Patent ID: 12258693

DETAILED DESCRIPTION

An embodiment of the disclosure will be described with reference to the drawings. Physical configurations of a sewing machine1, an embroidery device40, and a foot controller90will be described with reference toFIGS.1A and1B. An up-down direction, a lower left side, an upper right side, an upper left side, and a lower right side in each ofFIGS.1A and1Bindicate an up-down direction, a front side, a rear side, a left side, and a right side of the sewing machine1and the embroidery device40, respectively. A longitudinal direction of a bed11and an arm13is a left-right direction of the sewing machine1. The side on which the upright arm12is disposed is the right side. A direction in which the upright arm12extends is the up-down direction of the sewing machine1. InFIG.1B, a presser foot is omitted.

As illustrated inFIGS.1A and1B, the sewing machine1includes a bed11, an upright arm12, an arm13, a head14, and a sewing unit9. The bed11is a base of the sewing machine1that extends in the left-right direction. The bed11includes a needle plate10. The sewing machine1includes a lower shaft, a feed mechanism, a retraction mechanism, and a shuttle mechanism in the bed11. The feed mechanism includes a feed dog. The feed dog moves a workpiece backward or forward during sewing of a utility stitch pattern. The retraction mechanism retracts the feed dog below an upper surface of the needle plate10during embroidery sewing. The shuttle mechanism having a known configuration is driven with the rotation of the lower shaft. The upright arm12extends upward from a right end of the bed11. The upright arm12has, on its front surface, an LCD15and a touch screen16.

The sewing machine1includes a terminal17on a right surface of the upright arm12. The terminal17is a terminal for connecting the foot controller90to the sewing machine1. The terminal17can be used for connecting an external device to the sewing machine1to which the foot controller90is not connected.FIG.1Aillustrates that the embroidery device40is connected to the sewing machine1as an external device, andFIG.1Billustrates that the foot controller90is connected to the sewing machine1. The foot controller90includes a pedal91, a cord92, and a connector93. The foot controller90changes the sewing speed of the sewing machine1by outputting speed data, which corresponds to how far the user depresses the pedal91, to the sewing machine1, in addition to instructing the sewing machine1to start sewing when the user depresses the pedal91.

The arm13faces the bed11and extends leftward from the upper end of the upright arm12. The head14is connected to the left end of the arm13. The sewing unit9includes a needle bar8and a sewing machine motor37, and is configured to drive the needle bar8in the up-down direction with the power of the sewing machine motor37for forming stitches. A needle7is detachably attached to a lower end of the needle bar8. A presser bar6is disposed behind the needle bar8. A presser foot5is detachably attached to a lower end of the presser bar6. A start/stop switch29is provided on the front surface of the head14. The start/stop switch29is used to start or stop the operation of the sewing machine1, that is, to input an instruction to start or stop sewing.

The embroidery device40includes a moving unit41, an LCD51, a switch52, a cord53, and a connector54. The embroidery device40is disposed to the left of the sewing machine1, and is configured to move a workpiece, which is held by an embroidery hoop20, relative to the needle bar8when the connector54is electrically connected to the terminal17of the sewing machine1. The moving unit41is configured to move the embroidery hoop20, which holds the workpiece taut, relative to the needle bar8. The moving unit41includes a main body case18and a carriage19. The main body case18houses an X-movement mechanism (not shown) that includes an X-axis motor81(refer toFIG.2) for moving the embroidery hoop20in the left-right direction. The carriage19houses a Y movement mechanism (not shown) that includes a Y-axis motor82(refer toFIG.2) for moving the embroidery hoop20in the front-rear direction. At the time of embroidery sewing, the user attaches one embroidery hoop20selected from a plurality of types of embroidery hoops having different sizes to the carriage19. The embroidery hoop20is moved by the Y movement mechanism and the X movement mechanism to a needle drop point indicated by an XY coordinate system (embroidery coordinate system) specific to the embroidery device40. The needle drop point is a point at which the needle7attached to the sewing machine1drops when the sewing unit9is driven. The sewing machine1forms an embroidery pattern on the workpiece held by the embroidery hoop20by driving the sewing unit9in conjunction with the movement of the embroidery hoop20by the embroidery device40.

Referring toFIG.2, an electrical configuration of the sewing machine1and the embroidery device40will be described. The sewing machine1includes a CPU2, a ROM22, a RAM23, a storage24, and an input/output (I/O) interface26. The CPU2is connected via a bus25to the ROM22, the RAM23, the storage24and the I/O interface26. The I/O interface26is connected to drive circuits31and32, an encoder38, a touch screen16, a start/stop switch29, and an IF circuit35. The storage24stores various setting values. The CPU2is configured to control the sewing unit9.

The drive circuit31is connected to the sewing machine motor37. The drive circuit31drives the sewing machine motor37in accordance with a control signal from the CPU2. As the sewing machine motor37is driven, a needle bar drive mechanism of the sewing unit9is driven, and the needle bar8is driven in the up-and-down direction. The encoder38detects a rotation position and a rotation speed of an output shaft of the sewing machine motor37and inputs a detection result to the I/O interface26. The CPU2specifies the position of the needle bar8in the up-down direction using the detection result of the encoder38. The drive circuit32allows the LCD15to display an image in accordance with a control signal from the CPU2. The IF circuit35is electrically connected to the terminal17.

