Embroidery data producing device and embroidery data producing program stored in a computer readable medium

An embroidery data producing device reads an image composed of a plurality of areas to produce embroidery data including sewing data for filling each area with stitches and underlying stitch sewing data for carrying out underlying stitch sewing for each of the areas. The embroidery data producing device includes a synthesized outline data producing unit which produces data of a synthesized outline defining an outline of a synthesized area formed by synthesizing a part or all of a plurality of the areas and an underlying stitch sewing data producing unit which produces data of underlying stitch sewing based on the synthesized outline data.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to an embroidery data producing device and an embroidery data producing program, and more particularly to such an embroidery data producing device and an embroidery data producing program capable of producing underlying stitch sewing data so that a pattern corresponding to an image comprising a plurality of areas is sewn or so that an embroidery pattern comprising a plurality of embroidery areas is sewn.

2. Description of the Related Art

It is generally known that a part of work cloth inside an outline is filled with stitches in one type of embroidery sewing manner. When the aforesaid embroidery sewing manner is carried out, rough underlying stitches are sewn under the stitches of embroidery sewing in order that work cloth may be prevented from shrinking during embroidering or that a sewn embroidery pattern may have a three-dimensional effect. For example, Japanese Patent Application Laid-Open No. 2002-119780 discloses an embroidery data processing device which is capable of producing data of underlying stitches on an embroidery pattern including a plurality of embroidery areas.

Underlying stitch sewing data are produced for a plurality of embroidery areas respectively in the foregoing processing device. Accordingly, an embroidery pattern46of an angel includes a plurality of embroidery areas Bi where i=1, 2, 3 and so on as shown inFIG. 8. The underlying stitch sewing is carried out for each embroidery area Bi of the embroidery pattern46based on the underlying stitch sewing data produced by the embroidery data processing device of the cited reference, as shown inFIG. 21.

However, the underlying stitch sewing is carried out for each one of a plurality of embroidery areas Bi in the foregoing reference. As a result, there arises a drawback that the above-described effects of the underlying stitch sewing cannot be achieved. Particularly, few underlying stitches can be sewn in a narrow embroidery area Bi. As a result, work cloth cannot be reinforced sufficiently in the embroidering. Furthermore, embroidered patterns are not three-dimensional, resulting in a drawback that the quality of sewn products is reduced. Yet furthermore, since underlying stitch sewing data is produced for each one of a plurality of embroidery areas Bi, the underlying stitch sewing data is complicated, whereupon stitches sewn on the basis of the complicated underlying data are also complicated and a sewing time required for the underlying stitch sewing is disadvantageously increased.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide an embroidery data producing device capable of synthesizing a plurality of areas composing an image or a plurality of embroidery areas composing an embroidery pattern and producing underlying stitch sewing data based on synthesized outline defining an outline of the synthesized area.

The present invention provides an embroidery data producing device reading an image composed of a plurality of areas to produce embroidery data including sewing data for filling each area with stitches and underlying stitch sewing data for carrying out underlying stitch sewing for each of the areas, the device comprising synthesized outline data producing means for producing data of a synthesized outline defining an outline of a synthesized area formed by synthesizing a part or all of a plurality of the areas, and underlying stitch sewing data producing means for producing data of underlying stitch sewing based on the synthesized outline data.

In the foregoing device, synthesized outline data is produced with respect to a synthesized area formed by synthesizing a part or all of a plurality of areas constituting an image. Underlying stitch sewing data is produced on the basis of the synthesized outline data. The underlying stitches are sewn using the produced underlying stitch sewing data. Consequently, an embroidery pattern sewn over the underlying stitches can achieve a three-dimensional effect. Furthermore, since work cloth can be reinforced sufficiently in the embroidery sewing, the sewing quality can be improved. Particularly, the foregoing effects can be achieved even in the case of narrow areas where few underlying stitches can conventionally be sewn. Yet furthermore, since the areas are synthesized together so that the underlying stitch sewing data is produced, the underlying stitch sewing data can be simplified. Consequently, the underlying stitch sewing work carried out using the underlying stitch sewing data can be simplified and a time period required for sewing underlying stitches can be reduced.

