Abstract:
A hook and bobbin locator apparatus and method consisting of a mounting plate and more than one hook and bobbin combination. Each of the more than one hook and bobbin combinations is connected with a stepper motor and each of the more than one hook and bobbin combinations are removably connected with the mounting plate. A stepper motor is also connected with the mounting plate and a controller is connected with the mounting plate stepper motor and the hook and bobbin combination stepper motors such that movement of the mounting plate and the hook and bobbin combinations are controlled by the controller.

Description:
FIELD OF THE INVENTION 
     This invention relates to a hook and bobbin locator device. In particular, in accordance with one embodiment, the invention relates to a hook and bobbin locator apparatus consisting of a mounting plate and more than one hook and bobbin combination. Each of the more than one hook and bobbin combinations is connected with a stepper motor and each of the more than one hook and bobbin combinations are removably connected with the mounting plate. A stepper motor is also connected with the mounting plate and a controller is connected with the mounting plate stepper motor and the hook and bobbin combination stepper motors such that movement of the mounting plate and the hook and bobbin combinations are controlled by the controller. 
     BACKGROUND OF THE INVENTION 
     A problem exists with regard to the use of machines using bobbins containing thread. The problem is that bobbins contain only a limited amount of thread. Once empty the practice is to stop and replace the empty bobbin with a full bobbin. In particular, by way of example only and not by way of limitation, the process of creating quilts by use of sewing machines typically requires the use of twelve to twenty-five bobbins full of thread. This is a problem because, again, when a bobbin runs out of thread, the process must be stopped and the empty bobbin removed and replaced with a new bobbin with thread. This is a time consuming and tedious, repetitive process that, in aggregate, adds considerable wasted time. 
     Further, a problem exists in that the absence of thread in the bobbin is not readily observable in prior art systems. This results in the advancement of the material for some distance after thread has run out. This creates a tremendously difficult problem of trying to locate the place where the bobbin thread ran out after replacing the empty bobbin with a full bobbin. The best that can be done now is to “eyeball” the location which is thus dependent on operator skill and precision. Even the most skilled operator is not always entirely accurate and thus it is currently the state of the art to simply accept the fact that misplaced stitching is something simply to be accepted as a “minor” annoyance. 
     Still further, the prior art systems using bobbins continuously turns the bobbin when connected with the system. This causes wear and tear on the bobbin and requires them to be replaced frequently and at some added expense. 
     Thus, there is a need in the art for an apparatus and method for quickly and easily replacing bobbins that are empty with bobbins with thread. There is a further need for a system that ensures that once a bobbin with thread is in position, that the position is located precisely at the point the last bobbin ran out of thread. Still further there is a need in the art for a system that controllably operates bobbins only as and when needed. 
     It therefore is an object of this invention to provide a hook and bobbin locator apparatus and method that provides a source of many bobbins filled with thread that is quickly and easily maneuverable to move a bobbin with thread to the position of a bobbin without thread and to ensure that thread is started at the precise location that thread ran out. A further object of the invention is to enable controlled operation of a bobbin when and as needed. 
     SUMMARY OF THE INVENTION 
     Accordingly, the hook and bobbin locator apparatus of the present invention, according to one embodiment, includes a mounting plate and more than one hook and bobbin combination. Each of the more than one hook and bobbin combinations is connected with a stepper motor and each of the more than one hook and bobbin combinations are removably connected with the mounting plate. A stepper motor is also connected with the mounting plate and a controller is connected with the mounting plate stepper motor and the hook and bobbin combination stepper motors such that movement of the mounting plate and the hook and bobbin combinations are controlled by the controller. 
     All terms used herein are given their common meaning so that “hook and bobbin combination” identifies and describes combinations of hooks and bobbins now known or hereafter developed for containing thread and delivering thread from the bobbin to the hook, for example only. Likewise, “stepper motor” identifies a motor that divides a full rotation into a number of equal steps, as now known or hereafter developed and not described more fully hereafter. Further, “controller” identifies a device or group of devices designed to govern in some predetermined manner the performance of a motor. A motor “controller” may include manual or automatic means for starting and stopping a motor, such as a stepper motor, for selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque and protecting against overloads and faults for example only and not by way of limitation. 
     According to another aspect of the invention, an encoder is connected with the hook and bobbin combination stepper motors and the mounting plate stepper motor. 
     As used herein, the term “encoder” is used to describe a device, as known, that maintains position information with regard to the object to which it is attached when power is removed from the system and is not described more fully hereafter. 
     In another aspect, a shaft is connected with the mounting plate and another shaft is connected with the mounting plate stepper motor. Timing gears are connected to both the mounting plate shaft and the mounting plate stepper motor shaft and a timing belt is connected with the timing gears. 
