Patent Description:
In sewing plants, etc., it is required to manage operation information of the sewing machines being used. For example, a technique for obtaining operation information regardless of types of sewing machines is disclosed in Japanese Patent Application Publication No. <CIT>.

<CIT> discloses a method and apparatus for the pattern-correct sewing together of two pieces of cloth having the same pattern by a sewing machine with one cloth feed mechanism arranged over and one arranged under the cloth pieces, the feed quantity of which is variably by at least one positioning system relative to each other, uses a sensor arranged upstream of a stitch forming point for each cloth piece and a signal processing unit which processes signals from the sensors corresponding to the relative position of the cloth pieces and which influences the positioning system for the feed mechanism in accordance with the established relative position of the cloth pieces. For the pattern-correct sewing together of the two cloth pieces, the pattern structure of each cloth piece is continuously determined by the sensors by measuring values of a structure-or pattern-typical criterion. The found values are sent as signals to the signal processing unit, and the signals of both sensors, taken from the two cloth pieces within the same predetermined length before the stitch forming point, are stored independently of each other in the signal processing unit as signal sequences. From the signal sequences the signal processing unit determines the momentary offset between the two cloth parts by calculation of their degree of overlap and thereby controls the positioning system.

<CIT> discloses a device for collecting needle number of an industrial sewing machine and a piece counting method and belongs to the technical field of garment producing and sewing. The device comprises a sewing machine relative movement mechanism, a needle number collection sensor component, a signal processing unit and a server/cloud platform, and the needle number collection sensor component is mounted on the sewing mechanism relative movement mechanism and connected with the signal processing unit which collects data of a needle number collection sensor and sends the same to the server/cloud platform.

In a traditional method for obtaining the operation information, even if it was possible to detect the start or stop of the rotation of a sewing machine and thread trimming etc., it was not possible to detect information related to other operations. Therefore, in the related art, there is a room for improvement in effectively utilizing the obtained operation information of the sewing machine.

The present application is intended to effectively utilize the operation information of the sewing machine.

According to the present application, an operation information obtaining device includes: a storage portion, configured to store pattern information associating detection information and a sewing pattern of a sewing machine, the detection information is configured to identify an action of a sewing needle of the sewing machine, and the sewing pattern corresponds to the detection information; an estimation portion, configured to estimate the sewing pattern of the sewing machine based on the pattern information and the detection information of the sewing needle detected by a detection device; and an obtaining portion, configured to obtain operation information of the sewing machine having the estimated sewing pattern.

According to the present application, the operation information of the sewing machine may be effectively utilized.

The examples of the present application are described below with reference to the accompanying drawings, but the present application is not limited to the examples.

<FIG> is a structural diagram of a sewing management system according to an example of the present application. As shown in <FIG>, the sewing management system <NUM> includes operation information collection systems <NUM> and a management terminal <NUM>. The operation information collection system <NUM> is constructed for each sewing plant with respect to sewing machines belonging to sewing plants SP1 to SP3. The management terminal <NUM> is communicatively and respectively connected to a plurality of the operation information collection systems <NUM>. In addition, only the structure of the operation information collection system <NUM> for the sewing plant SP2 is shown in <FIG>, and diagrams of the operation information collection systems <NUM> for the sewing plants SP1 and SP3 are omitted since each of the operation information collection systems <NUM> for the sewing plants SP1 to SP3 has the same structure.

The operation information collection systems <NUM> for the plurality of the sewing plants SP1 to SP3 are connected to the management terminal <NUM> through network NW1 such as the Internet. All the operation information collected by the operation information collection system <NUM> for each of the sewing plants SP1 to SP3 may be sent to the management terminal <NUM> or may be viewed in the management terminal <NUM>. A manager may confirm operation condition etc. of each of the sewing plants SP1 to SP3 from the management terminal <NUM>. The manager may, for example, change settings of various parameters related to sewing in each of the sewing plants SP1 to SP3 through the management terminal <NUM> by confirming the operation condition etc. In addition, the management terminal <NUM> is composed of conventional personal computers (PCs), tablet PCs, or smart devices (smart phones, smart watches, smart glasses, etc.).

In each of the sewing plants SP1 to SP3, a plurality of the sewing machines with different manufacturers, models, specifications, and years of manufacturing constitute a sewing production line. Strictly speaking, there are a wide variety of the sewing machines constituting the sewing production line, but these sewing machines may generally be classified into two types: a sewing machine <NUM> and a sewing machine <NUM>. Namely, the sewing machine <NUM> belonging to one classification is equipped with an equipped detection device that detects a state change of a structure of the sewing machine, and has a function of outputting the detection information or operation information based on the detection information to the outside. It should be noted that the term "equipped" here refers to being equipped to the sewing machine initially, and does not include a detection device added in a following modification, or an external detection device not belonging to the equipment of the sewing machine. In addition, the sewing machine <NUM> belonging to another classification does not include an equipped detection device that detects a state change of the structure of the sewing machine, or does not include a function of outputting detection information of an equipped detection device or operation information based on the detection information to the outside.

The operation information collection system <NUM> for each of the sewing plants SP1 to SP3 includes: a plurality of the sewing machines <NUM> belonging to the sewing production line; a plurality of the sewing machines <NUM> belonging to the sewing production line and operation information obtaining devices100 separately attached to the sewing machines <NUM>; and a management server <NUM>, which is used as a collection device, collects the operation information from each of the sewing machines <NUM>, and collects the operation information from each of the sewing machines <NUM> through the operation information obtaining device <NUM>. The management server <NUM>, each of the sewing machines <NUM>, and each of the operation information obtaining devices <NUM> are connected to a network NW2 of the operation information collection system <NUM>.