The embroidery device40includes a CPU3, a ROM62, a RAM63, a storage64and an input/output (I/O) interface66. The CPU3is connected via a bus65to the ROM62, the RAM63, the storage64and the I/O interface66. The I/O interface66is connected to an IF circuit71, drive circuits72,73, and74, encoders83and84, and a switch52. The storage64stores various setting values. The storage64stores a plurality of sewing data each corresponding to a pattern that is candidate for a pattern to be sewn by the embroidery device40. The sewing data includes coordinate data. The coordinate data represents coordinates of needle drop points for forming a plurality of stitches for an embroidery pattern in an embroidery coordinate system of the embroidery device40. The CPU3is configured to control the moving unit41.

The IF circuit71is electrically connected to the terminal17. The drive circuit72is connected to the X-axis motor81. The drive circuit73is connected to the Y-axis motor82. The drive circuit72drives the X-axis motor81in accordance with a control signal from the CPU2, and drive circuit73drives the Y-axis motor82in accordance with a control signal from the CPU2. As the X-axis motor81and the Y-axis motor82are driven, the embroidery hoop20attached to the embroidery device40moves in the left-right direction (X direction) and the front-rear direction (Y direction) by a movement amount corresponding to the control signal. The encoder83detects a rotation position and a rotation speed of an output shaft of the X-axis motor81and inputs detection results to the I/O interface66. The encoder84detects a rotation position and a rotation speed of an output shaft of the Y-axis motor82and inputs detection results to the I/O interface66. The switch52detects various instructions and inputs detection results to the I/O interface66. The CPU3specifies a current position of the embroidery hoop20in the embroidery coordinate system using the detection results of the encoder83,84.

Referring toFIG.3, the IF circuit35of the sewing machine1and the IF circuit94of the foot controller90will be described. The IF circuit35includes an analog port AP1, an analog port AP2, an output port OP1, an output port OP2, a power supply line L1, a ground line L2, a pull-up resistor R1, and a pull-up resistor R2. The power supply line L1is connected to the analog port AP1, and carries +5V via the pull-up resistor R1(e.g., about 4.7 kΩ). The ground line L2carries +5V via the pull-up resistor R2(e.g., about 200Ω). The output port OP1is connected to the analog port AP1, and the output port OP2is connected to the analog port AP2.

The IF circuit94of the foot controller90includes a power supply line L3, a ground line L4, a diode95, a resistor R3, and a variable resistor R4. The diode95that is used for rectification is located between the power supply line L3and the ground line L4such that its cathode is connected to the power supply line L3and its anode is connected to the ground line L4, and connected in parallel with the resistor R3(e.g., about 1 kΩ) and the variable resistor R4(e.g., maximum resistance value: about 50 kΩ). The variable resistor R4has a resistance value that varies in a range from approximately 0Ω to approximately 50 kΩ in accordance with how far the user depresses the pedal91(refer toFIG.1). The power supply line L3is connected to the analog port AP1via the connector93, the terminal17, and the power supply line L1. The power supply line L4is connected to the analog port AP2via the connector93, the terminal17, and the power supply line L2.

Referring toFIG.4, the IF circuit71of the embroidery device40will be described. The IF circuit71includes a power supply line L5, a ground line L6, diodes101and102, a photocoupler100, resistors R5to R10, and field-effect transistors (FETs)111,112, and113. The photocoupler100is composed of a light emitting element103such as a light emitting diode and a light receiving element114such as a transistor. The diode101and the light emitting element103are located between the power supply line L5and the ground line L6such that their cathodes face toward the power supply line L5and their anodes face toward the ground line L6. The diode102is connected in parallel with the light emitting element103in a direction opposite to the light emitting element103. The diode102is provided for reverse voltage protection of the photocoupler100.

The resistor R6(e.g., about 50 kΩ) is located in parallel with the diodes101and102and the light emitting element103between the power supply line L5and the ground line L6. The resistor R5(e.g., about 1 kΩ) is located on the power supply line L5and between the diode101and the resistor R6. The resistors R7and the FET111are located in parallel with the resistor R6between the power supply line L5and the ground line L6. The resistors R8and the FET112are located in parallel with the resistor R6between the power supply line L5and the ground line L6. The resistors R9and the FET113are located in parallel with the resistor R6between the power supply line L5and the ground line L6. The ground line L6is grounded between the FET112and the FET113. The light receiving element114carries +5V at one end via a pull-up resistor R10(e.g., about 4.7 kΩ). The light receiving element114is grounded at the other end.

