Patent ID: 12209342

The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.

DETAILED DESCRIPTION

In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.

Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

An embroidery system according to an embodiment of the present disclosure is described referring to the drawings.

Embroidery System

FIG.1is a schematic diagram illustrating an embroidery system300, according to an embodiment. The embroidery system300illustrated inFIG.1includes a liquid discharge apparatus100. The liquid discharge apparatus100may be an in-line embroidery apparatus. The liquid discharge apparatus100includes a supply reel102, a liquid application device103, a fixing device104, a post-processing device105, and an embroidery head106. A thread101is wound around the supply reel102. The thread101is a liquid application target member to which liquid is applied. The embroidery head106is an example of an embroidery forming section. The embroidery system300includes a dyeing device150and an embroidery device160. The dyeing device150includes a liquid application device103, the fixing device104, and the post-processing device105. The embroidery device160includes the embroidery head106.

The liquid discharge apparatus100includes a plurality of rollers, e.g., a roller108and a roller109, each guiding the thread101fed out from the supply reel102. The thread101fed out from the supply reel102is guided while contacting the outer circumferential surface of the roller108and the roller109and is conveyed to the embroidery head106. The thread101is continuously routed from the supply reel102to the embroidery head106.

FIG.2is a schematic diagram illustrating the liquid application device103of the liquid discharge apparatus100. The liquid application device103includes multiple liquid discharge heads and a maintenance unit2. The multiple liquid discharge heads include, for example, a liquid discharge head1a, a liquid discharge head1b, a liquid discharge head1c, and a liquid discharge head1d. In the following description, the liquid discharge head1a, the liquid discharge head1b, the liquid discharge head1c, and the liquid discharge head1dmay be collectively referred to as a “liquid discharge head1” or “liquid discharge heads1,” to simplify the description, unless they need to be distinguished from one to another. Each of the liquid discharge heads1discharges liquid of a desired color to the thread101. The liquid discharge head1a, the liquid discharge head1b, the liquid discharge head1c, and the liquid discharge head1drespectively discharge liquids of, for example, cyan (C), magenta (M), yellow (Y), and black (K). The liquid discharge head1is an example of a recording head.

The maintenance unit2includes multiple individual maintenance units20, e.g., an individual maintenance unit20a, an individual maintenance unit20b, an individual maintenance unit20c, and an individual maintenance unit20d.

The multiple individual maintenance units20performs maintenance for the liquid discharge heads1, respectively. Each of the individual maintenance units20performs maintenance operation to eliminate or reduce non-discharge, discharge bending, variation in discharge speed, and variation in discharge amount due to clogging of the liquid discharge heads1or thickening of ink, and to maintain or recover the discharge state. The individual maintenance units20may perform cleaning operations such as purging, dummy discharge, flushing, and wiping.

FIG.3is a bottom view illustrating the liquid discharge heads1of the liquid application device103. As illustrated inFIG.3, each of the liquid discharge heads1includes multiple nozzles11, each discharging liquid. The liquid discharge head1includes a surface12of a nozzle plate on which the nozzles11are formed. The nozzles11arranged in the conveyance direction of the thread101constitutes a nozzle row10. The liquid discharge heads1are arranged in the conveyance direction of the thread101.

As illustrated inFIG.1, the fixing device104is disposed downstream from the liquid application device103in the conveyance direction of the thread101. The thread101to which liquid is applied by the liquid application device103is fed to the fixing device104. The fixing device104performs a fixing process (a drying process) on the thread101to which liquid is applied. The fixing device104includes a heater that heats the thread101. Examples of the heater includes, but are not limited to, an infrared irradiator and a hot air sprayer. The fixing device104heats the thread101to dry the thread.

The post-processing device105is disposed downstream from the fixing device104in the conveyance direction of the thread101. The post-processing device105may include, for example, a cleaner, a tension adjuster, a feed amount detector, and a lubricant applier. The cleaner cleans the thread101. The tension adjuster adjusts tension of the thread101. The feed amount detector detects an amount of movement of the thread101. The lubricant applier applies a lubricant to the surface of the thread101.