The sewing machine <NUM> and the sewing machine <NUM> include, for example: a main shaft motor; a main shaft, driven rotationally through the main shaft motor; a needle rod and a sewing needle, reciprocating up and down with power from the main shaft; a thread take-up lever component, reciprocating up and down at a same period as the needle rod; a shuttle or a looper, wrapping a lower thread around an upper thread of the sewing needle; a fabric feeding mechanism, conveying fabric at a specified seam spacing; and a thread trimming device, trimming the upper thread and the lower thread.

<FIG> is a block diagram showing a control system of the sewing machine <NUM>. As shown in <FIG>, the sewing machine <NUM> includes: a control portion <NUM>, controlling the entire sewing machine <NUM>; a storage portion <NUM>, connected to the control portion <NUM>; a display portion <NUM>; an input portion <NUM>; a communication portion <NUM>; an operation portion <NUM>; and a drive portion <NUM>. The control portion <NUM> is composed of central computing devices, such as central processing unit (CPU). The storage portion <NUM> stores a program executed by the control portion <NUM> and functions as a working area of the control portion <NUM>.

The display portion <NUM> displays information required for an action of the sewing machine <NUM>. The input portion <NUM> receives an input of an instruction or a setting from an operator. The communication portion <NUM> communicates with the management server <NUM> through the network NW2. For example, the communication portion <NUM> sends the operation information of the sewing machine <NUM> to the management server <NUM>.

The handling section <NUM> receives a sewing-related operation from the operator. For example, the operation portion <NUM> receives a drive operation for a sewing from the operator (such as executing sewing start, sewing stop, reverse feed, thread trimming, etc.). The drive portion <NUM> includes: the main shaft motor mentioned above, an actuator for executing the thread trimming, an actuator for changing the seam spacing, and other drive sources related to various sewing actions.

The detection device <NUM> is an equipped detection device equipped on the sewing machine <NUM>, and belongs to a sensor class used to detect detection information for obtaining the operation information. Examples of the operation information are "operation time", "number of stitches", "sewing speed", "number of thread trimmings", "yield", and other information may also be obtained. The detection device <NUM> is an encoder detecting a rotational speed of the main shaft motor. In addition, other detection devices may also be added based on the type of the operation information.

The "operation time" as the operation information refers to the elapsed time from a start of a sewing to an end. The encoder may detect a start and a stop of a drive of the main shaft motor, and the control portion <NUM> may count the elapsed time from the start of the drive to the stop to obtain the "operation time". The "number of stitches" as the operation information refers to a cumulative number of needle drops during a sewing, which may be obtained from a cumulative value of a rotational speed of the main shaft motor detected by the encoder. The "sewing speed" as the operation information refers to an average number of needle drops per unit time during a sewing, which may be obtained from the rotational speed of the main shaft motor detected by the encoder. The "number of thread trimmings" as the operation information refers to a cumulative execution number of thread trimmings, which may be obtained by counting an input of the thread trimming instruction detected by the operation portion <NUM>. The "yield" as the operation information refers to the number of sewn articles completed. Due to a fixed number of thread trimmings to be performed on a sewn article, the "yield" may be determined by dividing the "number of thread trimmings" by the number of thread trimmings to be performed on one sewn article. In addition, the number of thread trimmings to one sewn article is pre-determined and input by the input portion <NUM>.

The above operation information is obtained by a detection etc., of the detection device <NUM>, and a comparison to a built-in clock of the control unit <NUM>, and the operation information is temporarily stored in the storage portion <NUM>. In addition, the control portion <NUM> periodically, or at a specified time, or based on a requirement from the management server <NUM>, sends the obtained operation information to the management server <NUM>.

On the other hand, the plurality of the sewing machines <NUM> are not limited to a same model, and the structures may vary in individual cases. Sewing machine <NUM> includes, at least, the operation portion and the drive portion, which is the same as sewing machine <NUM>, but does not include a detection device for obtaining the operation information or a communication portion for sending information to the outside. Therefore, it is not possible to send operation information from the sewing machine <NUM> to the management server <NUM>. Therefore, an operation information obtaining device <NUM> is separately attached to the sewing machine <NUM> for obtaining the operation information from outside the sewing machine.

<FIG> is a block diagram showing a control system of the operation information obtaining device <NUM>. In addition, in an example shown in <FIG>, the operation information obtaining device <NUM> illustrates five devices from the operation information obtaining device 100A to 100E, which are recorded as "operation information obtaining device <NUM>" without repeating the explanation when explaining the common content. In addition, when explaining the differences, the operation information obtaining devices 100A, 100B, 100C, 100D, and 100E are recorded and described separately.

As shown in <FIG>, the operation information obtaining device <NUM> includes: a control portion <NUM>, executing a processing or a control for obtaining detection information <NUM> of a detection device <NUM>; a storage portion <NUM>, connected to the control portion <NUM>; a display portion <NUM>; an input portion <NUM>; a communication portion <NUM>; and the detection device <NUM>. The control portion <NUM> is composed of a central computing device such as a CPU. The storage portion <NUM> stores a program executed by the control portion <NUM> and plays functions as a working area of the control portion <NUM>.

The storage portion <NUM> may store various information such as a program <NUM>, device information <NUM>, sewing machine information <NUM>, detection information <NUM>, operation information <NUM>, pattern information <NUM>, etc. The program <NUM> is a program that causes the control portion <NUM> to execute a function for implementing various actions related to the operation information obtaining device <NUM>. The device information <NUM> includes inherent information of the operation information obtaining device <NUM>, such as the acquisition device ID. The sewing machine information <NUM> includes information such as a sewing machine ID of the sewing machine <NUM> being assigned to be equipped with the operation information obtaining device <NUM>. The detection information <NUM> includes information capable of identifying an action of the sewing needle of the sewing machine <NUM>. The operation information <NUM> includes information related to an operation of the sewing machine <NUM> based on a detection result of the detection device <NUM>. The pattern information <NUM> includes information that may associate the detection information capable of identifying the action of the sewing needle of the sewing machine <NUM> and the sewing pattern of the sewing machine <NUM> corresponding to the detection information. An example of the operation information <NUM> and the pattern information <NUM> will be described later.

