Abstract:
A sewing machine comprising one or more motion means to effect a sewing function, each motion means having a dedicated motion control processor responsive to sewing commands addressed to said motion control processor, for controlling said motion means to effect said sewing faction; and a high speed communications interface for exchanging information between each said motion control processor and an external computer, whereby said sewing commands are determined by the external computer.

Description:
This application claims priority from Canadian Patent Application Nos. 2,355,513 and 2,355,540, both filed on Aug. 20, 2001, and incorporated herein by reference. 
     The invention relates to the field of automated sewing machines, and more specifically to automated sewing machines that are controlled by external computers over high speed networks. 
     BACKGROUND OF THE INVENTION 
     It is assumed in the following description that sewing includes all forms of thread manipulation, such as embroidering, button holing and the like. 
     Existing automated sewing machines for commercial and industrial use may be classified into two main categories. The first category includes automated machines that have an integrated control panel and a dedicated on-board computer, that reads design files describing a sewing or embroidery pattern from a floppy drive, that allow for limited manipulation of the design, and that control machine operations to produce the design. The second category includes automated sewing machines that typically have a RS-232 communications port for the purpose of receiving design data or files from an external computer. Being stored temporarily, the files are then interpreted and sewn by the machine. 
     A disadvantage of both of these categories of machines is that they rely on slow interfaces that are coupled to an on-board computer that reads design files, interprets the files, and then operates the machine. The use of slow interfaces such as RS-232 limits machine networking capabilities and operational flexibility. Moreover, the dedicated nature of the on-board computer represents a barrier to creating low cost, automated machines. 
     Recent domestic sewing and embroidery machine models sold to consumers for household use may allow for communication of data files from a personal computer (“PC”) via a serial connection. However, compared to traditional home sewing machines, these newer machines have proven to be quite expensive. These machines are limited in functionality and quality as machine designers have been forced to compromise their operational and mechanical specifications in order to achieve a lower target price. In these machines, the serial connection serves merely as a relatively slow means for transferring an entire or partial data file to the machine. That is, the serial connection is typically not adequate for providing real time control from an external host control system or to support networking. In addition to controlling machine operation, the dedicated on-board computer must perform the functions of reading a design file and interpreting it and responding to the minimal human machine interface (“HMI”) that is typically resident on the machine&#39;s control panel. 
     There is thus a need to reduce the price limitations while improving the operational limitations of current sewing systems. 
     A still further need exists for a cost-effective automated sewing machine system that will allow for efficient networking and machine control. 
     SUMMARY OF THE INVENTION 
     In accordance with this invention, there is provided a sewing machine comprising: 
     (a) one or more motion means to effect a sewing function, each motion means having a dedicated motion control processor responsive to sewing commands addressed to said motion control processor, for controlling said motion means to effect said sewing function; and 
     (b) a high speed communications interface for exchanging information between each said motion control processor and an external computer, whereby said sewing commands are determined by the external computer. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Embodiments of the invention may best be understood by referring to the following description and accompanying drawings in which: 
     FIG. 1 is a block diagram illustrating an automated sewing machine system in accordance with an embodiment of the invention; and 
     FIG. 2 is a schematic diagram showing a networked arrangement of sewing machines according to an embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known structures and/or processes have not been described or shown in detail in order not to obscure the invention. In the description and drawings, like numerals refer to like structures or and/or processes. 
     The invention provides an automated sewing machine system that includes a high-speed communications interface to an external network or computer for control of sewing machine functions. The high-speed communications interface may include Ethernet, USB, or IEEE1394 (e.g. Firewire™, i.Link™). 
     Advantageously, the invention allows control electronics to be located in a low cost PC system thereby allowing for the removal of expensive on-board, embedded or integrated control computers from sewing machines. This provides considerable cost savings and increased system operation flexibility. 
     System. Referring to FIG. 1, there is shown a block diagram illustrating an automated sewing machine system  100  in accordance with an embodiment of the invention. The automated sewing machine system  100  includes an external computer  110 , an automated sewing machine  120 , and an interface cable  130  between the computer  110  and automated sewing machine  120 . 
     The external computer  110  may include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device. 
     The automated sewing machine  120  includes a serial interface connector  140 , motion means such as integrated motors  160  with associated sensors  161 , intelligent input/output (“I/O”) boards  170  with associated solenoids/relays  171  and sensors  172 , and motion control processors such as intelligent driver boards  180  for motors  181 . The integrated motors  160 , I/O boards  170 , and intelligent driver boards  180  are connected to a serial network  150 . The serial network  150  is connected to the external computer  110  through the serial interface connector  140  and interface cable  130 . The automated sewing machine  120  or its internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  may also include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device. 
     The automated sewing machine system  100  has stored therein data representing sequences of instructions which when executed cause the method described herein to be performed. Of course, the sewing machine system  100  may contain additional software and hardware a description of which is not necessary for understanding the invention. 
     The automated sewing machine  120  includes electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  necessary for machine control and a high speed connection  130 ,  140  in the form of an Ethernet interface, a USB interface, or an IEEE1394 interface. The automated sewing machine  120  and/or its internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  includes software for receiving machine commands from an external source such as the external computer  120  via the high-speed connection  130 ,  140 . The automated sewing machine  120  and/or its internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  also includes software for sending machine control or status commands to an external computer  120 , be it a host PC, a PDA, or another machine with an embedded CPU or host computer, via the high-speed connection  130 ,  140 ,  150 . 