The embroidery head106sews the thread101on a cloth, to form embroidery. The cloth is an example of a target object. The cloth is just one example of the target object. Other examples of the target object include, but are not limited to, a sheet-shaped object such as paper or leather.

The liquid discharge apparatus100may be applicable to not only to the embroidery apparatus but also to, e.g., an apparatus that uses a linear object such as a thread. Examples of the apparatus that uses the linear object include, but are not limited to, an apparatus such as a loom and a sewing machine.

Examples of the “thread” include glass fiber thread; wool thread; cotton thread; synthetic fiber thread; metallic thread; mixed thread of wool, cotton, polymer, or metal; and linear object (linear member or continuous base material) to which yarn, filament, or liquid can be applied. Examples of the “thread” also include braided cord and flatly braided cord.

Drive Waveform Applier

FIG.4is a block diagram illustrating the liquid discharge apparatus100. As illustrated inFIG.4, the liquid discharge head1includes multiple piezoelectric elements13. Further, the liquid discharge head1includes pressure chambers respectively communicating with the nozzles11. Each of the piezoelectric element13applies pressure to liquid in the corresponding pressure chamber, to cause ink in the pressure chamber to be discharged from the nozzle11.

The liquid discharge apparatus100includes a drive waveform applier400. The drive waveform applier400applies a drive waveform to the liquid discharge head1. The drive waveform applier400includes a head controller401, a drive waveform generator402, a waveform data storage403, a head driver410, and a discharge timing generator404. The discharge timing generator404generates a discharge timing pulse stb indicating a discharge timing. The elements in the drive waveform applier400may be implemented by circuitry. In particular, in this example, the head controller401may be referred as control circuitry.

In response to a reception of a discharge timing pulse stb, the head controller401outputs a discharge synchronization signal LINE that triggers generation of the drive waveform, to the drive waveform generator402. The head controller401outputs a discharge timing signal CHANGE to the drive waveform generator402. The discharge timing signal CHANGE corresponds to an amount of delay from the discharge synchronization signal LINE.

The drive waveform generator402generates a common drive waveform signal Vcom at a timing based on the discharge synchronization signal LINE and the discharge timing signal CHANGE.

The head controller401receives image data and generates a mask control signal MN according to the image data. The mask control signal MN is for selecting a predetermined waveform of the common drive waveform signal Vcom according to the size of the liquid droplet to be discharged from each of the nozzles11of each of the plurality of the liquid discharge heads1. The mask control signal MN is a signal at a timing synchronized with the discharge timing signal CHANGE.

The head controller401transmits image data SD, a synchronization clock signal SCK, a latch signal LT instructing latch of the image data, and the generated mask control signal MN to the head driver410.

The head driver410includes a shift register411, a latch circuit412, a gradation decoder413, a level shifter414, and an analog switch array415.

The shift register411receives (inputs) the image data SD and the synchronization clock signal SCK transmitted from the head controller401. The latch circuit412latches each resister value received from the shift register411by the latch signal LT transmitted from the head controller401.

The gradation decoder413decodes a value (image data SD) latched by the latch circuit412and the mask control signal MN and outputs the result. The level shifter414converts a level of a logic level voltage signal of the gradation decoder413to a level at which an analog switch AS of the analog switch array415is operatable.

The analog switch AS of the analog switch array415is turned on or tuned off by an output from the gradation decoder413received via the level shifter414. The analog switch AS is provided for each of the nozzles11of the liquid discharge head1and is coupled to an individual electrode of each of the piezoelectric elements13corresponding to each of the nozzles11. The common drive waveform signal Vcom from the drive waveform generator402is input to the analog switch AS. Further, as described above, the timing of the mask control signal MN is synchronized with the timing of the common drive waveform signal Vcom.

Therefore, the analog switch AS is switched between on and off timely in accordance with the output from the gradation decoder413via the level shifter414. With this operation, the waveform to be applied to the piezoelectric element13corresponding to each of the nozzles11is selected from the drive waveforms forming the common drive waveform Vcom. As a result, the size of the droplet discharged from the each of the nozzles11is controlled.