The embroidery device40outputs four kinds of speed data to the sewing machine1according to states of the FETs111to113between ON and OFF. When the FETs111to113are all OFF, the embroidery device40outputs zero sewing speeds, that is, an instruction to stop sewing, to the sewing machine1. When the FET111is ON and the FETs112and113are OFF, the embroidery device40outputs, to the sewing machine1, speed data indicating a low speed (e.g., a predetermined value within a range of 50 to 100 stitches per minute). When the FET111and the FET112are ON and the FET113is OFF, the embroidery device40outputs, to the sewing machine1, speed data indicating a medium speed (e.g., a predetermined value within a range of 100 to 200 stitches per minute). When the FETs111to113are all ON, the embroidery device40outputs, to the sewing machine1, speed data indicating a high speed (e.g., a predetermined value within a range of 200 to 500 stitches per minute). The CPU3of the embroidery device40detects a pulse width or pulse cycle of a pulse signal output from the sewing machine1using the photocoupler100to receive needle position data.

Referring toFIGS.5and6, a main process performed at the sewing machine1will be described. In the main process, operations related to a device with a connector connected to the terminal17are performed. When the connector54of the embroidery device40is connected to the terminal17, the sewing machine1performs embroidering an embroidery pattern on a workpiece held by the embroidery hoop20in cooperation with the embroidery device40, in accordance with the main process. The embroidery device40receives sewing data indicating a formation position of the embroidery pattern from the storage64in response to an instruction from the user. Sewing the embroidery pattern is started by pressing the start/stop switch29of the sewing machine1or the switch52of the embroidery device40. The CPU2starts the main process in response to detecting a start signal indicating that the user has connected the connector93of the foot controller90or the connector54of the embroidery device40to the terminal17. In response to detecting the start signal, the CPU2reads a program for performing the main process stored in a program storage area of the ROM22into the RAM23. The CPU2performs the following steps in accordance with instructions included in the program read into the RAM23. Hereinafter, step will be abbreviated as S. Various parameters used for performing the main process are stored in the storage24. Various kinds of data received in the main process are stored in the RAM23as appropriate. When the connector93of the foot controller90is connected to the terminal17, the foot controller90can input the speed data to the sewing machine1via the terminal17. When the connector54of the embroidery device40is connected to the terminal17, the sewing machine1and the embroidery device40can perform data input and output via the terminal17.

The CPU2determines whether the connector93of the foot controller90or the connector54of the embroidery device40is connected to the terminal17(S1). The CPU2determines that the connector54of the embroidery device40is connected in response to detecting a signal obtained by changing an analog voltage output at S31described later according to a predetermined rule. When the connector93of the foot controller90is connected to the terminal17(S1: NO), the CPU2sets a normal mode (S21). In the normal mode, the CPU2deactivates the start/stop switch29to input an instruction. The CPU2does not drive the retraction mechanism and allows the feed dog to transfer the workpiece. Until the CPU2receives an end instruction (S24: NO), the CPU2continues to receive the speed data for controlling the sewing speed from the foot controller90via the terminal17(S22). The value of the voltage output to the sewing machine1changes as the resistance value of the variable resistor R4of the IF circuit94changes in accordance with how far the pedal91of the foot controller90is depressed. The CPU2receives speed data by detecting a sewing speed using a voltage output from the foot controller90. The CPU2controls the sewing machine motor37in accordance with the received speed data (S23). To end the main process, the user of the sewing machine1inputs an end instruction on the touch screen16. In response to receiving the end instruction (S24: YES), the CPU2ends the main process.

When the connector54of the embroidery device40is connected to the terminal17(S1: YES), the CPU2sets an embroidery mode (S2). In the embroidery mode, the sewing machine1activates the start/stop switch29to input an instruction. The sewing machine1drives the retraction mechanism to move the feed dog below the needle plate10, thereby disabling transferring the workpiece by the feed dog. The CPU2transmits a signal indicating that the embroidery mode has been set to the embroidery device40via the terminal17, the connector54, and the cord53(S3). The CPU2outputs various signals to the embroidery device40according to patterns of a pulse signal switched between ON and OFF. Specifically, as illustrated inFIG.6, the CPU2changes a duty ratio like a signal J1, changes a cycle like a signal J2, or combines the change of the duty ratio and the change of the cycle, and outputs various signals as output data from the sewing machine1to the embroidery device40.

When the connector54of the embroidery device40is connected to the terminal17, the CPU2determines whether the position of the needle7in the up-down direction satisfies a predetermined criterion that the needle7is located above the needle plate10(S4). More particularly, the CPU2determines whether the current position of the lower end of the needle7in the up-down direction is at a needle upper position that is above the needle plate10and above the embroidery hoop20based on output results of the encoder38(S4). In response to determining that the position of the needle7in the up-down direction does not satisfy the predetermined criterion (S4: NO), the CPU2transmits an NG signal indicating that the position of the needle7in the up-down direction does not satisfy the sewing start condition, that is, the needle7is at a needle lower position below the upper end of the embroidery hoop20, to the embroidery device40via the terminal17, the connector54, and the cord53, and moves the needle bar8upward until the position of the needle7in the up-down direction satisfies the predetermined criterion (S5). The CPU2may control the LCD15to display a message prompting the user to raise the needle bar8before starting the operation of raising the needle bar8. The CPU2may perform the operation of S5in response to receiving a movement instruction from the user or the embroidery device40. The CPU2returns the operation to S4. In this manner, in response to determining that the position of the needle7in the up-down direction does not satisfy a predetermined criterion (S4: NO), the CPU2does not start a sewing-control operation. When the needle7is at the needle upper position (S4: YES), the CPU2transmits an OK signal indicating that the position of the needle7in the up-down direction satisfies the sewing start condition to the embroidery device40(S6). As illustrated by a signal J3inFIG.6, the CPU2interprets the OK signal as an ON signal and the NG signal as an OFF signal.