The display portion <NUM> displays information and a set value required for obtaining the operation information <NUM>. The input portion <NUM> receives an input from the operator of the set value required by the acquisition of the operation information <NUM>. The communication portion <NUM> communicates with the management server <NUM> through the network NW2. For example, the communication portion <NUM> sends the detection information <NUM> and the operation information <NUM> detected from the sewing machine <NUM> to the management server <NUM>.

The detection device <NUM> is an external detection device that detects a sewing action of the sewing machine <NUM> from an outside of a main frame <NUM> described later. The detection device <NUM> is a sensor type that detects the detection information <NUM> for obtaining the operation information <NUM> of the sewing machine <NUM>. The detailed information about the sensor class will be described later. The detection device <NUM> provides the detection information <NUM> indicating a detection result to the control portion <NUM>. The detection information <NUM> includes, for example, various information such as a rotation sensor signal during sewing a pattern of the sewing machine <NUM>, and detection state of the sewing needle. In the operation information <NUM> obtained by the operation information obtaining device <NUM>, "operation time", "number of stitches", "sewing speed", "number of thread trimmings", "yield", "sewing pattern", "poor condition", etc. may be listed. The operation information <NUM> further includes information other than the above. The method for obtaining the operation information <NUM> by the operation information obtaining device <NUM> will be described later.

The operation information obtaining devices 100A to 100E may include detection devices <NUM> detecting different objects. In the following description, it is assumed that the operation information obtaining devices 100A to 100E include the same detection device <NUM>.

<FIG> is a partial side view of a sewing machine showing an example of a detection state of a photoelectric sensor. As shown in <FIG>, the detection device <NUM> of the operation information obtaining device <NUM> includes: a photoelectric sensor 51A, a current sensor, a light-emitting portion, a light sensor, and a yield switch not shown in the figure. The photoelectric sensor 51A is provided outside the main frame <NUM> of the sewing machine <NUM> to detect a state change of an action component that performs a periodic action with the same period as the up and down action of the sewing needle <NUM>. The current sensor is a current detection device that detects energization from the outer side of the current cable through which the motor current of the main shaft motor flows. The main shaft motor is pulled out from the main frame <NUM> to the outside. The light-emitting portion includes a power lamp that emits light when a main power source of the sewing machine <NUM> is turned on. The light sensor is a light detection device that detects a luminous state of the light-emitting portion. The yield switch is a yield input portion that detects a yield through an operation of the operator using the sewing machine <NUM>. It should be noted that the detection device <NUM> of the operation information obtaining device <NUM> includes at least the photoelectric sensor 51A, but may do not include the current sensor, the light sensor, and the yield switch.

A state C1 in <FIG> represents a detection state of the photoelectric sensor 51A. A state C2 in <FIG> represents a non-detection state of the photoelectric sensor 51A. The photoelectric sensor 51A detects a presence or an absence of the thread take-up lever component <NUM>, the thread take-up lever component <NUM> serves as the action component that performs a periodic action at the same period as the up and down action of the sewing needle <NUM>. An end portion of the thread take-up lever component <NUM>, in which a threading hole for passing the upper thread is formed, extends outwardly from a front side (a surface opposite to the operator) of a sewing machine arm portion of the main frame <NUM>. The thread take-up lever component <NUM> receives power from a rotation of the main shaft, and a front end of the thread take-up lever component <NUM> reciprocally oscillates up and down in the same period as the up and down action of the sewing needle <NUM>. An upper stop point in the reciprocating oscillation of the thread take-up lever component <NUM> is consistent with a stop position of the needle rod (stopping in a state where the sewing needle <NUM> retreats above a throat plate), which is a stop position of the main shaft at a stop of the sewing of the sewing machine <NUM>.

The photoelectric sensor 51A is a reflective type including a light-emitting element and a light-receiving element facing in the same direction, and can detect a presence or an absence of an object directly opposite to a detection surface of the photoelectric sensor 51A through a presence or an absence of a reflected light. The photoelectric sensor 51Ais installed on an external front side of the sewing machine arm portion of the main frame <NUM> so that the detection surface of the photoelectric sensor 51A may be directly opposite to a position at which the front end of the thread take-up lever component <NUM> at the upper stop point may be detected. In addition, a reflective sheet 52A is provided at the front end of the thread take-up lever component <NUM> in a configuration opposite to the photoelectric sensor 51A. Even without the reflective sheet 52A, the photoelectric sensor 51A may still detect the front end of the thread take-up lever component <NUM>. However, by providing the reflective sheet 52A, a better detection may be performed. The photoelectric sensor 51A may be fixed using any method such as bonding, thread fastening, or thread fastening through a bracket. In addition, the photoelectric sensor 51A may not be directly installed on a surface of the main frame <NUM>, for example, the photoelectric sensor 51A may be supported by a support body on a front side of the main frame <NUM> of the sewing machine <NUM>.

The detection device for detecting the front end of the thread take-up lever component <NUM> is not limited to a reflective type photoelectric sensor, but may be a transmissive type photoelectric sensor. Furthermore, it is possible to use not only the photoelectric sensor 51A, but also all sensors capable of detecting a presence or an absence of the front end of the thread take-up lever component <NUM>. For example, a distance detection sensor may be used to detect a proximity of the front end of the thread take-up lever component <NUM>, or a sensor that utilizes magnetism or ultrasound to detect the proximity of the front end of the thread take-up lever component <NUM> may be used.

<FIG> show examples of signal detection for the photoelectric sensor 51A. <FIG> are output line diagrams showing examples of signal detection for the photoelectric sensor. In <FIG>, the detection state of the photoelectric sensor 51A on the front end of the thread take-up lever component <NUM> is set to L, and the non-detection state is set to H. The detection of the photoelectric sensor 51A indicates a state in which the main shaft motor is stopped at a needle rod upper stop position when the state L is continuous. The detection of the photoelectric sensor 51A indicates a state in which the main shaft motor is stopped at a needle rod lower stop position when the state H is continuous.