The invention also provides an embroidery data producing device reading sewing data of embroidery pattern composed of a plurality of embroidery areas to produce underlying stitch sewing data for the embroidery areas on the basis of the sewing data, the device comprising outline data extracting means for extracting outline data of each embroidery area from the sewing data, synthesized outline data producing means for producing data of a synthesized outline by synthesizing a part or all of a plurality of the outline data corresponding to a plurality of the embroidery areas extracted by the outline data extracting means and underlying stitch sewing data producing means for producing data of underlying stitch sewing based on the synthesized outline data.

In the above-described device, sewing data of an embroidery pattern composed of a plurality of embroidery areas is read and outline data of each embroidery area is extracted from sewing data by the outline data extracting means. A part of or all of a plurality of the outline data are synthesized to be produced as synthesized outline data. Since underlying stitch sewing data is produced on the basis of the synthesized outline data, underlying stitches sewn using the underlying stitch sewing data can give a cubic effect to an embroidery pattern embroidered over the underlying stitches. Furthermore, the sewing quality can be improved since work cloth is reinforced by the underlying stitches when an embroidery patter is sewn. The aforementioned effect can be achieved even in a narrow embroidery area in which few underlying stitches have conventionally been sewn. Still further, since the outlines are synthesized to be produced as underlying stitch sewing data, the underlying stitch sewing data can be simplified. Consequently, the sewing work for the underlying stitches using the underlying stitch sewing data can be simplified and accordingly, a time period required for the sewing work for the underlying stitch sewing can be reduced.

DETAILED DECRIPTION OF THE INVENTION

An embodiment of the present invention will be described with reference toFIGS. 1 to 13. In the embodiment, the invention is applied to an embroidery data producing device for producing embroidery data provided for sewing an embroidery pattern using an embroidering and sewing machine and including underlying stitch sewing data, and further to an embroidery data producing program on which the embroidery data producing device is operated. An embroidering and sewing machine1is shown as being connected via a data transfer cable3to an embroidery data producing device2, as shown inFIG. 1.

Firstly, the embroidering and sewing machine1will be described in brief with reference toFIG. 1. The embroidering and sewing machine1comprises a sewing machine body4and an embroidery frame moving mechanism5for moving an embroidery frame17right and left or in the X-direction and back and forth or in the Y-direction. The sewing machine body4includes a sewing bed6, a sewing pillar7standing from a right end of the bed6and a sewing arm8extending leftward from an upper end of the pillar7so as to be opposed to the bed6. The body4is installed on a sewing machine table9with the bed6being assembled into the table. The arm8has at its left end an arm head provided with a needle bar11to which a sewing needle10is attached. The needle bar11is moved up and down by a needle bar driving mechanism (not shown). A shuttle mechanism (not shown) is provided below a needle plate12and driven in synchronization with the up-and-down movement of the needle bar11.

The embroidery frame moving mechanism5will now be described. The sewing table9is provided with two moving members13and14both of which are movable right and left. The moving members13and14are spaced from each other in the Y-direction. Two guide rods15and16are provided so as to be spaced away from each other right and left in parallel to each other between the moving members13and14. The embroidery frame holding work cloth has a left end which is coupled to the guide rods15and16so as to be movable in the Y-direction. A pair of right and left brackets18and19are secured to the sewing table9. A lead shaft20and a transmission shaft21are rotatably supported by the brackets18and19. The moving member13is brought into threading engagement with the lead shaft20so as to be moved in the X-direction. A wire23extends between the moving members13and14. The left end of the embroidery frame17is connected to the wire23.

The lead shaft20is rotated by an X-axis drive motor22. When the moving member13is driven in the X-axis direction by the rotation of the lead shaft20, the moving member14and the embroidery frame17are also moved together with the moving member13. On the other hand, when the transmission shaft21is rotated by a Y-axis drive motor24, rotation of the shaft21is transmitted via the wire23to the embroidery frame17, thereby driving the latter in the Y-axis direction. In the embroidering and sewing machine1, on the basis of embroidery data produced by the embroidery data producing device2, the embroidery frame17is moved in the X-axis and Y-axis directions by the X-axis and Y-axis drive motors22and24so that work cloth is moved in the X-axis and Y-axis directions, whereby embroidery sewing is carried out.

