stitch data generating unit which generates stitch data for the
stitch-forming region determined by the determination unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the accompanying drawings:
[0013] FIG. 1 is a perspective view of an overall sewing machine
according to a first embodiment;
[0014] FIG. 2 is a left side view of a sewing machine head, showing
a state in which a camera is disposed;
[0015] FIG. 3 is a block diagram showing an electrical arrangement
of the sewing machine;
[0016] FIG. 4 illustrates three types of pocket clothes with
different configurations;
[0017] FIG. 5 illustrates three types of patterns of reinforcing
stitches;
[0018] FIG. 6 is a flowchart showing a processing procedure for
generation of stitch data executed by a control device; and
[0019] FIG. 7 is a perspective view of a stitch data generating
device according to a second embodiment.
DETAILED DESCRIPTION
[0020] A first embodiment will be described with reference to FIGS.
1 to 6. Referring to FIG. 1, an overall construction of the sewing
machine 1 according to the first embodiment, as viewed from the
front thereof (the user side) is shown. In the following
description, the side where the user who operates the sewing
machine stands will be referred to as "front" and the opposite side
will be referred to as "back." The front-back direction thereof
will be referred to as "Y direction" as shown in FIG. 1.
Furthermore, the side where a pillar 3 is located will be referred
to as "right" and the opposite side will be referred to as "left."
The right-left direction of a sewing machine 1 will be referred to
as "X direction."
[0021] The sewing machine 1 includes a sewing machine bed 2
extending in the right-left direction (X direction) as viewed in
FIG. 1, the pillar 3 extending upward from a right end of the
sewing machine bed 2 and an arm 4 extending leftward from an upper
end of the pillar 3, all of which are formed integrally with the
sewing machine 1. The arm 4 has a distal end serving as a sewing
machine head 5. The head 5 includes a needle bar 6 which is mounted
so as to be movable upward and downward and swingable in the
right-left direction as shown in FIG. 2 as well as FIG. 1. The
needle bar 6 has a lower end to which a needle 7 is attached. A
presser bar 8 is mounted on the head 5 so as to be located in the
rear of the needle bar 6 as shown in FIG. 2. The presser bar 8 has
a lower end to which a presser foot 9 is mounted.
[0022] A known presser driving mechanism (not shown) is provided in
the head 5 and includes a presser drive motor 10 (see FIG. 3)
serving as a drive source of the presser driving mechanism. The
presser driving mechanism moves the presser foot 9 or the presser
bar 8 between an upper position and a lower position. In the arm 4
are provided a main shaft rotated by a sewing machine motor 11 and
a main shaft angle detector 12 (see FIG. 3) which detects a
rotation angle of the main shaft. A needle bar driving mechanism is
provided in the head 5 to move the needle bar 6 upward and downward
by the drive of the sewing machine motor 11 or the main shaft.
Additionally, a needle bar swinging mechanism includes a needle
swinging pulse motor 13 (see FIG. 3) serving as a drive source and
swings the needle bar 6 in the right-left direction or the X
direction.
[0023] A cover 4a is mounted on an upper part of the arm 4 so as to
be openable and closable. A needle thread spool 14 is detachably
set inside the cover 4a in the arm 4 in order to supply a needle
thread. A plurality of operation switches 15 is provided on a lower
front of the arm 4. These operation switches 15 include a
start/stop key, a back stitch key, a needle up/down key, a thread
cut key, a presser up/down key and a speed adjusting knob although
a detailed description of these keys and knob will be
eliminated.
[0024] A large-sized vertically-long full-color liquid crystal
display (LCD) 16 serving as a display unit is mounted on the front
of the pillar 3. A touch panel 17 is mounted on the surface of the
LCD 16. When depressing the touch panel 17, the user can select a
desired one of ordinary patterns and embroidery patterns or cause
the sewing machine 1 to execute various functions about sewing.