The discharge timing generator404generates and outputs the discharge timing pulse stb each time the thread101is moved by a predetermined amount, on the basis of the detection result of the rotary encoder405that detects a rotation amount of the roller109illustrated inFIG.1. The rotary encoder405includes an encoder wheel405athat rotates together with the roller109and an encoder sensor405bthat reads the slit in the encoder wheel405a.

The thread101is conveyed (moved) as the thread is consumed in an embroidery operation by the embroidery head106that is provided downstream in the conveyance direction of the thread101. As the thread101is fed, the roller109guiding the thread101rotates to rotate the encoder wheel405aof the rotary encoder405. The encoder sensor405bgenerates and outputs an encoder pulse proportional to the linear velocity of the thread101.

The discharge timing generator404generates the discharge timing pulse stb on the basis of the encoder pulse from the rotary encoder405. The discharge timing pulse stb is used as the discharge timing of the liquid discharge head1. The application of liquid to the thread101is started as the thread101starts moving. Even if the linear speed of the thread101changes, the drive waveform, an interval of the discharge timing pulse stb changes according to the encoder pulse, whereby preventing deviation in a landing position of the ink droplet on the thread101.

Embroidery Data Creation Section

Referring toFIG.5, a description is now provided of an embroidery data creation section200. As illustrated inFIG.5, the embroidery system300includes an embroidery data creation section200. The embroidery data creation section200includes a data reading device210and a processor220. The embroidery data creation section200creates embroidery data from original data as a source of embroidery. The embroidery data creation section200outputs the created embroidery data to the liquid discharge apparatus100. Alternatively, the liquid discharge apparatus100may include the embroidery data creation section200.

Data Reading Device

The data reading device210illustrated inFIG.5reads three-dimensional data of an object as a source of embroidery (a design of embroidery). The data reading device210may be, for example, a three-dimensional scanner. Alternatively, the data reading device210may be a camera, for example. The data reading device210may include, for example, a memory that stores data. The data reading device210can acquire the original data.

Original Data

The original data is, for example, data relating to an object as a source of embroidery (a design of embroidery). The original data includes three-dimensional information of the object as the source of embroidery. The three-dimensional information (3D data) includes two-dimensional information (2D data) and height information. The original data may include image data (original picture data) relating to a photograph obtained by photographing an object as the source of embroidery. The image data includes data relating to a color of the object as the source of embroidery. The image data may include other information than the data relating to color.

Three-Dimensional Information

The three-dimensional information includes, for example, information on positions in an X-axis direction, a Y-axis direction, and a Z-axis direction orthogonal to each other.

Two-Dimensional Information

The two-dimensional information includes data of, for example, a position and a shape of the object as the source of embroidery (the design of embroidery). The two-dimensional information includes information on positions in the X-axis direction and the Y-axis direction.

Height Information

The height information is information relating to a height of the object as a source of embroidery (a design of embroidery). The height information may be information relating to a height from a reference position of the object as the source of embroidery. The height information includes information on a position in the Z-axis direction. The height information may be information relating to a thickness of the object as the source of embroidery.

FIG.6is a schematic diagram illustrating an example of data contained in the three-dimensional information of a model M as a source of embroidery.FIG.7is a cross-sectional view of the model as a source of embroidery along a height direction of the model M. The model M is an example of an object. The data as illustrated inFIG.6can be acquired by reading the model M as the source of embroidery by the data reading device210. The data illustrated inFIG.6includes two-dimensional information indicating a shape of the model M and height information of an area R1, an area R2, and an area R3included in the model M.

The model M includes multiple areas, e.g., the area R1, the area R2, and the area R3. The model M is divided into the multiple areas, e.g., the area R1, the area R2, and the area R3according to the height information. The area R1is, for example, a portion that forms a circular shape at the center.

The area R2is an annular portion surrounding the area R1. The area R3is an annular portion surrounding the area R2.