The embroidery data producing device2will now be described. The embroidery data producing device2produces data of a synthesized outline defining an outline of synthesized area formed by synthesizing a part or all of a plurality of areas composing an image. The embroidery data producing device2further produces underlying stitch sewing data based on the synthesized outline data.

The embroidery data producing device2comprises a personal computer25which will hereinafter be referred to as “PC25,” a display26, a key board27, a mouse28, an image scanner29, etc. When an embroidery pattern46as shown inFIG. 8is to be sewn, an image45corresponding to the embroidery pattern46is read in as shown inFIG. 7, so that data of an outline47, sewing data, underlying stitch sewing data and the like are produced. The outline47defines an outline of embroidery area Bi of the embroidery pattern46.

PC25manages the whole control about the origination of embroidery data as shown inFIG. 2. PC25includes a microcomputer further including CPU31, ROM32, RAM33and buses34connecting the formers. PC25further includes a hard disc drive (HDD)36provided with a hard disc (HD)35connected to the bus34. PC25yet further includes an input/output interface39and the like. A flexible disc drive37and a CD-ROM drive38are also connected to the bus34. Furthermore, to the input/output interface39are connected the embroidering and sewing machine1, a display drive circuit40for connecting the display26, the keyboard27, the mouse28, the image scanner and the like.

ROM32stores a start-up program to start up the PC25upon power-on thereof etc. HD35stores an operating system (OS), drivers for rendering the display26, keyboard27, mouse28, image scanner29and the like usable respectively and various programs such as an embroidery data producing program which will be described later. Furthermore, HD35also stores input image data read in by the image scanner29, embroidery data of the embroidery pattern46produced on the embroidery data producing program and the like.

The following will describe the embroidery data producing program executed by the embroidery data producing device2. Symbol Si where i=1, 2, 3 and so on designates a step number. The embroidery data producing program is used to produce embroidery data including sewing data and underlying stitch sewing data. More specifically, for example, the image scanner29reads in an image of an angel45composed of a plurality of areas Ai (where i=1, 2, 3 and so on) divided by color, as shown inFIG. 7. Based on the aforesaid sewing data, the embroidery area Bi corresponding to the area Ai as shown inFIG. 8is filled with stitches sewn using an embroidery thread of each of a plurality of colors so as to be buried, whereby the embroidery pattern46of the angel is embroidered. The embroidering is carried out on the basis of the aforesaid sewing data. Furthermore, the underlying stitch sewing is carried out for the embroidery pattern46on the basis of the aforesaid underlying stitch sewing data. Further, line-like stitches are also formed along an outline of the embroidery pattern46of the angel.

A main routine will first be described with reference toFIG. 3. Firstly, the angel image45is read in by the image scanner29(step S1). The angel image45is divided by colors of red, blue, yellow etc. into a plurality of areas Ai including an angel's dress, hair, ring and so on. Data of an outline47defining each divided area Ai is extracted from the image data (step S2). Embroidery data for sewing the embroidery pattern46as shown inFIG. 8is produced on the basis of data of the outline47and the color of area Ai (step S3). Subsequently, a synthesized outline data producing process is carried out. More specifically, a part or all of a plurality of the areas Ai are synthesized into synthesized areas55and61as shown inFIGS. 11 and 12. Data of synthesized outlines56and60defining outlines of the synthesized areas55and61are produced respectively (step S4). Next, data of underlying stitch sewing which is to be sewn under embroidery stitches is produced on the basis of the produced synthesized outline data (step S5).

Read-in of the image45at step S1, extraction of the outline47at step S2and origination of sewing data at step S3are well known techniques in the art and accordingly, detailed description of these processes will be eliminated. Furthermore, in the process for producing underlying stitch sewing data based on the synthesized outline data at step S5, the same underlying stitch sewing data producing process as the conventional technique can be used with the exception that data of underlying stitch sewing62as shown inFIG. 13is produced on the basis of an offset line obtained by offsetting a synthesized outline, for example, inward about 1 mm. Accordingly, detailed description of step S5will be eliminated but in short, data is produced which is used for sewing the inside of the produced offset line with a thread density higher than the embroidery sewing (for example, thread density: 2 mm per thread and stitch pitch: 4 mm). The underlying stitch sewing data includes data of colors of embroidery threads used for the underlying stitch sewing. The thread color data is set so as to have the same thread color as the thread color data for the area in which embroidery sewing is initially carried out.