The CPU2waits until it receives an installation completion signal indicating that the embroidery device40has been installed from the embroidery device40via the connector54and the terminal17(S7: NO). In response to receiving the installation completion signal (S7: YES), the CPU2determines whether it receives an instruction to start embroidering (S8). In response to detecting pressing of the start/stop switch29, the CPU2determines that it has received an instruction to start embroidering, and transmits a start signal to the embroidery device40via the terminal17and the connector54. Alternatively, the CPU2determines that it has received the instruction to start embroidering in response to detecting the start signal transmitted from the embroidery device40by pressing of the switch52. The CPU2waits until it receives the instruction to start embroidering stands by until an instruction to start embroidering (S8: NO). In response to receiving the instruction to start embroidering (S8: YES), the CPU2determines whether embroidering is feasible (S9). The CPU2determines that embroidering is infeasible when there is no upper thread, there is no lower thread, or the upper end of the feed dog is above the needle plate10. When the embroidering is infeasible (S9: NO), the CPU2transmits an error to the embroidery device40, allows the LCD15to display a description on the error (S10), and returns the operation to S9. The user reads the description on the error displayed on LCD15, and performs an operation to cancel the error.

When the embroidering is feasible (S9: YES), the CPU2transmits a signal to start embroidering to the embroidery device40(S11). The CPU2receives speed data outputted from the embroidery device40(S12). At S12, the CPU2receives the speed data by detecting the sewing speed using the voltage output from the embroidery device40in the same manner as the operation of S22. The CPU2drives the sewing machine motor37at a speed corresponding to the speed data received at S12, moves the needle bar8from the upper end position to the lower end position in its movable range, and then returns the needle bar8to the upper end position again (S13). By repeating operations of S12to S15, the CPU2controls the sewing unit9in synchronization with the moving unit41of the embroidery device40in accordance with the speed data to embroider the embroidery pattern on the workpiece.

The CPU2determines whether to end embroidering in accordance with the speed data output from the embroidery device40(S14). When the speed data is data indicating a stop of sewing, the CPU2determines to end embroidering. In response to determining not to end embroidering (S14: NO), the CPU2outputs needle position data corresponding to the position of the needle7in the up-down direction to the embroidery device40(S15), and returns the operation to S12. At S15different from the operations of S5and S6, the CPU2interprets the needle position data indicating that the lower end of the needle7is above the upper end of the needle plate10as an OK signal, and interprets the needle position data indicating that the lower end of the needle7is below the upper end of the needle plate10as an NG signal.

In response to determining to end embroidering (S14: YES), the CPU2stops driving the sewing machine motor37(S16), and determines whether an instruction to end the main process has been received (S17). When the instruction to end the main process has not been received (S17: NO), the CPU2returns the operation to S8. To end the main process, the user of the sewing machine1inputs an end instruction on the touch screen16. In response to receiving the end instruction (S17: YES), the CPU2ends the main process.

Referring toFIG.7, a main process performed at the embroidery device40will be described. In the main process, operations for embroidering an embroidery pattern on a workpiece held by the embroidery hoop20in cooperation with the sewing machine1are performed. The CPU3starts the main process in response to detecting a start signal indicating that the user has connected the connector54of the embroidery device40to the terminal17. In response to detecting the start signal, the CPU3reads a program for performing the main process stored in a program storage area of the ROM62into the RAM63. The CPU3performs the following steps in accordance with instructions included in the program read into the RAM63. Hereinafter, step will be abbreviated as S. Various parameters used for performing the main process are stored in the storage64. Various kinds of date received in the main process are stored in the RAM63as appropriate.

As illustrated inFIG.7, the CPU3starts an operation for outputting a signal indicating that the embroidery device40is connected to the sewing machine1to the sewing machine1(S31). The CPU3outputs a signal indicating that the embroidery device40is connected to the sewing machine1by outputting a signal obtained by changing an analog voltage according to a predetermined rule via the connector54and the terminal17. The CPU3waits until it receives a signal indicating that the embroidery mode has been set in the sewing machine1from the sewing machine1(S32: NO).

The photocoupler100of the IF circuit71outputs a pulse signal to the CPU3in accordance with output data corresponding to a combination of on and off signals of an analog voltage output from the sewing machine1. The CPU3detects a pulse width or pulse cycle of the pulse signal received via the photocoupler100, and determines what the data output from the sewing machine1represents based on the detected results. In response to receiving a signal indicating that the embroidery mode has been set from the sewing machine1(S32: YES), the CPU3stops the operation started at S31(S33). The CPU3waits until it receives the needle position information in accordance with the data output from the sewing machine1(S34: NO). In response to receiving the needle position data (S34: YES), the CPU3determines whether the embroidery hoop20is movable in accordance with the needle position data (S35). When the needle position signal is an NG signal (that is an OFF signal) (S35: NO), the CPU3transmits a movement instruction to raise the needle bar8to the needle upper position to the sewing machine1(S36), and returns the operation to S34. The CPU3transmits various instructions to the sewing machine1by outputting a signal obtained by changing an analog voltage according to a predetermined rule via the connector54and the terminal17. Instead of transmitting the movement instruction, the CPU3may allow the LCD51to display a message prompting the user to raise the needle bar8to a position at which the embroidery hoop20can move as S36.