     In one aspect, thread is provided in the more than one hook and bobbin combinations and a thread break detector is provided for detection of the absence of thread in a hook and bobbin combination. As used herein, the term “absence of thread” is used to identify a situation where no thread is present or movement of thread past the thread break detector stops such that while some thread may be present at the thread break detector the lack of movement indicates an absence of thread due to an empty bobbin or break. A “thread break detector” may include an electronic eye or motion detector or a combination of that or other devices now known or hereafter developed and not described more fully hereafter. 
     According to another aspect, the thread break detector is connected with the controller. In a further aspect, the detection of absence of thread in one of the hook and bobbin combinations that is empty is sent to the controller such that the controller stops movement of the empty hook and bobbin combination. In another aspect, thereafter the controller operates the mounting plate to move such that the empty hook and bobbin combination position is moved and replaced by a hook and bobbin combination with thread. In another aspect, the controller then activates one of the hook and bobbin combinations with thread after movement of the mounting plate such that the full hook and bobbin combination is located in the position the empty hook and bobbin combination maintained before it was moved and uses the encoders such that thread is started at the exact location where the empty hook and bobbin combination became empty of thread. 
     In one aspect, the mounting plate is a circular shaped disc with a top and a bottom and the more than one hook and bobbin combinations are connected in spaced apart relation to the top of the mounting plate. 
     In another aspect, the more than one hook and bobbin combinations consist of a first section with top and a bottom, and a second section, with a bobbin in a bobbin case located within a surrounding hook at the top of the first section and where the second section includes the stepper motor connected at the bottom of the first section and an encoder connected with the stepper motor. 
     According to another embodiment, in a sewing machine, a hook and bobbin locator apparatus consists of a mounting plate connected to the sewing machine. More than one hook and bobbin combinations are provided, where each of the more than one hook and bobbin combinations is connected with a stepper motor and where each of the more than one hook and bobbin combinations is removably connected with the mounting plate and, further, where thread is included in bobbins in each of the hook and bobbin combinations. A stepper motor is connected with the mounting plate, a drive motor is connected with the sewing machine and an encoder is connected with the hook and bobbin combination stepper motors, the mounting plate stepper motor and the drive motor. A controller is connected with the drive motor, the mounting plate stepper motor and the hook and bobbin combination stepper motors such that movement of the mounting plate and the hook and bobbin combinations are controlled by the controller. A thread break detector is connected with the controller for detection of the absence of thread in a hook and bobbin combination. 
     As used herein the term “sewing machine” describes a powered device for manipulating a needle and thread or threads to join material together or to add thread in the nature of design stitching to material, such as is common in the creation of quilts, for example only and not by limitation. 
     According to another aspect of this invention, a shaft is connected with the mounting plate and another shaft is connected with the mounting plate stepper motor. Timing gears are connected to both the mounting plate shaft and the mounting plate stepper motor shaft and a timing belt is connected with the timing gears. 
     In one aspect, the detection by the thread break detector of absence of thread in one of the hook and bobbin combinations that is empty is sent to the controller such that the controller stops movement of the empty hook and bobbin combination. In another aspect, after the detection of absence of thread is sent to the controller, the controller operates the mounting plate to move such that the empty hook and bobbin combination position is moved and replaced by a hook and bobbin combination with thread. In another aspect, the controller utilizes the encoders and activates one of the hook and bobbin combinations with thread after movement of the mounting plate such that thread is started at the exact location where the empty hook and bobbin combination became empty of thread. 
     In another aspect, the mounting plate is a circular shaped disc with a top and a bottom and the more than one hook and bobbin combinations are connected in spaced apart relation to the top of the mounting plate. 
     In a further aspect, the more than one hook and bobbin combinations consist of a first section with top and a bottom, and a second section, with a bobbin in a bobbin case located within a surrounding hook at the top of the first section and the second section includes the stepper motor connected at the bottom of the first section and an encoder connected with the stepper motor. 
     According to another embodiment, a hook locator method consists of: 
     a. providing a mounting plate and more than one hook and bobbin combinations, where each of the more than one hook and bobbin combinations is connected with a stepper motor, and where the more than one hook and bobbin combinations are removably connected with the mounting plate; a stepper motor connected with the mounting plate; and a controller connected with the mounting plate stepper motor and the hook and bobbin combination stepper motors such that movement of the mounting plate and the hook and bobbin combinations are controlled by the controller; and
 
b. operating the controller so as to move the hook mounting plate to reposition the more than one hook bobbin combinations.
 
     In one aspect, this invention further includes an encoder connected with the hook and bobbin combination stepper motors and the hook mounting plate stepper motor. 
     In a further aspect, the invention includes thread in the more than one hook and bobbin combinations and a thread break detector connected with the controller for detection of the absence of thread in a hook and bobbin combination. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings in which: 
         FIG. 1  is a side partial cut away view of the hook and bobbin locator according to one embodiment; 
         FIG. 2  is a perspective partial cut away view of the invention of  FIG. 1 ; 
         FIG. 3  is an isolated perspective view of the mounting plate with attached hook and bobbin combination; and 
         FIG. 4  is an isolated view of a hook and bobbin combination. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the invention be regarded as including equivalent constructions to those described herein insofar as they do not depart from the spirit and scope of the present invention. 