The process of producing synthesized outline data at step S4will be described with reference toFIG. 4. Firstly, a mode setting screen is displayed on the display26(step S10). The mode setting screen is cable of setting a first mode or a second mode (step S10). PC25advances to step S12when the user selects the first mode using the mouse28or keyboard27(Yes at step S11). On the other hand, PC25advances to step S13when the user selects the second mode (No at step S11). The first mode produces data of synthesized outline defining an outline of a synthesized area obtained by synthesizing only a plurality of areas selected by the user to be synthesized. The second mode produces data of synthesized outline data defining an outline of synthesized area obtained by synthesizing all the areas.

A process for synthesizing selected areas will be described with reference toFIG. 5. The selected areas synthesizing process is carried out at step S12when the first mode has been selected. Firstly, the display26displays a selected areas synthesizing screen containing an outline47of the read image45, a select end button48, cursor49and the like, as shown inFIG. 9(step S20). A determination flag F is provided for determining whether a selected area Aiis an initial selected area. In this case, the flag F is set to “0” (step S21). Next, PC25advances to step S30when the user has not selected the area Ai(No at step S22). On the other hand, PC25advances to step S23when the user has operated via the mouse28the cursor49to select the area Ai(A1, for example) to be synthesized (Yes at step S22).

When F=0 (Yes at step S23) or this is the first time of selection of area Ai, the flag F is set to “1” (step S24) and the initially selected area Ai is set as a temporary synthesized area53(step S25). PC25then returns to step S22. Subsequently, when F=1 (No at step S23) or the currently selected area Aiis not a first one but an area Aihas already been selected to be set as a temporary synthesized area53, PC25advances to step S26to determine whether the currently selected area Ai(area A3, for example) is adjacent to the temporary synthesized area53. When determining that the area Aiis not adjacent to the area53(No at step S26), PC25displays on the display26an error message that the selected area Aicannot be synthesized (step S27), advancing to step S30.

On the other hand, when determining that the area Ai(area A2, for example) is adjacent to the area53(Yes at step S26), PC25synthesizes the outlines47of the respective areas Aito produce data of a temporary synthesized outline defining an outline of the new temporary synthesized area53obtained by synthesizing the selected area Aiand temporary synthesized area53(step S28). Successively, a temporary synthesized outline54as shown inFIG. 10is displayed on the display26on the basis of the temporary synthesized outline data (step S29).

PC25returns to step S22when the user has not operated the select end button48(No at step S30). When steps S21to S30have been repeated at a plurality of times so that the user has selected areas A1to A5corresponding to the skirt of the angel and then operated the select end button48(Yes at step S30), PC25determines that selection has ended and produces data of a synthesized outline56defining an outline of synthesized area55with the temporary synthesized outline data serving as the synthesized outline data (step S31). Furthermore, when the user has selected setting of another synthesized area (Yes at step S32), PC25returns to step S21. When the user has selected not setting a new synthesized area (No at step S32), PC25returns to the main routine.

The all area synthesizing process to be carried out at step S13upon selection of the second mode will now be described with reference toFIG. 6. Firstly, the area A1is set as a temporary synthesized area (step S35) and “1” is set to the synthesis list for storing already synthesized area numbers (step S36). “1” is further set to the area number i (step S37). Subsequently, (i+1) is set to i (step S38) and then, PC25determines whether i has been set to the synthesis list. When i has been set to the synthesis list (Yes at step S39), PC25returns to step S38since the area Aihas been synthesized. On the other hand, when i has not been contained in the synthesis list (No at step S39), PC25then determines whether the area Aiis adjacent to the temporary synthesized area. When determining that the area Aiis not adjacent to the temporary synthesized area (No at step S40), PC25returns to step S38since the area Aicannot be synthesized with the temporary synthesized area.