When the needle position data is an OK signal (that is an ON signal) (S35: YES), the CPU3controls the drive circuits72and73to move the embroidery hoop20to an initial position of the embroidery hoop20that the sewing data indicates (S37). Based on the detection results of the encoders83and84, the CPU3determines whether the embroidery hoop20has been moved to the initial position indicated in the sewing data. After moving the embroidery hoop20to the initial position, the CPU3outputs a signal indicating that the embroidery hoop20is at the initial position to the sewing machine1(S38).

The CPU3waits until it detects an instruction to start embroidering (S39: NO). In response to receiving the start signal transmitted from the sewing machine1upon pressing of the start/stop switch29, the CPU3determines that it has received the instruction to start embroidering. Alternatively, in response to detecting the start signal transmitted from the embroidery device40upon pressing of the switch52, the CPU3determines that it has received the instruction to start embroidering, and transmits the start signal to the sewing machine1via the connector54and the terminal17. In response to detecting the instruction to start embroidering (S39: YES), the CPU3transmits speed data to the sewing machine1(S40).

The CPU3determines whether it has received an error signal output from the sewing machine1(S41). In response to receiving the error signal (S41: YES), the CPU3allows the LCD51to display an error cancellation instruction (S42). In response to the error cancellation instruction, the CPU3allows the LCD51to display a message prompting the user to cancel the error. The CPU3returns the operation to S41. In response to not receiving the error signal (S41: NO), the CPU3starts embroidering (S43).

The CPU3transmits speed data to the sewing machine1(S44). The CPU3waits until it receives the needle position data from the sewing machine1(S45: NO). In response to receiving the needle position data (S45: YES), the CPU3determines whether the embroidery hoop20is movable in the same manner as at S35(S46). In response to determining that the embroidery hoop20is movable (S46: YES), the CPU3controls the drive circuits72and73to move the embroidery hoop20to a needle drop position indicated in the sewing data (S47). Through the operations of S45to S47, the CPU3controls the moving unit41to move the embroidery hoop20relative to the needle bar8during a period in which the embroidery hoop20is movable, in accordance with the needle position data output from the sewing machine1via the connector54. Based on the detection results of the encoders83and84, the CPU3determines whether the embroidery hoop20has moved to the needle drop point indicated in the sewing data. The CPU3returns the operation to S44.

In response to determining that the embroidery hoop20is not movable (S46: NO), the CPU3determines whether embroidering has been completed in accordance with the sewing data (S48). In response to determining that the embroidery hoop20has not moved to the last needle drop point indicated in the sewing data, that is, embroidering has not been completed (S48: NO), the CPU3reads a next needle drop point indicated in the sewing data and returns the operation to S45. In response to determining that the embroidery hoop20has moved to the last needle drop point indicated in the sewing data (S48: YES), the CPU3transmits a signal indicating that embroidering has been completed to the sewing machine1(S49). The CPU3determines whether it has received an instruction to end the main process (S50). In response to not receiving the end instruction (S50: NO), the CPU3returns the operation to S39. In response to receiving the end instruction (S50: YES), the CPU3ends the main process.

Referring toFIG.8, an IF circuit135which is a modification of the IF circuit35will be described. InFIG.8, the same components as those of the IF circuit35are denoted by the same reference numerals, and descriptions thereof will be omitted below. As illustrated inFIG.8, the IF circuit135includes an analog port AP1, an analog port AP2, a communication port IF1, a communication port IF2, an output port OP1, an output port OP2, an output port OP3, an output port OP4, a power supply line L1, a ground line L2, a pull-up resistor R1, a pull-up resistor R2, a switch SW1, and a switch SW2. The output port OP1is connected to the analog port AP1, and the output port OP2is connected to the analog port AP2.

The switch SW1is connected to the analog port AP1, and switches connection of the IF circuit135to the CPU2of the sewing machine1between the analog port AP1and the communication port IF1in accordance with the detection result. The switch SW2is connected to the analog port AP2, and switches connection of the IF circuit135to the CPU2of the sewing machine1between the analog port AP2and the communication port IF2in accordance with the detection result. The switches SW1and SW2are each configured by, for example, a FET, a logic IC, or other semiconductor device. The embroidery device40has components similar to the switches SW1and SW2, and the communication ports IF1and IF2. The communication ports IF1and IF2each include a general-purpose communication standard (UART, I2C, differential-signal), and enable two-way communication between the sewing machine1and the embroidery device40. The output ports OP3and OP4are provided separately from the output ports OP1and OP2and are each used to output a signal for controlling the embroidery device40.