As illustrated inFIG.7, a height H1of the area R1is higher than a height H2of the area R2. The height H2of the area R2is higher than a height H3of the area R3. The height information includes the heights H1to H3of the areas R1to R3. The height H1of the area R1may be a height that is highest in the area R1. The height H2of the area R2may be an average height of the area R2. The height H3of the area R3may be a height that is lowest in the area R3.

InFIG.6, the height information is expressed by, for example, gradation. The lower the value of the height information, the lighter the gradation color. The higher the value of the height information, the darker the gradation color. The area R1is illustrated in a darker color than the area R2and the area R3. The area R2is illustrated in a darker color than the area R3.

Embroidery Data

Embroidery data includes coordinates indicating a position at which a needle of the embroidery head106is to be inserted and data indicating an order in which the needle is to be inserted. The embroidery data may be continuous data relating to the order in which the needle is to be inserted.

The embroidery data is data containing embroidery parameters such as a thread density (embroidery density) and a sewing direction. The embroidery data further includes data relating to an amount of liquid droplets to be applied to the thread used for embroidery. The embroidery data may include data relating to a stitch width. The stitch width may be set according to the height information.

The embroidery data is data in which data of coordinates to which the needle is to be moved is associated with items to be executed at the corresponding coordinates. Examples of the items to be executed at the corresponding coordinate include operation such as: (1) inserting the needle into a cloth to catch the lower thread and then return the needle to the surface of the cloth; (2) after the operation of (1), moving the needle to the next position at which the needle is to inserted; (3) cutting the thread to end the embroidery; and (4) moving the needle to an initialization position.

Thread Density

FIG.8is a cross-sectional view of an example of a thread density in embroidery. A density of the thread101may be, for example, the number of threads101in a predetermined area. The density of the thread101may be, for example, a thickness of the thread101in a predetermined area. The density of the thread101may be a value indicating whether the value is larger or smaller than a reference value.

The density of the thread101is changeable according to the height information. For example, the thread density in an area R31that corresponds to the area R1is, for example, a thread density D1. The thread density in an area R32that corresponds to the area R2is, for example, a thread density D2. The thread density in an area R33that corresponds to the area R3is, for example, a thread density D3. The thread density D1, the thread density D2, and the thread density D3are higher in the order of the thread density D3, the thread density D2, and the thread density D1.

The thread density D1of the area R31in which the value of the height information is small is higher than the thread density D2and the thread density D3of the area R32and the area R33in which the value of the height information is smaller than the value of the height information of the area R31. The thread density D3of the area R33in which the value of the height information is small is lower than the thread density D1and the thread density D2of the area R31and the area R32in which the value of the height information is larger than the value of the height information of the area R33. The values of the thread densities are greater (D1>D2>D3) in descending order of the height information (H1>H2>H3).

Processor

The processor220acquires data from the data reading device210and processes the acquired data.

The processor220may be, for example, an image processor, and may be referred to as processing circuitry. The processor220includes, for example, a central processing unit (CPU)221, a read only memory (ROM)222, and a random access memory (RAM)223. The processor220performs data processing, to create the embroidery data from the image data.

The processor220can determine the embroidery parameter according to the height information included in the original data. The processor220reflects the embroidery parameter in the embroidery data.

When the value of the height information included in the original data is large, the processor220can set the thread density higher than when the value of the height information included in the original data is small. When the value of the height information indicates a first height, the processor220can set the thread density to a first density. When the value of the height information indicates a second height, which is higher than the first height, the processor220can set the thread density to a second density, which is higher than the first density. The processor220can set the thread density to be higher as the value of the height information is larger. The processor220can set the thread density to be lower as the value of the height information is smaller.

As illustrated inFIG.8, the thread density D1of the area R31in which the value of the height information (height H1) is the largest is higher than the thread density D2and the thread density D3of the area R32and the area R33in which the values of the height information (height H2and height H3) are lower than the value of the height information of the area R31. In other words, D1>D2>D3. The thread density D3of the area R33in which the value of the height information (height H3) is the smallest is lower than the thread density D1and the thread density D2of the area R31and the area R32in which the values of the height information (height H1and height H2) are larger than the value of the height information of the area R33. The processor220can thus set the thread density D1, the thread density D2, and the thread density D3according to the height information.