On the other hand, when determining that the area Aiis adjacent to the temporary synthesized area (Yes at step S40), PC25produces data of temporary synthesized outline defining an outline of a new temporary synthesized area obtained by synthesizing the area Ai and the temporary synthesized area (step S41). An area number i of the synthesized area Aiis registered on the synthesis list (step S42). When still determining that not all the areas Aihave been synthesized, based on the synthesis list (No at step S43), PC25returns to step S37. When determining that all the areas Aihave been synthesized on the basis of the synthesis list (Yes at step S43), PC25produces data of synthesized outline60defining the outline of the synthesized area61with the temporary outline data as synthesized outline data (step S44). Successively, a synthesized outline60as shown inFIG. 12is displayed on the display26on the basis of the synthesized outline data. PC25then returns to the main routine to produce data of underlying stitch sewing62as shown inFIG. 13at step S5.

The operation and advantages of the embroidery data producing device will now be described. In the embodiment, the embroidery data producing device produces the data of the synthesized outlines56and60defining the outlines of the synthesized areas55and61obtained by synthesizing a part or all of a plurality of the areas Aiconstituting the image45. The embroidery data producing device then produces the underlying stitch sewing data based on the synthesized outline data. Accordingly, since the embroidery pattern46is sewn over the underlying stitches sewn using the underlying stitch sewing data, the three-dimensional effect can be achieved. Furthermore, since the work cloth can sufficiently be reinforced in the embroidery sewing, the sewing quality can be improved. In particular, the foregoing effects can be achieved even in such a narrow area where the underlying stitches cannot almost be sewn conventionally. Yet furthermore, since the underlying stitch sewing data is produced by synthesizing the areas Ai, the underlying stitch sewing data can be simplified. Consequently, the underlying stitch sewing operation can be simplified and the sewing time period required for the underlying stitch sewing can be reduced.

Furthermore, the embroidery data producing device can be set either to the first or to the second mode by the user. When the embroidery data producing device is set to the first mode, the synthesized outline56of the synthesized area55obtained by synthesizing only the areas Aican be produced. Accordingly, freedom in the underlying stitch sewing can be improved. Furthermore, when the embroidery data producing device is set to the second mode, data origination can be simplified regarding the synthesized outline60used in the case where the underlying stitch sewing is carried out for all the areas Ai. Yet furthermore, the thread color data for the underlying stitch sewing is the same as the thread color data for the initial area Aito be embroidered. Accordingly, the embroidery sewing machine can be transferred from the underlying stitch sewing to the embroidery sewing without change in the thread.

FIGS. 14 to 17illustrate a second embodiment of the invention. In the second embodiment, the invention is applied to an embroidery data producing device reading in sewing data of an embroidery pattern composed of a plurality of embroidery areas and producing data of underlying stitch sewing for the embroidery areas on the basis of the read sewing data, and an embroidery data producing program. The control system of the embroidery data producing device in the second embodiment is similar to that of the first embodiment and accordingly, the description of the control system will be eliminated.

An embroidery data producing program carried out by the personal computer of the embroidery data producing device2will be described with reference toFIGS. 14 to 17. A main routine will first be described. The personal computer firstly reads sewing data stored on FD or CD-ROM or for example, reads via FDD37, CD-ROM drive38or the like sewing data of the embroidery pattern46of the angel composed of a plurality of embroidery areas Bi as shown inFIG. 8(step S50). Subsequently, data of an outline47of each embroidery area Bi is extracted from the read sewing data (step S51). Synthesized outline data56and60are produced by synthesizing a part or all of a plurality of outline data corresponding to a plurality of the embroidery areas Biextracted at step S51respectively (step S52). Data of underlying stitch sewing is produced on the basis of the synthesized outline data (step S53).

Read-in of sewing data at step S50is a well known technique and origination of underlying stitch sewing data at step S53is similar to that in the first embodiment. Accordingly, the description of techniques will be eliminated. Furthermore, regarding origination of synthesized outline data at step S52, the same processing is executed in the second embodiment as that in the first embodiment with exception of the change from the area Aito the embroidery area Bi. Accordingly, the description of origination of synthesized outline data will be eliminated.