As shown in <FIG>, when the detection of the photoelectric sensor 51A repeats the state H and the state L in a short period of time, the control portion <NUM> may detect the "number of stitches" by counting the number of times of a rising edge Eu indicating a transition from the state L to the state H. For example, in <FIG>, since the rising edge Eu occurs twice and is stopped, the number of stitches is counted as <NUM>. In <FIG>, the number of stitches is counted as <NUM>, and in <FIG>, the number of stitches is counted as <NUM>.

In addition, the control portion <NUM> may determine a stop of the main shaft motor when it is detected that the state L or the state H continues a predetermined stop determination time t1 or more. The stop determination time t1 for determining the stop may be arbitrarily set from an input portion <NUM>. For example, the stop determination time t1 may be set to a value equal to <NUM> [s], which is a period of a very low main shaft rational speed <NUM> spm without a normal sewing. Moreover, the control portion <NUM> may count the elapsed time from the detection of an initial rising edge Eu to a final rising edge Eu before the stop, and obtain the "operating time" from this elapsed time. Furthermore, the control portion <NUM> may obtain the "sewing speed" by dividing the obtained "number of stitches" by the obtained "operation time".

For example, in <FIG>, since the detection of the photoelectric sensor 51A continues in the state H at the time of stopping, the control portion <NUM> determines that the control has stopped at the lower stop position of the needle rod. On the other hand, in <FIG>, since the detection of the photoelectric sensor 51A continues in the state L at the time of stopping, the control portion <NUM> determines that the control has stopped at the upper stop position of the needle rod. The stopping at the lower stop position of the needle rod is usually handled as follows, maintaining a state where the sewing needle <NUM> pierces to the fabric and is constrained, and then the sewing is resumed by changing a direction of the needle.

In contrast, the stopping at the upper stop position of the needle rod is usually handled as follows: the fabric is in a state where the fabric is unconstrained by the sewing needle <NUM>, the sewing is finished, and the thread is shifted to thread trimming. Therefore, as shown in <FIG>, in the case where the control portion <NUM> is stopped at the upper stop position of the needle rod, it is considered that the thread trimming has been executed, and the "number of thread trimmings" is counted and a value of the "number of thread trimmings" may be obtained.

In addition, the photoelectric sensor 51A and the reflective sheet 52A (or the thread take-up lever component <NUM>) are configured to detect the upper stop position of the thread take-up lever component <NUM>, but the lower stop position of the needle rod may also be detected by changing these configurations. In this case, instead of counting the "number of thread trimmings" by detecting the stopping at the upper stop position of the needle rod, the "number of thread trimmings" may be counted by detecting the stopping in a state that the lower stop position of the needle rod is not detected.

As in the case of the sewing machine <NUM>, since the number of thread trimmings to be performed on one sewn article is determined, the control portion <NUM> calculates the "yield" by dividing the "number of thread trimmings" by the number of thread trimmings x to be performed on one sewn article. In addition, the number of thread trimmings x to be performed on one sewn article may be arbitrarily set by the input portion <NUM> in advance.

The control portion <NUM> may obtain the operation information <NUM> based on the detection signal of the photoelectric sensor 51A when an inching is performed. The inching refers to a low-speed sewing of one stitch at a time to align the needle dropping position at the corners, etc. Due to the fact that the inching is a one-stitch drop during a sewing procedure, a one-stitch drop is performed from a state of the stopping at the lower stop position of the needle rod, and then stops again at the lower stop position of the needle rod. Therefore, during a process in which the detection of the photoelectric sensor 51A is stopped in the state H, a rising edge Eu is detected once, and a stop in the state H is detected again, and the execution of inching may be detected.

During the inching, due to the rising edge Eu is only detected once, the "number of stitches" = <NUM>, and the above "operation time" cannot be calculated, correspondingly, the "sewing speed" cannot be calculated. Therefore, considering that the inching is generally carried out at a low speed, assuming that the inching is carried out at the lowest sewing speed of <NUM> [spm] in a conventional sewing machine, and when the "inching" is detected, the operation information <NUM> is obtained with the "number of stitches" of <NUM>, the "operation time" of <NUM> [s], and the "sewing speed" of <NUM> [spm]. In addition, the operation time t2 during the inching may be arbitrarily set by the input portion <NUM>.

In addition, the detection device <NUM> may also be a structure that detects a rotation of a pulley, and the pulley serves as an action component that performs a periodic action with the same period as the up and down action of the sewing needle <NUM>. The pulley is located on a side of the main frame <NUM> of the sewing machine <NUM>, and the pulley is configured to be exposed from the outside and may be manually rotated from the outside. The pulley <NUM> is connected to the main shaft and rotates in conjunction with the main shaft. Therefore, the pulley rotates at the same period as the up and down action of the sewing needle <NUM>.

For example, the reflective sheet is pasted near a specified position of a peripheral surface or a periphery of a circular end face of the pulley, and the detection device <NUM> is configured near the sewing machine <NUM> or on a surface of the main frame <NUM> of the sewing machine <NUM> in such a manner: the photoelectric sensor irradiates a detection light to a position of the reflective sheet at the upper stop position of the needle rod. As for the detection device <NUM>, through structures of the photoelectric sensor and the reflective sheets, the photoelectric sensors may detect the upper stop position of the needle rod of the sewing machine <NUM> from a change in a light intensity of a reflected light of the detection light. Specifically, at the upper stop position of the needle rod of the sewing machine <NUM>, the reflective sheet reflects the detection light, and the photoelectric sensor is in a high-light-intensity detection state. In addition, at positions other than the upper stop position of the needle rod of the sewing machine <NUM>, the photoelectric sensor is in a low-light-intensity detection state because the reflective sheet is located in a position that does not reflect the detection light.