Furthermore, the user can also select a reinforcement stitch
pattern on the touch panel 17 as will be described later. The touch
panel 17 thus serves as a setting unit which sets a reinforcement
stitch pattern.
[0025] A needle plate (not shown) is mounted on the upper surface
of the bed 2 so as to correspond to the needle bar 6. A shuttle
mechanism, a feed dog driving mechanism and the like are provided
in the bed 2 so as to be located below the needle plate although
none of them are shown. The shuttle mechanism accommodates a bobbin
and serves to form stitches on a cloth as an object to be sewn in
cooperation with the needle 7. The shuttle mechanism and the feed
dog driving mechanism are driven by the sewing machine motor 11
serving as a drive source. Thus, a stitch forming unit which forms
stitches on the object comprises the sewing machine motor 11, the
needle bar driving mechanism and the shuttle mechanism.
[0026] A known embroidering apparatus 18 is detachably mounted on a
left part of the bed 2. When mounted on the bed 2, the embroidering
apparatus 18 is electrically connected via a connector 24 (see FIG.
3) provided in the bed 2 to a control device 25 of the sewing
machine 1. The embroidering apparatus 18 includes a carriage (not
shown) to which is detachably attached an embroidery frame 19
serving as a holding member for holding the cloth. The embroidering
apparatus 18 also includes a transfer unit which freely moves the
embroidery frame 19 holding the cloth in two predetermined
directions or in an X direction (a right-left direction) and a Y
direction (front-back direction) on the bed 2.
[0027] More specifically, the embroidering apparatus 18 includes a
body 20 which is attached to the bed 2 and a moving member 21 which
is long in the front-back direction and is movable in the
right-left direction (X direction). The carriage is mounted on a
right side surface of the moving member 21 so as to be movable in
the front-back direction (the Y direction). The embroidery frame 19
is detachably attachable to the carriage. The embroidering
apparatus 18 is configured so that the moving member 21 is freely
moved in the right-left direction (the X direction) by an X-axis
motor 22 (see FIG. 3) mounted in the body 20 and so that the
carriage or the embroidery frame 19 is freely moved in the
front-back direction (the Y direction) by a Y-axis motor (see FIG.
3) incorporated in the moving member 21. An auxiliary table is
detachably attached to the bed 2 with the embroidering apparatus 18
being detached although not shown.
[0028] The sewing machine 1 having the above-described construction
is capable of executing an embroidery sewing operation on the cloth
by driving the needle bar 6 serving as the aforementioned stitch
forming unit, and the like while the embroidery frame 19 holding
the object is freely moved in the X and Y directions. The sewing
machine 1 is provided with a function of automatically executing a
pocket sewing work in which a pocket cloth P serving as the upper
cloth and further as the object to be sewn is sewn onto a lower
cloth C serving as the object by using the embroidering apparatus
18, as shown in FIG. 1. The lower cloth C is here assumed to be a
cloth of the front of clothes, for example.
[0029] In the pocket sewing work, the embroidery frame 19 is
attached to the carriage of the embroidering apparatus 18 while the
lower cloth C with the pocket cloth P being tacked thereon by dress
pins (not shown) is held on the embroidery frame 19. Based on
stitch data for sewing the pocket cloth P, the embroidering
apparatus 18, the needle bar 6 and the like are controlled so that
stitches S are formed along the outline of the pocket cloth P while
the embroidery frame 19 is freely moved. In this case, the stitch
data is mainly composed of data of an amount of movement of the
embroidery frame 19 per stitch, that is, data of amounts of
movement of the lower cloth C held on the embroidery frame 19 in
the X and Y directions.
[0030] The above-described sewing machine 1 is further provided
with a function of generating stitch data necessary for execution
of the pocket sewing work as will be described in detail later. A
camera 26 serving as an imaging unit is provided on the sewing
machine 1 for generating stitch data, as shown in FIG. 2. The
camera 26 comprises a CMOS image sensor, for example and is mounted
in the head 5 so as to be directed downward, thereby imaging the
pocket cloth P temporarily tacked on the lower cloth C held on the
embroidery frame 19.