An outline data extracting process will be described with reference toFIG. 15. In the process, data of outline47is extracted on the basis of data of needle drop position Picontained in the sewing data. The number of embroidery areas is designated by N. Firstly, “1” is substituted for the embroidery area number n (step S55) and a final needle drop position number I of the embroidery area number n is read in (step S56). “1” is then substituted for i (step S57). Subsequently, i is incremented by 1 (step S58) and data of coordinates of needle drop positions Pi−1, Pi and Pi+1corresponding to needle drop position numbers Pi−1, i and i+1 respectively are read in (step S59). Angle ∠Pi−1, Piand Pi+1is then calculated (step S60). Whether angle ∠Pi−1, Piand Pi+1is less than or equal to 90° (step S61).

For example, when angle ∠Pi−1, Piand Pi+1is less than or equal to 90° (Yes at step S61), PC25determines that the needle drop position Piis a stitch point which is a turning pint of stitches, as shown inFIG. 16. In this case, the needle drop position Piis registered as a point on the outline47(step S62). On the other hand, when angle ∠Pi−1, Piand Pi+1is greater than 90° (No at step S61), PC25determines that the needle drop position Piis a needle drop position between the outlines47such as in the case of “tatami” stitches (fill stitches). In this case, PC25skips step S62and accordingly does not register needle drop position Pi, advancing to step S63. When i=I−1 (Yes at step S63), PC25assumes that it has been determined whether all the needle drop positions of embroidery area Bnof area number n are the points on the outline, advancing to step S64where outline data of the embroidery area Bnis produced (step S64) On the other hand, when i≠I−1 (No at step S63), PC25returns to step S58where calculation is carried out for the subsequent needle drop position. When determining that n=N (Yes at step S65), PC25determines that outline data has been produced for all the embroidery areas, returning to the main routine. When determining that n≠N (No at step S65), PC25increments n to n+1 (step S66), returning to step S56where outline data of the subsequent embroidery area Bnis produced. In the second embodiment, outline data is extracted on the basis of the needle drop position Piof the sewing data. Consequently, the work for extracting the outline data can be simplified. Description is eliminated regarding the same advantages as achieved from the first embodiment.

A modified form of the second embodiment will now be described with reference toFIGS. 18 to 20. Only the outline data extracting process carried out at step S51is modified in the modified form. Accordingly, the outline data extracting process will be described. For example, firstly,FIG. 19illustrates stitches65sewn on the basis of the read sewing data. Each stitch65is converted to a bold line or virtual stitch66to be drawn as shown inFIG. 20. As a result, gaps between the stitches65are buried so that an image of each stitch area Biis produced (step S70). Subsequently, a folded point of each stitch65extends out of the normal embroidery area Bisince the stitches65are thickened. Accordingly, the image corresponding to each embroidery area Biis scaled down about one half of the thickness of the each virtual stitch66(step S71). Subsequently, PC25then extracts outline data based on the outline of the imaged embroidery area Bi(step S72), returning to the main routine. In the above-described modified form, the outline data extracting process can be simplified since the outline data is extracted on the basis of the outline of the embroidery area Biimaged from the virtual stitches66obtained by converting the stitches65to bold lines.

Furthermore, when outline data is contained in sewing data read from FD or the like, only the outline data may be extracted from the sewing data in the outline data extracting process at step S51.

Modified forms common to the foregoing first and second embodiments will be described. The thread color data contained in the underlying stitch sewing data may be set to one of a plurality of the thread color data contained in the sewing data, which one thread color data has a highest brightness of the thread color data. The color with high brightness includes white, light gray, light yellow and other light colors. Consequently, the sewing quality of the embroidery pattern formed over the underlying stitches can be improved without the underlying stitches being conspicuous. Furthermore, the user may set the thread color data of the underlying stitch sewing. Consequently, the freedom in the thread color of the underlying stitch sewing can be improved.

Yet furthermore, the first mode should not be limited to the case where only the areas selected by the user are synthesized. One or more of the areas may automatically be synthesized. For example, only one or more of the areas on which the embroidery sewing is carried out using the same color thread may automatically be synthesized.

The foregoing description and drawings are merely illustrative of the principles of the present invention 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 invention as defined by the appended claims.