In this case, the detection device <NUM> replaces the high-light-intensity detection state with the state L of the detection of the photoelectric sensor 51A, and replaces the low-light-intensity detection state with the state H of the detection of the photoelectric sensor 51A. Thus, it is possible to detect the "operation time", "number of stitches", "sewing speed", "number of thread trimmings", "yield", etc. as the operation information <NUM>.

It should be noted that the detection device for detecting a specific part of the pulley is not limited to the photoelectric sensor, and all sensors capable of detecting a proximity to the specified position of the specific part of the pulley may be used. For example, a protrusion may be provided instead of the reflective sheet of the pulley, and a proximity of a specific part of the pulley may be detected through a distance detection sensor. Alternatively, a magnetic member may be pasted instead of the reflective sheet of the pulley, and a magnetic sensor may be used for detection.

Returning to <FIG>, the control portion <NUM> includes functional portions such as: an estimation portion <NUM>, an obtaining portion <NUM>, a collection portion <NUM>. The control portion <NUM> implements functional portions such as the estimation portion <NUM>, the obtaining portion <NUM>, and the collection portion <NUM> by executing the program <NUM>. The program <NUM> is a program used to enable the control portion <NUM> of the operation information obtaining device <NUM> to function as the estimation portion <NUM>, the obtaining portion <NUM>, and the collection portion <NUM>. The control portion <NUM> implements or performs the information processing functions or usages described below.

The estimation portion <NUM> estimates the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM> of the sewing needle <NUM> detected by the detection device <NUM>. The sewing pattern includes a figure, shape, design, and other patterns formed by the sewing machine <NUM> on the fabric and other to-be-sewing articles. The pattern of the sewing machine <NUM> is sewn based on the determined number of stitches, thread trimming position, and sewing time. Therefore, an action of the needle <NUM> (the main shaft) of the sewing machine <NUM> is a determined action corresponding to the sewing pattern. The detection device <NUM> outputs the detection information <NUM> that detects a pulse signal of the rotation sensor corresponding to the action of the sewing needle <NUM> (the main shaft) of the sewing machine <NUM>.

For example, the estimation portion <NUM> extracts, from the pattern information <NUM>, patterns similar to a shape and a pattern of a certain pulse train, represented by the detection information <NUM> during a pattern sewing, of the rotation sensor, and estimates the sewing pattern associated with the extracted pattern as the sewing pattern of the sewing machine <NUM>. Based on the detection information <NUM> and the pattern information <NUM> that may identify a periodic action and a non-action state of the sewing needle <NUM>, the estimation portion <NUM> estimates the sewing pattern with a sewing and an idle feeding of the sewing machine <NUM>. The estimation portion <NUM> estimates the poor condition of the sewing of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM>. An example of determination will be described later. The estimation portion <NUM> stores the determination result of the sewing pattern of the sewing machine <NUM> in the storage portion <NUM>.

The obtaining portion <NUM> obtains the operation information <NUM> of the sewing machine <NUM> including the estimated sewing pattern. Obtaining the operation information <NUM> includes generating the operation information <NUM>. The obtaining portion <NUM> obtains, for example, the operation information <NUM> that may identify the estimated sewing pattern and the action state of the sewing needle <NUM>, and stores the estimated sewing pattern and the action state of the sewing needle <NUM> in the storage portion <NUM>. The obtaining portion <NUM> obtains the operation information <NUM> that may identify the poor condition of the sewing of the sewing machine <NUM> determined by the estimation portion <NUM>. The obtaining portion <NUM> may store the obtained operation information <NUM> in an external storage device or provide the obtained operation information <NUM> to the management server <NUM>, the management terminal <NUM>, etc..

The collection portion <NUM> collects the detection information <NUM> of the sewing machine <NUM> that has executed the sewing pattern, and stores the pattern information <NUM> associating the detection information <NUM> with the sewing pattern in the storage portion <NUM>. The collection portion <NUM> performs teaching processing that associates the information of the sewing pattern input through the input portion <NUM> with the detection information <NUM> detected by the detection device <NUM>, generates the pattern information <NUM>, and stores the pattern information <NUM> in the storage portion <NUM>.

The above describes the functional structure example of the operation information obtaining device <NUM> of this embodiment. In addition, the above structure illustrated using <FIG> is only an example, and the functional structure of the operation information obtaining device <NUM> of this embodiment is not limited to this example. The functional structure of the operation information obtaining device <NUM> of this embodiment may be flexibly deformed based on specifications and applications.

<FIG> shows an example of a sewing pattern of the operation information obtaining device <NUM> of the present application. <FIG> shows an example of a pulse train corresponding to <FIG>. <FIG> shows an example of a relationship between a sewing point of a seam and an action of a sewing machine. <FIG> shows an example of the pattern information <NUM> according to an embodiment of the present application.

In the implementation, the positional relationship of each part is described based on a sewing machine coordinate system defined in the sewing machine <NUM>. As shown in <FIG>, the sewing machine coordinate system is defined by a three-dimensional orthogonal coordinate system. The coordinate system of the sewing machine is defined by an Xm axis, a Ym axis, and a Zm axis. The Xm axis is defined on a predetermined plane. The Ym axis is defined to be orthogonal to the Xm axis on the predetermined plane. The Zm axis is defined to be orthogonal to the predetermined plane. In the implementation, it is set that the predetermined plane is parallel to a horizontal plane, and a direction parallel to the Zm axis is an up-and-down direction. In addition, in the implementation, the predetermined surface is appropriately referred to as an XmYm plane.

The sewing machine <NUM> holds the upper end of the sewing needle <NUM> so that the sewing needle <NUM> extends in the Zm axis. In the sewing machine <NUM>, an upper thread is threaded in the sewing needle <NUM>. The sewing machine <NUM> supports a back of the to-be-sewn article through the throat plate. An upper surface of the throat plate is parallel to the XmYm plane. The throat plate supports the to-be-sewn article from below. The throat plate includes a needle hole through which the sewing needle <NUM> may pass. The sewing machine <NUM> is provided with a shuttle below the throat plate, the shuttle holds a bobbin housed in a bobbin case. In the sewing machine <NUM>, a lower thread is wound on the bobbin. The shuttle of the sewing machine <NUM> rotates synchronously with the reciprocating movement of the needle rod, and the lower thread is fed from the shuttle.