[0031] FIG. 3 schematically shows an electrical arrangement of the
sewing machine 1. A control device 25 controlling an entire sewing
machine 1 is mainly composed of a microcomputer including a CPU 27,
a ROM 28, a RAM 29, an EEPROM 30, an input interface 31 and an
output interface 32 all of which are connected to one another by a
bus bar 33. The ROM 28 stores a control program for controlling a
sewing operation, a stitch data generating program as will be
described later, various data necessary for a sewing operation, and
the like.
[0032] The aforementioned main shaft angle detector 12, the touch
panel 17 and the operation switches 15 are connected to the input
interface 13. Operation signals generated by these elements or
components are supplied to the control device 25. Furthermore, an
image processing section 34 executes image processing such as
binarization is applied to image data obtained by the camera 26.
The image data processed by the image processing section 34 is
supplied via the input interface 31 to the control device 25. The
display 21 is connected via a drive circuit 35 to the output
interface 32. The sewing machine motor 11, the needle swinging
pulse motor 13, and the presser driving motor 10 are also connected
via respective drive circuits 36, 37 and 38 to the output interface
32. The control device 25 executes a sewing operation while
controlling the aforementioned detector 12, the touch panel 17, the
operation switches 15, the camera 26, the display 21, the sewing
machine motor 11, the needle swing pulse motor 13, the presser
drive motor 10 and the like. The aforementioned connector 24 is
also connected to the output interface 32, whereby the control
device 25 controls the aforementioned mechanisms of the sewing
machine 1 to execute the sewing operation.
[0033] The control device 25 executes a software configuration,
that is, the stitch data generating program thereby to realize a
function of a stitch data generating device which automatically
generates stitch data necessary for sewing the pocket cloth P onto
the lower cloth C, together with the camera 26. In this case, the
camera 26 functions as an imaging unit, and the control device 25
functions as an outline calculation unit, a determination unit and
a stitch data generating unit. Furthermore, the control device 25
automatically executes a pocket sewing operation based on the
generated stitch data. The stitch data generating program may be
stored on an external storage medium such as an optical memory
disc, a magnetic disc, a flash memory or a USB memory, for example,
so as to be loaded from the external storage medium to the control
device 25.
[0034] More specifically, the user attaches to the embroidery frame
19 the lower cloth C with the pocket cloth P being temporarily
tacked thereon, for example, by the dress pins, whereby the lower
cloth C is held on the embroidery frame 19. Upon execution of the
stitch data generating program, the control device 25 firstly
executes an imaging routine of moving the embroidery frame 19 to a
predetermined imaging location and thereafter imaging the outline
of the pocket cloth P temporarily tacked on the lower cloth C by
the camera 26.
[0035] The control device 25 then executes an outline calculation
or computation routine of calculating the outline of the pocket
cloth P from the image data of the pocket cloth P imaged by the
camera 26. In the outline calculation, an edge of the pocket cloth
P which is a boundary between the lower cloth C and the pocket
cloth P is obtained from the obtained image data, and locations of
feature points are extracted in an outline of the pocket cloth P.
In this case, the feature points include an intersection (an apex)
of two straight lines, a contact point between a straight line and
a curved line or a contact point or an inflection point in the case
where plural curved lines are continuous.
[0036] FIGS. 4A to 4C exemplify three typical forms of the pockets
P respectively. The pocket cloth P shown in FIG. 4A has a
pentagonal shape with a downwardly slightly sharp-pointed lower
hem. Five feature points F1 to F5 are obtained in the case of FIG.
4A. The pocket cloth P shown in FIG. 4B basically has a rectangular
shape with right and left curved (arc-shaped) corners of a lower
hem. Six feature points F1 to F6 are obtained in the case of FIG.