     The automated sewing machine system  100  operates as follows. Being connected to an external computer  110 , the automated sewing machine&#39;s internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  receive initialization and motion and sewing commands via the high-speed interface  130 ,  140 ,  150 . The internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  then execute machine operations based on the received commands while monitoring machine functioning, responding to alarms provided by safety systems (not shown), or sewing machine sensors  161 ,  172 , and providing machine operation or status feedback to the external computer  110  via the high-speed interface  130 ,  140 ,  150 . 
     The motion and sewing commands and parameters received by the internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  contain all the information required by the automated sewing machine  120  to sew or cut a desired design. The machine&#39;s internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181  take the motion and sewing commands and parameters and generate the desired action. Sensors  161 ,  181  in the system feedback information to the external computer  120  concerning machine operation. This fedback information may be used to refine subsequent motion and sewing commands and parameters. 
     An advantage of the present invention is the high-speed interface  130 ,  140 ,  150  that is integrated with the automated sewing machine  120 . As mentioned, this interface  130 ,  140 ,  150  may be an Ethernet interface, a USB interface, or an IEEE1394 interface. The interface  130 ,  140 ,  150  provides high-speed communications allowing for real-time or near real-time control and monitoring of the automated sewing machine  120  by an external computer, PDA or other machine  110 . This allows the automated sewing machine  120  to be optimized to perform The functions of sewing, cutting, etc. the desired design as specified by the external computer  120 . 
     Another advantage of the invention is that the high-speed serial network or bus  150  allows the automated sewing machine  120  to have distributed control functionality. For example, each motor  181  included in the machine  120  includes a controller  180  having a unique identification (“ID”), for responding only to commands received with that unique identification from the external computer  120 . In this way, the motors  181  may be connected to a single bus  150  and respond only to commands having their unique ID while ignoring other commands. By using such distributed control functionality the cost of the automated sewing machine  120  is typically reduced while its flexibility is increased. 
     Referring to FIG. 2, there is shown a block diagram illustrating an automated sewing machine network  200  in accordance with an embodiment of the invention. The automated sewing machine network  200  includes an external computer  110  which is coupled to multiple automated sewing machines  120  via an interface cable network  130 . Each automated sewing machine  120  includes internal electronics including intelligent driver boards or motion control processors  180  and motors  181 . The external computer  110  connects to each machine&#39;s internal network  150  via a serial interface  140 . Through the automated sewing machine network  200 ,  150 , an external computer  110  can send commands (i.e. Command  1 , Command  2 , . . . , Command X) to addressed machines and/or machine components (e.g. ID  1 , ID  2 , . . . , ID N) on the network. The computer  110  can be separate from or attached to a given machine  120 . All control commands and responses are transmitted along the serial network  150  within the machine  120 . Intelligent devices such as motion control processors  180  may have one or more network interfaces that allow connection to the network backbone  150 . The network  200 ,  150  may have a daisy chain, multi drop, or tree structure. This is an advantage over existing automate sewing machines that typically have a central controller within the machine that is connected to multiple motor drivers and I/O interfaces. 
     In an alternate embodiment, the automated sewing machine includes on-board controller  111  that is coupled between the serial interface connector  140  and serial network  150 . This on-board controller acts as an intermediary between the external computer  110  and serial network  150  and it may include a central processing unit or CPU, memory, and a display. The input device may be a keyboard, mouse, trackball, or similar device. The CPU may include dedicated coprocessors and memory devices. The memory may include RAM, ROM, databases, or disk devices. And, the display may include a computer screen or terminal device. 
     With this alternate embodiment, the automated sewing machine&#39;s control, monitoring, and design manipulation electronics and software are again separated from the machine&#39;s internal electronics  160 ,  161 ,  170 ,  171 ,  172 ,  180 ,  181 . The on-board controller  111  performs the function of command exchange with the external computer  110 . The external computer  110  handles the function of interpreting the desired design and transforming it into motion commands. It also provides an interface for machine parameter adjustment and monitors machine sensors  161 ,  172 , providing safety and user feedback functions. 
     Advantageously, this embodiment also provides an automated sewing machine  120  without an internal control system for interpreting design files and for generating and providing motion commands to the machine&#39;s internal electronics, with the exception of safety related mechanisms. By using an external control system or computer  110 , the automated sewing machine  120  requires minimal electronics to execute motion and to sense operation. A dedicated, feature rich, user interface for the automated sewing machine  120  becomes unnecessary and this user interface may be provided using the external computer  110 . The function of modifying designs based on direct user interaction is performed using the external computer. This reduces cost, complexity and size, allowing for advances in design and market penetration. The external control system or computer  110  may include an inexpensive, mass produced PC which will allow for diversity and flexibility through continued independent advances in software and hardware. 
     Data Carrier Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system  100  of FIG. 1 can be contained in a data carrier product according to an embodiment of the invention. This computer software product can be loaded into and run by the automated sewing machine system  100  of FIG.  1 . 
     Computer Software Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system  100  of FIG. 1 can be contained in a computer software product according to an embodiment of the invention. This computer software product can be loaded into and run by the automated sewing machine system  100  of FIG.  1 . 
     Integrated Circuit Product. The sequences of instructions which when executed cause the method described herein to be performed by the automated sewing machine system  100  of FIG. 1 can be contained in an integrated circuit product including a coprocessor or memory according to an embodiment of the invention. This integrated circuit product can be installed in the automated sewing machine system  100  of FIG.  1 . 
     Although preferred embodiments of the invention have been described herein, it will be understood by those skilled in the art that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.