The sewing machine <NUM> presses the to-be-sewn article from above through a pressing component. The pressing component is provided above the throat plate and in contact with the surface of the to-be-sewn article. The pressing component holds the to-be-sewn article between the throat plate and the pressing component. When the needle rod of the sewing machine <NUM> is lowered, the sewing needle <NUM> held by the needle rod penetrates the to-be-sewn article and passes through the needle hole provided on the throat plate. When the sewing needle <NUM> passes through the needle hole of the throat plate, the sewing machine <NUM> hangs the lower thread fed from the shuttle on the upper thread hanging on sewing needle <NUM>. When in a state where the lower thread is hung on the upper thread, the sewing needle <NUM> rises and leaves from the to-be-sewn article. When sewing needle <NUM> penetrates through the to-be-sewn article, the to-be-sewn article stops. When sewing needle <NUM> leaves from the to-be-sewn article, the to-be-sewn article moves towards a sewing direction corresponding to the sewing pattern PT through the feeding mechanism of the sewing machine <NUM>. The sewing machine <NUM> repeatedly moves and stops in the sewing direction of the to-be-sewn article while causing the sewing needle <NUM> to move back and forth, thereby forming a seam PM on the to-be-sewn article. The seam PM formed on the to-be-sewn article becomes the shape corresponding to the sewing pattern PT.

As shown in <FIG>, the sewing machine <NUM> forms a seam PM on the to-be-sewn article by operating sewing needle <NUM> to form the sewing pattern PT. In an example shown in <FIG>, the sewing pattern PT has a plurality of curved seams PM, and a roughly circular pattern is formed through the plurality of seams PM. The sewing point P1 of the pattern PT is a starting position for pattern sewing, and the sewing point P8 is an ending position for pattern sewing. The sewing points P2 to P7 of the sewing pattern PT are the positions where the state of pattern sewing changes. The state of pattern sewing includes, for example, sewing, thread trimming, and idle feeding etc. In addition, the sewing pattern PT may also be, for example, a pattern with shapes such as lines, circles, polygons, or a combination of these shapes.

As shown in <FIG>, when the sewing machine <NUM> performs sewing based on sewing pattern PT, the detection device <NUM> detects a pulse signal indicating the action state of the main shaft motor of the sewing machine <NUM>, and obtains the detection information <NUM> indicating the pulse train SG. The detection information <NUM>, for example, includes information that may identify the pattern, numbers, time, and other information of the pulse train SG from sewing point P1 to sewing point P2, from sewing point P3 to sewing point P4, from sewing point P5 to sewing point P6, and from sewing point P7 to sewing point P8. That is, the pulse train SG represents the switching from the state L to the state H mentioned above. The pulse train SG may be used to detect a start and an end of pattern sewing by treating the pulse group PG as a block. The pulse train SG, for example, may identify the number of stitches and the sewing time of the seam PM by counting the number of pulses in the pulse group PG from a start of sewing (sewing point P1) to the thread trimming (sewing point P2).

The pulse train SG includes a first state G1 and a second state G2. The first state G1 represents a periodic action state of sewing needle <NUM>, including a pulse group PG corresponding to the number of stitches of the sewing needle <NUM>. The second state G2 represents the state where the sewing needle <NUM> is not in action and does not include a pulse group PG. For each of the plurality of sewing patterns PT, the time, number of pulses, and combination of the first state G1 and second state G2 of the pulse train SG are different. In this way, the pulse train SG may represent the corresponding pulse train SG of the sewing pattern PT as a combination of a plurality of the first state G1 and the second state G2. For example, in the pattern PT shown in <FIG> and the pattern PT of seam PM with different shapes and lengths compared to <FIG>, the combination of the first state G1 and the second state G2 of the pulse train SG is different. Therefore, the operation information obtaining device <NUM> may determine the sewing pattern PT by comparing the actual detected detection information <NUM> with the pulse train SG.

As shown in <FIG>, the sewing points P1 to P2 of the pulse train SG represent sewing, and the sewing point P2 represents the thread trimming. The sewing points P2 to P3 of the pulse train SG represent an idle feeding of the sewing machine <NUM>. The idle feeding refers to not using the sewing needle <NUM> to form the seam PM. The sewing points P3 to P4 of the pulse train SG represent sewing, and P4 represents the thread trimming. The sewing points P4 to P5 of the pulse train SG represent the idle feeding of the sewing machine <NUM>. The sewing points P5 to P6 of the pulse train SG represent sewing, and the sewing point P6 represents a position of the thread trimming. The sewing points P6 to P7 of the pulse train SG represent a position of the idle feeding of the sewing machine <NUM>. The sewing points P7 to P8 of the pulse train SG represent sewing, and the sewing point P8 represents the thread trimming and the pattern sewing is completed.

The sewing pattern PT and the pulse train SG may associate their respective sewing points P1 to P8. The pattern information <NUM> includes information that associates the sewing pattern PT with the pulse train SG. In this embodiment, the operation information obtaining device <NUM> stores a plurality of pattern information <NUM> based on the detection information <NUM> of pulse trains SG corresponding to different sewing patterns PT in the storage portion <NUM>. The pattern information <NUM> associates the detection information <NUM> of the pulse train SG corresponding to an action of the sewing needle <NUM> of the sewing machine <NUM> with the pattern ID indicating the sewing pattern PT of the sewing machine <NUM> corresponding to the detection information <NUM>.