The IF circuit135of the modification switches control circuits in the CPU2of the sewing machine1depending on whether the connector93of the foot controller90or the connector54of the embroidery device40is connected to the terminal17. In the main process of the sewing machine1including the IF circuit135of the modification, the operations are performed by switching control circuits in the CPU2of the sewing machine1depending on whether the connector93of the foot-controller90or the connector54of the embroidery device40is connected to the terminal17.

In the above-described embodiments, the sewing machine1, the CPU2, the needle7, the needle bar8, the sewing unit9, the needle plate10, the terminal17, the start/stop switch29, and the sewing machine motor37are examples of a sewing machine, a control unit, a needle, a needle bar, a sewing unit, a needle plate, a terminal, an input unit, and a sewing machine motor of the disclosure, respectively. The embroidery device40, the moving unit41, the CPU3, the switch52, and the embroidery hoop20are examples of an embroidery device, a moving unit, an embroidery control unit, an input unit, and an embroidery hoop of the disclosure, respectively. The foot controller90is an example of a foot controller of the disclosure. The operation of S22is an example of a speed-data receiving operation of the disclosure. The operation of S23is an example of a speed-control operation of the disclosure. The operations of S8and S12are each an example of an input-data receiving operation of the disclosure. The operations of S3, S5, S6, S10, and S15are each an example of a data-outputting operation. A series of operations of S11to S16is an example of a sewing-control operation of the disclosure. The operation of S1is an example of a device-determination operation of the disclosure. The operation of S39is an example of an instruction-outputting operation of the disclosure. The operation of S4is an example of a height-determination operation of the disclosure. The operation of S5is an example of a moving operation of the disclosure.

The sewing machine1of the above-described embodiment includes the sewing unit9, the terminal17, and the CPU2. The sewing unit9includes the needle bar8having the lower end to which the needle7is attachable, and the sewing machine motor37. The sewing unit9drives the needle bar8in the up-down direction with power of the sewing machine motor37for forming stitches. The terminal17is a single terminal17for connecting the foot controller90to the sewing machine1, and can be connected to the connector54of the embroidery device40, which is an example of an external device, when the connector93of the foot controller90is not connected. When the connector93of the foot controller90is connected to the terminal17, the CPU2receives speed data for controlling the sewing speed from the foot controller90via the terminal17(S22). The CPU2controls the sewing machine motor37in accordance with the speed data received at the operation of S22(S23). When an external device is connected to the terminal17(S1: YES), the CPU2receives input data from the external device via the terminal17(S8, S12). When an external device is connected to the terminal17(S1: YES), the CPU2outputs output data to the external device via the terminal17(S3, S5, S6, S10, S15). The sewing machine1can perform, via the single terminal17, data output to and data output from an external device such as the embroidery device40.

As illustrated inFIG.1A, when the external device connected via the terminal17is the embroidery device40including the moving unit41, which moves the embroidery hoop20holding the workpiece relative to the needle bar8, and the CPU3, which controls the moving unit41, the CPU2receives the speed data from the embroidery device40(S12). The CPU2controls the sewing unit9in synchronization with the moving unit41of the embroidery device40in accordance with the received speed data to embroider an embroidery pattern on the workpiece (in a sequence of processes from S11to S16). The CPU2outputs needle position data corresponding to the position of the needle7in the up-down direction to the embroidery device40(S5, S6, S15). The sewing machine1can be connected to the embroidery device40for data communications by using the terminal17used for connection to the foot controller90. The sewing machine1has a simplified structure that enables connection and data transmissions with the embroidery device40using the single terminal17, compared with the known sewing machine that requires a plurality of terminals. If the embroidery device40is connected to the sewing machine1via, for example, a universal serial bus (USB) terminal, which is different from the terminal17, input data needs to be controlled in accordance with the USB terminal. However, the sewing machine1is capable of inputting and outputting data that enables the sewing machine1to perform the main process in synchronization with the embroidery device40by inputting and outputting on and off signals of an analog voltage or signals into which an analog voltage is translated according to a predetermined rule to and from the embroidery device40via the terminal17, thus eliminating complicated control.

The CPU2receives speed data by detecting a sewing speed using a voltage output from the foot controller90(S22). At S12, the CPU2receives the speed data by detecting the sewing speed using the voltage output from the embroidery device40in the same manner as the operation of S22. When the connector54of the embroidery device40is connected to the terminal17, the sewing machine1can receives the sewing speed in the same manner as when the connector93of the foot controller90is connected to the terminal17. The sewing machine1can thus receive the sewing speed by the same control in a case where the connector93of the foot controller90is connected to the terminal17and in a case where the connector54of the embroidery device40is connected to the terminal17, and can establish connection with the embroidery device40via the terminal17with a simple structure.

The CPU2determines whether the connector93of the foot controller90or the connector54of the embroidery device40is connected to the terminal17(S1). The sewing machine1can determine whether the device connected to the terminal17is the foot controller90or an external device, and can easily perform control in accordance with the device connected to the terminal17based on the determination result.