4B. The pocket cloth P shown in FIG. 4C basically has a rectangular
shape but right and left corners of the lower hem are cut out into
obliquely straight lines such that the pocket cloth P has a
hexagonal shape. Six feature points F1 to F6 are obtained in the
case of FIG. 4C. Arrangement patterns of these three types of
feature points F1 to F5 or F6 are stored as template data on the
ROM 28.
[0037] Next to the above-described outline calculation routine or
feature point extraction routine, the control device 25 executes a
determination routine of determining a stitch-forming region
provided for sewing the pocket cloth P onto the lower cloth C. In
the determination routine, a region where stitches are to be formed
(a region to be sewn) and a region where no stitches are to be
formed (a region not to be sewn) are determined with respect to the
outline or a periphery of the pocket cloth P. The region other than
an upper edge or hem defining the pocket opening is determined as a
stitch-forming region, and the upper edge defining the pocket
opening is determined as a region not to be sewn. More
specifically, the extracted feature points are compared with the
template data stored on the ROM 28 so that the upper edge defining
the pocket opening of the pocket cloth P is discriminated, and a
stitch-forming region along the outline other than the upper edge
defining the pocket opening is determined. Thus, the periphery of
the pocket cloth P includes a first part corresponding to the
stitch-forming region and a second part corresponding to the region
not to be sewn.
[0038] In the example shown in FIG. 4A, a straight section obtained
by connecting the feature points F5 and F1 is determined as an
upper edge or hem defining a pocket opening in which no stitches
are to be formed. Four straight sections obtained by connecting the
feature points F1, F2, F3, F4 and F5 sequentially are determined as
a stitch-forming region. In the example shown in FIG. 4B, a
straight section obtained by connecting the feature points F6 and
F1 is determined as an upper edge or hem defining a pocket opening
in which no stitches are to be formed. Three straight sections and
two curved sections obtained by connecting the feature points F1,
F2, F3, F4, F5 and F6 sequentially are determined as a
stitch-forming region. In the example shown in FIG. 4C, a straight
section obtained by connecting the feature points F6 and F1 is
determined as an upper edge or hem defining a pocket opening in
which no stitches are to be formed. Five straight sections obtained
by connecting the feature points F1, F2, F3, F4, F5 and F6
sequentially are determined as a stitch-forming region.
[0039] Upon determination of the stitch-forming region, the control
device 25 executes a stitch data generating routine which generates
stitch data according to which the determined stitch-forming region
or a region along the contour of the pocket cloth P is sewn onto
the lower cloth C by the forming of stitches S (see FIGS. 5A to 5C)
in a predetermined pattern. The generated stitch data is stored on
the EEPROM 30 or the like. In the embodiment, the control device 25
also has a function as a reinforcement stitch data generating unit
which generates reinforcement stitch data for forming reinforcement
stitches on both ends of the upper edge or hem of the pocket cloth
P defining the pocket opening respectively.
[0040] FIGS. 5A to 5C show three examples of reinforcement stitch
patterns formed on both ends of the upper edge of the pocket cloth
P defining the pocket opening respectively. FIG. 5A shows right
triangular reinforcement stitch patterns R1 formed on the pocket
cloth P. The reinforcement stitch patterns R1 are continuous from
both ends of the stitch pattern S and turn at a right angle at
upper ends of the pocket cloth P, extending inward, respectively.
The reinforcement stitch patterns R1 thereafter return diagonally
so as to partially overlap the reinforcement stitch pattern S. FIG.
5B shows generally C-shaped reinforcement stitch patterns R2 formed
on the pocket cloth P. The C-shaped reinforcement stitch patterns
R2 are continuous from both ends of the stitch pattern S and turn
at a right angle at upper ends of the pocket cloth P, extending
inward, respectively. The reinforcement stitch patterns R2
thereafter extend downward. FIG. 5C shows bar tacking reinforcement
stitch patterns R3 formed on the pocket cloth P. The reinforcement
stitch patterns R3 are formed by partially overlapping zigzag chain
stitches on both ends of the reinforcement stitch pattern S
respectively. It is needless to say that the reinforcement stitch
pattern may be any pattern other than those exemplified in FIGS. 5A
to 5C.