As shown in <FIG>, the collection portion <NUM> collects a plurality of pattern information <NUM> associating the sewing pattern with the detection information <NUM> through a teaching function. For example, when a sewing pattern is input through the input portion <NUM>, the collection portion <NUM> obtains the measurement information <NUM> when the sewing pattern is actually sewn, and generates the pattern information <NUM> that associates the detection information <NUM> with the sewing pattern information. The collection portion <NUM> generates the pattern information <NUM> according to different sewing patterns, as to store a plurality of pattern information <NUM> in the storage portion <NUM>, the external storage device, etc. In an example shown in <FIG>, pattern information <NUM> associates sewing patterns PID-<NUM>, PID-<NUM>, and PID-<NUM> with detection information <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> in a one-to-one correspondence relationship. The collection portion <NUM> may be a structure that, for example, collects a plurality of different types of pattern information <NUM> from a server device and stores the pattern information <NUM> in the storage portion <NUM>.

<FIG> is a diagram for illustrating an example of a poor condition of a sewing pattern PT. As shown in <FIG>, the sewing machine <NUM> sometimes stops sewing during pattern sewing due to a poor condition of sewing. In this case, the estimation portion <NUM> of the operation information obtaining device <NUM> extracts the pattern information <NUM> similar to the detection information <NUM> of the sewing needle <NUM> detected by the detection device <NUM> from a plurality of pattern information <NUM> in the storage portion <NUM>. The estimation portion <NUM> estimates the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> and the extracted pattern information <NUM>, and estimates whether a poor condition of the sewing machine <NUM> occurs. Therefore, the estimation portion <NUM> compares the pulse train SG represented by the detection information <NUM> with the pulse train SG represented by the pattern information <NUM>, and estimates that the sewing pattern represented by the pattern information <NUM> is the sewing pattern of the sewing machine <NUM> when a consistency is higher than a determination threshold.

In an example shown in <FIG>, regarding the estimation portion <NUM>, the sewing pattern from sewing point P1 to sewing point P7 of the sewing pattern PT-<NUM> is consistent with the sewing pattern PT shown in <FIG>, and the sewing pattern from sewing point P7 to sewing point P9 is different from the section from sewing point P7 to sewing point P8 of the sewing pattern PT. In this case, due to the fact that sewing point P9 is closer to sewing point P7 than sewing point P8, the estimation portion <NUM> may estimate that the sewing machine <NUM> stops sewing in the pattern sewing procedure. The estimation portion <NUM> estimates that an inconsistent section from sewing point P7 to sewing point P9 is a location where the poor condition occurred, and stores the estimation result in the storage portion <NUM>.

The obtaining portion <NUM> of the operation information obtaining device <NUM> obtains the operation information <NUM> that may identify the poor condition of a sewing of the sewing machine <NUM>. For example, the obtaining portion <NUM> obtains operation information <NUM> including the sewing machine ID represented by the sewing machine information <NUM>, and the occurrence of the poor condition, occurring date and time etc. in the sewing pattern PT-<NUM>, and stores the operation information <NUM> in the storage portion <NUM> etc..

Next, an example of the processing procedure of the operation information obtaining device <NUM> will be described. <FIG> is a flowchart showing an example of the processing procedure executed by the operation information obtaining device <NUM>. The processing procedure shown in <FIG> may be achieved by executing program <NUM> by the control portion <NUM> of the operation information obtaining device <NUM>. The processing procedure shown in <FIG> is executed by the control portion <NUM> at a specified time. The specified time includes an action time of the sewing machine <NUM>, a set time, etc..

As shown in <FIG>, the control portion <NUM> of the operation information obtaining device <NUM> obtains the detection information <NUM> from the detection device <NUM> (step S101). For example, the control portion <NUM> obtains the detection information <NUM> output by the detection device <NUM> and stores the detection information <NUM> in the storage portion <NUM>. When procedure in step S101 is completed, the control portion <NUM> proceeds the procedure to step S102.

The control portion <NUM> estimates the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM> (step S102). For example, the control portion <NUM> extracts the pattern information <NUM> similar to the pulse train SG represented by the detection information <NUM> from the storage portion <NUM>, and estimates the sewing pattern of the sewing machine <NUM> as the sewing pattern represented by the pattern information <NUM>. When the procedure in step S102 is completed, the control portion <NUM> proceeds the procedure to step S103.

The control portion <NUM> obtains the operation information <NUM> of the sewing machine <NUM> that may identify the estimated sewing pattern (step S103). For example, the control portion <NUM> generates the operation information <NUM> including the detection information <NUM> obtained in step S101 and the estimated sewing pattern information, obtains the operation information <NUM> and stores the operation information <NUM> in the storage portion <NUM> in chronological order. When the procedure in step S103 is completed, the control portion <NUM> proceeds the procedure to step S104.

The control portion <NUM> determines whether a poor condition occurs (step S104). For example, the control portion <NUM> compares the detection information <NUM> of sewing needle <NUM> detected by detection device <NUM> with similar pattern information <NUM> corresponding to the sewing pattern PT of the sewing machine <NUM>. When the sewing pattern PT is not completed, it is estimated whether the sewing machine <NUM> has a poor condition. When the control portion <NUM> estimates that no poor condition has occurred (No in step S104), the processing procedure shown in <FIG> is ended.

In addition, when the control portion <NUM> estimates that a poor condition has occurred (Yes in step S104), the processing procedure is advanced to step S105. The control portion <NUM> determines the poor condition in the pattern sewing (step S105). For example, the control portion <NUM> compares the detection information <NUM> of the sewing needle <NUM> with the similar pattern information <NUM>, and it is estimated that the different section of the pulse train SG of the sewing pattern PT is the poor condition in the pattern sewing of the sewing machine <NUM>. When the procedure in step S105 is completed, the control portion <NUM> proceeds the procedure to step S106.

The control portion <NUM> attaches the poor condition information to the operation information <NUM> (step S106). For example, the control portion <NUM> generates poor condition information that may identify the content, occurrence date and time of the poor condition based on the determination result in step S105, and attaches the poor condition information to the operation information <NUM> obtained in step S103. The control portion <NUM> ends the processing procedure shown in <FIG> when the procedure in step S106 is completed.