The embroidery device40includes the switch52for the user to input an instruction to start sewing. In response to detecting the instruction input by the switch52(S39), the CPU3outputs the instruction to the sewing machine1as input data (S40). The CPU2receives the start instruction from the embroidery device40as input data (S8: YES), and starts embroidering at S11in response to receiving the start instruction from the embroidery device40. In response to the start instruction input from the embroidery device40, the sewing machine1performs the operations of S12to S15synchronized with the embroidery device40.

The sewing machine1includes the start/stop switch29for the user to input an instruction to start sewing. In response to detection an instruction input by the start/stop switch29(S8: YES), the CPU2starts embroidering (S11). In response to detecting the instruction input by the start/stop switch29(S8: YES), the CPU2outputs output data indicating to start driving the moving unit41to the embroidery device40(S11). The sewing machine1can output an instruction to start the moving unit41to the embroidery device40in response to an instruction input by the sewing machine1, and can start the operations of S12to S15synchronized with the embroidery device40.

The sewing machine1includes the needle plate10that is disposed below the needle bar8. When the connector54of the embroidery device40is connected to the terminal17, the CPU2determines whether the position of the needle7in the up-down direction satisfies the predetermined criterion that the needle7is located above the needle plate10(S4). In response to determining that the position of the needle7in the up-down direction does not satisfy the predetermined criterion (S4: NO), the CPU2does not start the sewing-control operation. In order to place the embroidery hoop20below the needle bar8, the needle7is to be above the needle plate10. When the connector54of the embroidery device40is connected to the terminal17and the CPU2determines that the position of the needle7in the up-down direction does not satisfy the predetermined criterion, the CPU2does not start the sewing-control operation. This can reduce the possibility that sewing starts in a state in which the embroidery hoop20is not disposed below the needle bar8.

When the connector54of the embroidery device40is connected to the terminal17, the CPU2determines whether the position of the needle7in the up-down direction satisfies the predetermined criterion for being above the needle plate10(S4). In response to determining that the position of the needle7in the up-down direction does not satisfy the predetermined criterion in the operation of S4, the CPU2allows the needle bar8to move upward until the position of the needle7in the up-down direction satisfies the predetermined criterion (S5). When the sewing machine1determines that the position of the sewing needle7in the up-down direction does not satisfy the predetermined criterion in a case where the connector54of the embroidery device40is connected to the terminal17, the sewing machine1moves the needle bar8upward until the position of the sewing needle7in the up-down direction satisfies the predetermined criterion. This obviates the necessity for the user to move the needle bar8when setting the embroidery hoop20.

The embroidery device40includes the connector54, the moving unit41, and the CPU3. The connector54is connectable to the terminal17of the sewing machine1. The moving unit41is configured to move the embroidery hoop20, which holds a workpiece, relative to the needle bar8. Based on the needle position data output from the sewing machine1via the connector54, the CPU3controls the moving unit41to move the embroidery hoop20relative to the needle bar8during a period in which the embroidery hoop20is movable. The embroidery device40can be connected to the sewing machine1by using the terminal17used for connection with the connector93of the foot controller90, and can transmit and receive data. The embroidery device40has a simplified structure that enables connection and data transmissions with the sewing machine1using the connector54compared with a known embroidery device that requires a plurality of connectors.

The sewing machine, the embroidery device, and the sewing machine program, which are related to the disclosure, are not limited to those described in the above-described embodiment, and various modifications may be made without departing from the scope of the present invention. For example, the following modifications may be appropriately added.

(A) The configurations of the sewing machine1and the embroidery device40may be modified as appropriate. The placement of the embroidery device40relative to the sewing machine1may be changed as appropriate. For example, the embroidery device40may be placed behind the sewing machine1. Examples of the input unit of the sewing machine1and the input unit of the embroidery device40may include the touch screen16, a keyboard, a mouse, and a joystick, in addition to the start/stop switch29and the switch52. Examples of the LCDs15,51may include an organic EL display, a plasma display, a plasma tube array display, and an electronic paper display using electrophoresis. The LCDs15,51may be omitted if necessary. The sewing machine1may include a storage device in addition to the storage24. The embroidery device40may include a storage device in addition to the storage64. Example of the storage device may include a readable and writable removable medium such as a magnetic disk, a magneto-optical disk, an optical disk, or a semiconductor memory, and a non-portable storage device such as a built-in hard disk drive or a solid state drive (SSD). The sewing data of an embroidery pattern may be received from another device (e.g., a storage medium such as a USB memory, a smartphone, a tablet computer, or a PC) connected to the embroidery device40in a wired or wireless manner, or may be generated by the embroidery device40. The sewing data may be received by the sewing machine1and output to the embroidery device40via the terminal17and the connector54. Similarly to the embroidery device40, the sewing machine1may receive the sewing data from another device connected to the sewing machine1in a wired or wireless manner. The sewing machine1may not include the encoder38. In this case, the determination process using the position of the needle7in the up-down direction, for example, at S4may be performed using a detection result of a sensor such as an infrared sensor, or using a calculation result based on the driving amount of the sewing machine motor37after the adjustment of the origin position of the needle bar8.