[0041] The user can select the forming of reinforcement stitches or
the non-forming of stitches, for example, by operating the touch
panel 17. In this case, the ROM 28 stores data of the
above-described three reinforcement stitch patterns R1 to R3. When
forming reinforcement stitches, the user operates the touch panel
17 to set or select a desired one of the three reinforcement stitch
patterns R1 to R3. Thus, the ROM 28 serves as a storage unit and
the touch panel 17 serves as a setting unit.
[0042] The operation of the sewing machine 1 thus constructed will
be described with reference to FIG. 6 as well as FIGS. 1 to 5C. In
execution of a pocket sewing work, the user attaches the lower
cloth C with the pocket cloth P being tacked thereon by the dress
pins to the embroidery frame 19 so that the lower cloth C is held
by the embroidery frame 19. The embroidery frame 19 is then set to
the carriage of the embroidering apparatus 18. The stitch data
generating program is then executed. As a result, a stitch data
generating processing is firstly carried out for execution of a
work of sewing the pocket cloth P onto the lower cloth C.
[0043] FIG. 6 is a flowchart showing the procedure for generating
stitch data executed by the control device 25. More specifically,
the lower cloth C and the pocket cloth P both located inside the
embroidery frame 19 are imaged by the camera 26 at step S1 while
the embroidery frame 19 occupies a predetermined imaging location
(an imaging routine). Image data obtained by the camera 26 is
processed by the image processing section 34 (binarization) thereby
to be supplied to the control device 25. The outline of the pocket
cloth P is calculated at step S2, and the feature points of the
outline of the pocket cloth P are extracted at step S3 (the outline
calculation routine).
[0044] The extracted outline of the pocket cloth P or the feature
points are compared with the template at step S4. In this case,
arrangement patterns of the three types of feature points F1 to F5
or F6 are stored as template data as exemplified in FIGS. 4A to 4C.
The control device 25 determines with which one of the three
arrangement patters the arrangement pattern of feature points
extracted at step 33 corresponds. When the extracted arrangement
pattern corresponds with one of the three arrangement patters (YES
at step S5), the control device 25 proceeds to step S6 to determine
a stitch-forming region (the determination routine).
[0045] In the determination of the stitch-forming region, the
control device 25 determines, as a stitch-forming region, four
straight sections obtained by connecting the feature points F1, F2,
F3, F4 and F5 sequentially except for the upper edge or hem
defining the pocket opening or the straight section between the
feature points F5 and F1, in the case of the pattern as shown in
FIG. 4A. In the case of the pattern as shown in FIG. 4B, the
control device 25 determines, as a stitch-forming region, three
straight sections and two curved sections obtained by connecting
the feature points F1, F2, F3, F4, F5 and F6 sequentially except
for the upper edge or hem defining the pocket opening or the
straight section between the feature points F6 and F1. In the case
of the pattern as shown in FIG. 4C, the control device 25
determines, as a stitch-forming region, five straight sections
obtained by connecting the feature points F1, F2, F3, F4, F5 and F6
sequentially except for the pocket opening or the straight section
between the feature points F6 and F1.
[0046] On the other hand, when the extracted arrangement pattern or
the outline of the pocket cloth P corresponds with none of the
three arrangement patters (NO at step S5), the control device 25
proceeds to step S7 to control the LCD 16 so that a message, "The
stitch-forming region cannot automatically be determined." is
displayed. In this case, when the user operates the touch panel 17
to designate a stitch-forming region, the stitch-forming region is
manually determined by the user (YES at step S8). In this case, the
control device 25 is allowed to proceed to next step S9.