Next, an example of an action of the operation information obtaining device <NUM> and the management server <NUM> in the operation information collection system <NUM> will be described. The operation information collection system <NUM> includes an operation information obtaining device <NUM> for obtaining the operation information <NUM> of the sewing machine <NUM>, and a collection device for collecting the operation information <NUM> from the operation information obtaining device <NUM>, namely a management server <NUM>.

<FIG> shows an example of an action of the operation information obtaining device <NUM> and the management server <NUM>. As shown in <FIG>, the detection device <NUM> of the operation information obtaining device <NUM> detects the action of the sewing needle <NUM> of the sewing machine <NUM> (step S1101). The detection device <NUM> of the operation information obtaining device <NUM> outputs the detected detection information <NUM> to the control portion <NUM> (step S1102).

The control portion <NUM> of the operation information obtaining device <NUM> estimates the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM> (step S1201). The control portion <NUM> of the operation information obtaining device <NUM> obtains the operation information <NUM> based on the estimation result (step S1202). The control portion <NUM> of the operation information obtaining device <NUM> sends the obtained operation information <NUM> (step S1203). In this embodiment, the control portion <NUM> sends the obtained operation information <NUM> to the management server <NUM> through the communication portion <NUM>.

The management server <NUM> associates the operation information <NUM> received from the operation information obtaining device <NUM> with the sewing machine (step S1301) and save them. For example, the management server <NUM> determines the sewing machine <NUM> associated with the operation information obtaining device <NUM> that sends the operation information <NUM>, and associates the information indicating the determined sewing machine <NUM> with the operation information <NUM>. Then, the management server <NUM> executes a management processing for the operation information <NUM> (step S1302). The management processing includes, for example, assisting a start sewing and an end sewing of the pattern sewing based on the operation information <NUM>. The management processing includes, for example, assisting in managing and responding to the poor condition that occurs during the pattern sewing based on the operation information <NUM>. Afterwards, the operation information obtaining device <NUM> and the management server <NUM> perform the same processing.

As mentioned above, the operation information obtaining device <NUM> determines the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> detected by the detection device <NUM> and the pattern information <NUM> in the storage portion <NUM>, and obtain the operation information <NUM> with the sewing pattern. Therefore, since the operation information obtaining device <NUM> obtains the operation information <NUM> having the estimated sewing pattern, compared to the traditional operation information with only a rotation start and stop of the main shaft and the thread trimming, the operation information <NUM> of the sewing machine <NUM> may be effectively utilized in the present application.

The operation information obtaining device <NUM> may determine the sewing pattern with the sewing and the idle feeding of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM> that may identify the state of the periodic action and non-action of the sewing needle <NUM>. Therefore, the operation information obtaining device <NUM> may improve the estimation accuracy of complex sewing patterns.

The operation information obtaining device <NUM> determines the poor condition of the sewing machine <NUM> based on the detection information <NUM> and the pattern information <NUM>, and may obtain the operation information <NUM> that may identify the poor condition. Therefore, the operation information obtaining device <NUM> may obtain the poor condition in the sewing pattern of the sewing machine <NUM> through the operation information <NUM>, thereby improving the convenience of the operation information <NUM>.

The operation information obtaining device <NUM> collects the detection information <NUM> of the sewing machine <NUM> that has executed the sewing pattern, and stores the pattern information <NUM> associating the detection information <NUM> with the sewing pattern in the storage portion <NUM>. Therefore, the operation information obtaining device <NUM> may store a plurality of different types of pattern information <NUM> in the storage portion <NUM>, thereby improving the estimation accuracy of sewing patterns based on the detection information <NUM>.

The operation information obtaining device <NUM> is configured as a detection device <NUM> capable of detecting the detection information <NUM> of the sewing needle <NUM> of the sewing machine <NUM>. Therefore, the operation information obtaining device <NUM> is configured to be assembled on the sewing machine <NUM> or configured to be provided outside the sewing machine <NUM>, thereby improving convenience.

The operation information obtaining method determines the sewing pattern of the sewing machine <NUM> based on the detection information <NUM> detected by the detection device <NUM> and the pattern information <NUM> in the storage portion <NUM>, and obtains the operation information <NUM> with the sewing pattern through a computer. Therefore, the operation information obtaining method obtains the operation information <NUM> having the estimated sewing pattern, which may contribute to the effective utilization of the operation information <NUM> of the sewing machine <NUM> compared to the traditional operation information with only the rotation start and stop of the main shaft and thread trimming.

In the above implementation, a situation where the operation information obtaining device <NUM> is a structure having detection device <NUM> is described, but is not limited to this. For example, the operation information obtaining device <NUM> may also be configured as not having the detection device <NUM>, and the detection information <NUM> may be obtained from the external detection device <NUM> provided on the device main body.

Claim 1:
An operation information obtaining device (<NUM>) attached to a sewing machine (<NUM>, <NUM>), comprising:
a detection device (<NUM>), for measuring detection information of a sewing needle of the sewing machine (<NUM>, <NUM>); the operation information obtaining device (<NUM>) being characterized by further comprising:
a storage portion (<NUM>), for storing pattern information associating detection information and a sewing pattern of the sewing machine (<NUM>, <NUM>), wherein the detection information represents pulse trains indicative of needle movement, used for identifying the sewing pattern that corresponds to the detection information;
an estimation portion (<NUM>), for estimating that a sewing pattern represented by the pattern information is the sewing pattern sewn by the sewing machine (<NUM>, <NUM>) when a consistency of a comparison of the pulse train represented by the measured detection information with the pulse train represented by the stored detection information in the storage portion (<NUM>) is higher than a determination threshold; and
an obtaining portion (<NUM>), for obtaining operation information of the sewing machine (<NUM>, <NUM>) sewing the estimated sewing pattern.