The processor220can set an application amount of liquid droplets to be applied to the thread101. When the density of the thread101is a first density, the processor220can set the application amount of the liquid droplets to a first application amount. When the density of the thread101is a second density, which is higher than the first density, the processor220can set the application amount of the liquid droplets to a second application amount, which is larger than the first application amount. The processor220can set the amount of liquid droplets to be larger in an area where the density of the thread101is higher. The processor220can set the amount of liquid droplets to be smaller in an area where the density of the thread101is lower.

The embroidery data creation section200outputs the created embroidery data to the liquid discharge apparatus100. The liquid discharge head1can discharge liquid droplets according to the application amount of the liquid droplets set in the embroidery data. The embroidery data includes data relating to a color of the liquid droplets and data relating to the discharge amount.

Embroidery Head

The embroidery head106inserts a needle into a cloth120to cause to catch a lower thread. The embroidery head106returns the needle to the surface of the cloth120. The embroidery head106moves the needle to a position at which the needle is to be inserted next. The embroidery head106inserts the needle to adjust an arrangement interval of the threads101so that the thread density set by the embroidery data is implemented.

Embroidery Data Creation

Referring toFIG.9, a description is now provided of an operation of creating embroidery data.FIG.9is a flowchart illustrating an operation of creating embroidery data. First, the data reading device210acquires an embroidery model (the model M) as a source of embroidery. The data reading device210reads three-dimensional information of the embroidery model. The three-dimensional information includes the two-dimensional information (2D data) and the height information (height data) as described above.

As illustrated inFIG.9, the processor220inputs (receives) the two-dimensional information from the data reading device210(step S21). The processor220extracts an area for which embroidery is to be performed (step S22). The processor220can extract, from the two-dimensional information, an area of an object as an embroidery target and an area of a background other than the object. The processor220can set the area of the object as the embroidery target as an area to be embroidered.

In step S23, the processor220creates stitch data to fill the area to be embroidered. The stitch data includes, for example, a stitch width and coordinates of a position where a needle is to be inserted.

The processor220inputs (receives) the height information from the data reading device210(step S24). The processor220divides the model M to the area R1, the area R2, and the area R3respectively for the height information items (height H1, height H2, and height H3). The height information is associated with, for example, coordinate data, which is two-dimensional information. The processor220sets the thread density according to the height information (step S25). The processor220can set the thread density to be higher as the value of the height information is higher. The processor220sets the thread density R1, the thread density R2, and the thread density R3respectively for the area D1, the area D2, and the area D3. The processor220creates the embroidery data other than the thread density (step S26). The processor220may create the embroidery data so as to set color information for each of the areas. The processor220can create inkjet printing data from the color information and the embroidery data. The processor220can output the embroidery data and the printing data to the head controller401of the liquid discharge apparatus100.

Operation Control of Liquid Discharge Head

The head controller401controls operation of the liquid discharge head1to cause liquid to adhere to the thread101according to the embroidery data (printing data). The head controller401controls operation of the liquid discharge head1to adjust an amount of liquid discharged onto the thread101according to the stitch width W included in the embroidery data.

In one example, the head controller401controls the operation of the liquid discharge head1so that the higher the thread density, the greater the discharge amount of the liquid. The head controller401controls the operation of the liquid discharge head1so that the lower the thread density, the smaller the discharge amount of the liquid.

The head controller401controls the operation of the liquid discharge head1to adjust an amount of liquid droplets to be applied to the thread according to the embroidery data. The head controller401controls the operation of the liquid discharge head1so that the application amount of the liquid droplets is set to the first application amount when the density of the thread is the first density, and the application amount of the liquid droplets is set to the second application amount, which is larger than the first application amount, when the density of the thread is the second density, which is higher than the first density. The head controller401controls the operation of the liquid discharge head1so that the application amount of liquid droplets is larger in an area where the density of the thread is higher. The head controller401controls the operation of the liquid discharge head1so that the application amount of liquid droplets is smaller in an area where the density of the thread is lower.