[0047] Upon determination of the stitch-forming region, stitch data
is generated at step S9 (a stitch data generating routine). As the
result of the processing at step S9, the control device 25
generates stitch data according to which the determined
stitch-forming region or a region along the contour of the pocket
cloth P except for the section defining the pocket opening is sewn
onto the lower cloth C by the forming of stitches S along the
outline of the pocket cloth P, as shown in FIGS. 5A to 5C. The
control device 25 then proceeds to step S10 to determine whether or
not the reinforcement stitches should be formed. In this
determination, the LCD 6 displays a selection screen as to whether
or not reinforcement stitches are formed. When no reinforcement
stitches are to be formed (NO at step S10), the control device 25
finishes the processing.
[0048] When the reinforcement stitches are to be formed (YES at
step S10), processing is performed at step S11 so that a
reinforcement stitch pattern is set by the user. In this case, the
user operates the touch panel 17 to select a desired one of the
three types shown in FIGS. 5A-5C, that is, the right triangle R1,
the C-shape R2 or the bar tacking R3 (YES at step S11). At next
step S12, the control device 25 adds, to the aforementioned stitch
data, the reinforcement stitch data for forming the selected
reinforcement stitch patterns on the respective ends of the section
defining the pocket opening, finishing the processing.
[0049] Subsequently, the control device 25 controls the sewing
machine 1 so that a sewing operation is executed on the basis of
the generated stitch data, whereby the pocket cloth P can be sewn
onto the lower cloth C. In this case, no stitches are formed on the
section of the pocket cloth P defining the pocket opening.
Furthermore, the generated stitch data may be stored on the EEPROM
30 or an external storage medium, for example. When the pocket
cloth P with the same shape as the previously sewn one is again
sewn onto another lower cloth (the front of the clothes) or when
the same clothes as the previously made one is again made, the
stitch data stored on the EEPROM 30 or the external storage medium
is loaded such that a sewing work can easily be executed.
[0050] In the above-described embodiment, the sewing machine 1 can
automatically sew the pocket cloth P serving as the upper cloth
onto the lower cloth C based on the stitch data. In the sewing
machine 1, stitch data can be generated only for the stitch-forming
region of the outline of the pocket cloth P or the region which is
to be sewn onto the lower cloth P. More specifically, data of
stitches to be formed along the outline of the pocket cloth P is
generated although no stitch data is generated regarding the side
of the pocket cloth P defining the pocket opening. The sewing is
executed based on thus generated stitch data, whereupon the
stitches S are formed on the region except for the section defining
the pocket opening. Consequently, the pocket cloth sewing work can
desirably be carried out without the side defining the pocket
opening being sewn.
[0051] Furthermore, particularly in the foregoing embodiment, the
reinforcement stitch data for forming the reinforcement stitches R1
to R3 can be added to the aforementioned stitch data. Consequently,
the pocket cloth sewing work can further desirably be carried out.
Additionally, since the pattern of the reinforcement stitch R1, R2
or R3 desired by the user can easily be set and formed, a
reinforcement stitch according to user's preference can be
formed.
[0052] FIG. 7 shows an appearance of the stitch data generating
device 41 according to a second embodiment. The stitch data
generating device 41 is configured to be independent of the sewing
machine. More specifically, the stitch data generating device 41 is
configured to generate stitch data for use with an ordinary sewing
machine which is not provided with a function as the stitch data
generating device including the camera 26 and which can execute
embroidery sewing. Stitch data generated by the stitch data
generating device 41 may be read via an external storage medium
into the sewing machine, or the stitch data generating device 41
and the sewing machine may be linked together by wired or wireless
connection for transfer of stitch data.
[0053] The stitch data generating device 41 is composed of a
computer and more specifically comprises a device body 42 further
comprising a general purpose personal computer and a camera 43
serving as the imaging unit and connected to the device body 42.
The lower cloth C on which the pocket cloth P serving as the upper
cloth is temporarily tacked by the dress pins (not shown) is held
on the embroidery frame 19 and then imaged by the camera 43. The
stitch data is generated based on an image obtained by the camera
43.