Examples of the external device including the connector connectable to the terminal17may include an upper feed device, a stitch regulator, and a guard device, in addition to the embroidery device40. The upper feed device and the stitch regulator are each mounted, for example, below the presser bar6. The upper feed device includes an endless belt and a motor, and conveys a workpiece in contact with the belt by rotating the belt with the power of the motor. The upper feed device may receive the needle position data from the sewing machine1and output the speed data to the sewing machine1. The stitch regulator includes a sensor that detects a movement amount of the workpiece, and outputs a signal corresponding to a detection result of the sensor to the sewing machine1, thereby prompting the sewing machine1to form stitches having a length within a predetermined range. The guard device includes a transparent cover disposed around the sewing needle7so as to be openable and closable, and is a device for preventing the user from accidentally allowing their finger to come into contact with the reciprocating needle7. The guard device includes a sensor that detects opening and closing of the transparent cover, and outputs a signal corresponding to a detection result of the sensor to the sewing machine1. The sewing machine1does not drive the sewing machine motor37when the cover is open based on the detection result from the guard device. When the terminal17receives the connector of the external device, the sewing machine1normally disables the start/stop switch29, but it is preferable that the start/stop switch29is not disabled when any one of the upper feed device, the stitch regulator, and the guard device is attached to the sewing machine1.

(B) The program including the command for performing the main process of the sewing machine1inFIG.5may be stored in the storage device of the sewing machine1before the CPU2performs the program. Thus, the method of receiving the program, the path to the program, and the device storing the program may be changed as appropriate. The program performed by the CPU2may be received from another device via wired or wireless communication and stored in a storage device such as a flash memory. Example of the other device include a PC and a server connected via a network. The program including the command for performing the main process of the embroidery device40inFIG.7may be stored in the storage device of the embroidery device40before the CPU3performs the program.

(C) Each step of the main process of the sewing machine1is performed by the CPU2, but some or all of the steps may be performed by another electronic device (e.g., an ASIC). Each step of the main process of the sewing machine1may be subjected to distributed processing by a plurality of electronic devices (e.g., a plurality of CPUs). When necessary, the order of the steps of the main process of the sewing machine1can be changed, some of the steps can be omitted, and a new step can be added. The scope of the disclosure includes an aspect in which an operating system (OS) running on the sewing machine1performs some or all of the steps of the main process in accordance with a command from the CPU2. For example, the following modifications may be added to the main process of the sewing machine1as appropriate. Each step of the main process of the embroidery device40is performed by the CPU3, but some or all of the steps may be performed by another electronic device (e.g., an ASIC). For example, the following modifications may be added to the main process of the sewing machine1and the main process of the embroidery device40as appropriate.

The needle position data corresponds to the position of the needle7in the up-down direction, and may, for example, represent the position of the needle7in the up-down direction linearly in a stepwise manner. The needle position data may be data represented by a duty ratio of the pulse signal or may be data represented by a cycle of the pulse signal. For example, for the needle position data represented by the duty ratio of the pulse signal, as in the signal J1illustrated inFIG.6, an ON signal may be shorter than the criterion and an OFF signal may be longer than the criterion when the lower end of the needle7is above the needle plate10and the upper end of the embroidery hoop20, and the ON signal may be longer than the criterion and the OFF signal may be shorter than the criterion when the lower end of the needle7is below the upper end of the embroidery hoop20. For example, for the needle position represented by the cycle of the pulse signal, as in the signal J2illustrated inFIG.6, a signal may have a shorter cycle than the criterion when the lower end of the needle7is above the needle plate10and above the upper end of the embroidery hoop20, and may have a longer cycle than the criterion when the lower end of the needle7is below the upper end of the embroidery hoop20. The above criterion may be preset as appropriate. The same needle position data may be preset at S6and S15.

At least one of the sewing machine1and the external device such as the embroidery device40may receive data from the analog voltage received via the terminal17in a known method and the method may be changed as appropriate. For example, the CPU2of the sewing machine1may interpret a predetermined voltage A of analog voltages output from the external device as logic “0” and a predetermined voltage B different from the voltage A as logic “1”, thereby recognizing a change in the voltage output from the external device as a digital signal. The CPU2may interpret a voltage greater than a threshold as logic “0” and a voltage less than the threshold as logic “1”, thereby recognizing a change in voltage output from the external device as a digital signal. The predetermined voltages A and B and the threshold value may be appropriately preset. The CPU2may detect a sewing speed based on data, such as a change in the duty ratio and a change in the cycle of the pulse signal, other than the voltage value. The CPU2may skip the operation of S1. When the connector54of the embroidery device40is connected to the terminal17, the CPU2may deactivate the start/stop switch29and receive the start instruction from the embroidery device40or the touch screen16. The start instruction may be input from the sewing machine1or the embroidery device40simply. The CPU2may skip the operations of S4and S5as appropriate. The above-described modifications may be combined as appropriate as long as there is no contradiction. The techniques disclosed in the disclosure can be realized in various forms, such as a control method for a sewing machine, a control method for an embroidery device, a computer program for realizing the above-described methods, and a recording medium having the computer program recorded thereon.

While the disclosure has been described in detail with reference to the specific embodiment thereof, this is merely an example, and various changes, arrangements and modifications may be applied therein without departing from the spirit and scope of the disclosure.