Operation Control of Embroidery Head

The head controller401controls operation of the embroidery head106to form an embroidery according to the embroidery data.

According to the embroidery system300of the present embodiment, the data reading device210reads original data, and a thread density is set on the basis of height information of an object, the height information being included in the original data. Further, an application amount of liquid droplets to be applied to the thread is set to the first application amount when the thread density is the first density, and the application amount of the liquid droplets to be applied to the thread is set to the second application amount, which is larger than the first application amount, when the thread density is the second density, which is higher than the first density. The embroidery system300can set the application amount of the liquid droplets to be larger in an area where the density of the thread is higher. Further, the embroidery system300can set the application amount of the liquid droplets to be smaller in an area where the density of the thread is lower. A height can be expressed in an embroidery that is formed by the embroidery system300according to the embroidery data.

Further, in the embroidery system300, when the value of the height information indicates the first height, the processor220can set the thread density to the first density. When the value of the height information indicates the second height, which is higher than the first height, the processor220can set the thread density to the second density, which is higher than the first density. Thus, the embroidery system300can increase the thread density and the application amount of liquid droplets as the height of a part of an object as a source of the embroidery (a design of embroidery) increases. The embroidery system300can decrease the thread density and the application amount of liquid droplets as the height of a part of an object as a source of the embroidery decreases. As a result, the thread density and the shade of a color of the thread change on the basis of the height information, thereby making a difference in height stand out in the formed embroidery. According to the embroidery system300, an embroidery having a more three-dimensional texture can be created.

Further, according to the embroidery system300, the liquid discharge head1includes a pressure chamber that applies pressure to a liquid droplet. The liquid discharge apparatus100discharges a liquid droplet to which pressure is applied from the nozzle11and cause the liquid droplet to adhere to the thread101. Such an application of the liquid discharge head1of an inkjet type makes it possible to discharge ink with high accuracy and color the thread101. The liquid discharge apparatus100can create an embroidery in which a color changes in one surface area such as gradation expression. This configuration enhances the range of design and expression by embroidery.

In the related art, a single-color thread that is uniformly dyed in advance is typically used for embroidery. According to the liquid discharge apparatus100, unlike the embroidery of the related art, a thread does not have to be switched (in other words, a needle does not have to be inserted) for color switching, the degree of freedom in how a needle is inserted is enhanced. This enhances the degree of freedom of an embroidery pattern. The liquid discharge apparatus100can further enhance the expressiveness of embroidery based on photograph data having a wide range of colors.

The liquid discharge apparatus100including the liquid discharge head1of an inkjet type can enhance a degree of freedom of a sewing method in addition to widening the range of colors, thereby enhancing a texture and a three-dimensional effect of embroidery.

In the related art, an embroidery data creation apparatus just forms embroidery according to embroidery data. Height is not expressed in the formed embroidery.

According to one embodiment of the present disclosure, an embroidery system is provided that forms embroidery according to embroidery data, wherein height is expressed in the formed embroidery.

The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.

The functionality of the elements disclosed herein may be implemented using circuitry or processing circuitry which includes general purpose processors, special purpose processors, integrated circuits, application specific integrated circuits (ASICs), digital signal processors (DSPs), field programmable gate arrays (FPGAs), conventional circuitry and/or combinations thereof which are configured or programmed to perform the disclosed functionality. Processors are considered processing circuitry or circuitry as they include transistors and other circuitry therein. In the disclosure, the circuitry, units, or means are hardware that carry out or are programmed to perform the recited functionality. The hardware may be any hardware disclosed herein or otherwise known which is programmed or configured to carry out the recited functionality. When the hardware is a processor which may be considered a type of circuitry, the circuitry, means, or units are a combination of hardware and software, the software being used to configure the hardware and/or processor.