[0054] The device body 42 includes a CPU, a ROM, a RAM, an
input-output interface and an operational circuit which functions
as the outline calculation unit, the determination unit and the
stitch data generating unit. The device body 42 also includes a
keyboard 44 and a mouse both serving as setting units respectively,
a display device 45 and a hard disc drive which functions as a
storage unit. The device body 42 further includes a disc drive
which performs reading and writing data from and onto a CD-ROM, a
DVD and the like, for example, and a connector (a port) to which a
flash memory or a USB memory is connected. The stitch data
generating program may be stored on the hard disc drive.
Alternatively, the stitch data generating program may be stored on
an external storage medium such as a CD-ROM, a DVD, a flash memory
or a USB memory and may be retrieved from the external storage
medium.
[0055] The camera 43 may be a USB camera which necessitates no
driver and comprises a CMOS camera which is directly connectable to
the USE connector of the device body 42, for example. In use, the
camera 43 is mounted to a support pillar (not shown) so as to be
located above the embroidery frame 19 and so as to be directed
downward, as shown in FIG. 7. The pocket cloth P temporarily tacked
on the lower cloth C is imaged by the camera 43. Image data
obtained by the camera 43 is supplied to the operational circuit of
the device body 42.
[0056] The operational circuit of the device body 42 runs the
stitch data generating program to execute the imaging routine of
imaging the outline of the pocket cloth P by the camera 43.
Subsequently, the operational circuit executes the outline
calculation routine of calculating the outline of the pocket cloth
P from the image data obtained by the camera 43, thereby
determining a stitch-forming region which is used to sew the pocket
cloth P onto the lower cloth C. Subsequently, the operational
circuit executes the stitch-forming region determining routine of
determining the region other than the edge or hem defining the
pocket opening, as the stitch-forming region. The operational
circuit further executes a stitch data generating routine of
generating stitch data according to which the determined
stitch-forming region along the outline of the pocket cloth P is to
be sewn onto the lower cloth C by the forming the pattern of
stitches S along the outline of the pocket cloth P. The operational
circuit still further executes a user-designated reinforcement
stitch adding routine.
[0057] In the second embodiment, the stitch data generating device
41 can also generate the stitch data for use with the sewing
machine which can realize an automatic work of sewing the pocket
cloth P as the upper cloth onto the lower cloth C based on the
stitch data, as in the first embodiment. Consequently, the stitch
data can be generated with respect to only the pocket cloth outline
region which is to be sewn onto the lower cloth C. Thus, when
executing the sewing based on the stitch data, the sewing machine
can desirably sew the pocket cloth P onto the lower cloth C without
sewing the edge of the pocket cloth defining the pocket
opening.
[0058] Furthermore, it is needless to say that the above-described
advantageous effects can also be achieved when the stitch data
generating program is stored on an external storage medium and is
run by the stitch data generating device 41.
[0059] The foregoing embodiments should not be restrictive, and
various expanded and changed forms may be possible. For example,
although the reinforcement stitch data is generated and added to
the stitch data in the foregoing embodiments, the reinforcement
stitch data generating unit (the routine) may or may not be
provided. When the reinforcement stitch data is generated, the
reinforcement stitch pattern should not be limited to the
above-described three types as shown in FIGS. 5A to 5C. Other
stitch patterns or a single stitch pattern may be employed,
instead.
[0060] When being loaded into the stitch data generating device,
the stitch data generating program may be supplied from a storage
medium such as a flash memory or a memory card to the stitch data
generating device. Alternatively, the stitch data generating
program may be downloaded externally through a network or the like
directly to the stitch date generating device. Furthermore, the
camera 26 may be mounted on an outer surface of the arm. Thus,
various changes may be made regarding the mechanical configurations
of the sewing machine and the stitch data generating device.
[0061] The foregoing description and drawings are merely
illustrative of the present disclosure and are not to be construed
in a limiting sense. Various changes and modifications will become
apparent to those of ordinary skill in the art. All such changes
and modifications are seen to fall within the scope of the appended
claims.
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