     For example, the specific sequence of the described process may be altered so that certain processes are conducted in parallel or independent, with other processes, to the extent that the processes are not dependent upon each other. Thus, the specific order of steps described herein is not to be considered implying a specific sequence of steps to perform the process. In alternative embodiments, one or more process steps may be implemented by a user assisted process and/or manually. Other alterations or modifications of the above processes are also contemplated. For example, further insubstantial approximations of the process and/or algorithms are also considered within the scope of the processes described herein. 
     In addition, features illustrated or described as part of one embodiment can be used on other embodiments to yield a still further embodiment. Additionally, certain features may be interchanged with similar devices or features not mentioned yet which perform the same or similar functions. It is therefore intended that such modifications and variations are included within the totality of the present invention. 
     It should also be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative configurations are possible. 
     A preferred embodiment of the present invention is illustrated by way of example in  FIGS. 1-4 . With specific reference to  FIGS. 1 and 2 , hook and bobbin locator  10  includes a mounting plate  12 . In one embodiment, mounting plate  12  is circular in shape with a top  14  and a bottom  16 . A shaft  18  is connected with the mounting plate  12 , as at the bottom  16  for example, and a timing gear  20  is connected with shaft  18 , for use in movement of the mounting plate as will be described more fully hereafter. 
     Hook and bobbin combination  22  includes a hook  24  and a bobbin  26  (not shown but see  FIG. 4 ) in a bobbin case  28 . Preferably, bobbin  26  and bobbin case  18  are located within hook  24  as is shown in the figures. Multiple numbers of hook and bobbin combinations  22  are connected in equally spaced apart relation to each other to the mounting plate  12 , as on the top  14  of mounting plate  12  as shown. When ready for use, hook and bobbin combination  22  includes thread  30  on bobbin  26  located within bobbin case  28  within hook  24  as more clearly shown in  FIG. 4 . 
     Hook and bobbin combination  22  forms a first section  32  with a top  34  and a bottom  36  (see  FIG. 4 ). Stepper motor  38  is connected with the hook and bobbin combination  22  as at the bottom  36  of first section  32  and stepper motor  38  creates a second section  40  of hook and bobbin combination  22 . Preferably an encoder  42  is connected with stepper motor  38 , all again as more clearly shown in  FIG. 4 . 
     Referring to  FIG. 1 , stepper motor  44  includes a shaft  46  and, preferably, shaft  46  includes timing gear  48 . A timing belt  50  connects timing gear  48  on stepper motor  44  shaft  46  with the timing gear  20  on the shaft  18  of mounting plate  12 . Encoder  52  is connected with stepper motor  44 . 
     Still referring to  FIGS. 1 and 2 , controller  54  is illustrated and is connected with stepper motor  38  and encoder  42  as well as stepper motor  44  and encoder  52  for the control and operation of each of those devices. The controller  54  may be connected by hard wire or remotely or in some combination thereof. 
     These figures also illustrate sewing machine  56  with an arm  58  that extends over mounting plate  12  and includes a needle  60  bringing thread  62  from thread spool  64  to interact with one of the hook and bobbin combinations  22  as is known in the art. Drive motor  66  is shown connected with sewing machine  56  for operation of the sewing machine  56 , again as is known in the art and not described more fully hereafter. Encoder  68  is connected with drive motor  66  and both encoder  68  and drive motor  66  are connected with controller  54 . Controller  54  operates as described above to control the operation of drive motor  66  and encoder  68 . 
     Also illustrated is thread break detector  70 . Thread break detector  70  may be located in arm  58  of sewing machine  56  such that when a bobbin  26  runs out of thread  30 , needle  60  stops advancing thread  62  and this lack of motion of thread  62  indicates and absence of thread in bobbin  26 . Thread break detector  70  may also be positioned at the hook bobbin combination  22  that is actively providing thread  30  from its position underneath needle  60  so as to detect the absence of thread  30  directly. Wherever it is located, thread break detector  70  is connected with controller  54  such that upon notice from the thread break detector  70 , controller  54  operates to stop the empty hook and bobbin combination  22 . Then controller  54  activates stepper motor  44  to turn shaft  46  that moves timing belt  50  that engages timing gear  20  that turns mounting plate  12  so as to position a hook and bobbin combination  22  in the position vacated by the empty hook and bobbin combination  22  beneath needle  60 . Encoders  42  and  52  on hook and bobbin combinations  22  and stepper motor  44  provide the exact location of where thread  30  stopped such that thread  30  can be started at that precise location. When sewing machine  56  including drive motor  66  and encoder  68  are connected with controller  54  this same process is accomplished in conjunction with the use of thread  62  from thread spool  64 , for example. 
     The description of the present embodiments of the invention has been presented for purposes of illustration, but is not intended to be exhaustive or to limit the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. As such, while the present invention has been disclosed in connection with an embodiment thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention as defined by the following claims.