Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to Japanese Patent Application No. 2007-051839, filed Mar. 1, 2007, the disclosure of which is hereby incorporated herein by reference in its entirety. 
       BACKGROUND 
       [0002]    The present disclosure relates to a sewing machine and a computer-readable recording medium storing a sewing machine control program. More specifically, it relates to a sewing machine that can be used for free-motion sewing and a computer-readable recording medium storing a sewing machine control program for a sewing machine that can be used for free-motion sewing. 
         [0003]    Quilting is a conventional sewing method. In quilting, a batting is sandwiched between an outer material and a lining material, and then those materials may be sewn up along a stitch pattern, such as a straight line or a curve. In quilting, there is a case where stitches are formed while a user is freely moving a work cloth manually. Such sewing is referred to as free-motion sewing. In free-motion sewing, stitches may look unattractive if their stitch lengths are not uniform. Therefore, it is desirable to form stitches with a uniform stitch length as much as possible. However, it is difficult for a beginner, who is not skilled in sewing operations, to sew up a work cloth in such a manner as to form stitches with a substantially uniform stitch length while moving the work cloth in a desired direction. To solve this problem, a technique is disclosed in Japanese Patent Application Laid-Open Publication No. 2002-292175 in which driving of a sewing machine is controlled in such a manner as to form stitches with a uniform stitch length by obtaining a movement distance of a work cloth for each stitch, so that the sewing speed may be changed in accordance with the obtained movement distance. 
         [0004]    In some cases, a stippling stitch is used in free-motion sewing. A stippling stitch should be disposed evenly within a predetermined region so that a user may enjoy the resulting beautiful design (see  FIG. 21 ). In the stippling stitch, a uniform stitch length is not sufficient to obtain a beautiful result. Like stitch  902  in a predetermined region  901  shown in  FIG. 21 , a beautiful stippling stitch should create a smooth curve that is disposed within the region  901  in a well-balanced and even manner. The stitch line should not overlap itself, nor should it come too close to other parts of the stitch line. 
         [0005]    In a case where a user unskilled in the sewing operation sews the stippling stitch in the course of free-motion sewing with a sewing machine that employs the aforementioned conventional technique, the user can perform sewing in such a manner as to form stitches with a uniform stitch length. However, the user may still find it difficult to perform sewing while taking care not to form a stitch line with an overlapping part, and may even fail to do so. In such a case, the user may be involved in a troublesome task, because he must stop sewing, cut off a thread, remove the failed stitches, and then restart sewing. 
       SUMMARY 
       [0006]    Various exemplary embodiments of the general principles described herein provide a sewing machine and sewing machine control program recorded in a computer-readable recording medium that detects a likelihood of stitches overlapping with each other in free motion sewing in which a user performs sewing as he/she manually moves a piece of work cloth. 
         [0007]    Exemplary embodiments provide a sewing machine that sews a work cloth being moved by a user. The sewing machine includes a detection device that detects the work cloth, a movement calculation device that calculates a direction and a distance of movement of the work cloth as movement data when the work cloth is detected by the detection device, the movement being determined based on the location where the work cloth was previously detected by the detection device, and the movement data being in the form of two-dimensional coordinate data, a movement data storage device that stores the movement data calculated by the movement calculation device, a movement data creation device that causes the detection device to detect the work cloth for each stitch formed in sewing the work cloth, thereby causing the movement calculation device to calculate the movement data, and that stores the movement data calculated by the movement calculation device into the movement data storage device, a line segment specification device that specifies a line segment as a specified line segment based on the movement data stored in the movement data storage device, a determination device that determines whether a stitch to be formed next may overlap with an already formed stitch when the work cloth is detected by the detection device in a state where a sewing needle is above the work cloth, based on whether a line segment interconnecting a first position and a second position overlaps with the specified line segment or whether the specified line segment exists within a predetermined distance from the first position or the second position, the first position being a position on the work cloth below the sewing needle, and the second position being a most recent needle drop position, and an error control device that performs an error correction operation if it is determined by the determination device that the stitch to be formed next may overlap with the already formed stitch. 
         [0008]    Exemplary embodiments also provide a sewing machine that sews a work cloth being moved by a user, the sewing machine including a detection device that detects a stitch formed on the work cloth, a determination device that determines whether a stitch to be formed next will overlap with an already formed stitch, based on whether the stitch detected by the detection device exists within a predetermined range determined on the basis of a first position or whether a line segment interconnecting the first position and a second position overlaps with the stitch detected by the detection device, the first position being a position on the work cloth below a sewing needle when the stitch, is detected by the detection device in a state where the sewing needle is above the work cloth, the second position being a most recent needle drop position, and an error control device that performs an error correction operation if it is determined by the determination device that the stitch to be formed next will overlap with the already formed stitch. 
         [0009]    Exemplary embodiments further provide a computer-readable recording medium storing a sewing machine control program for a sewing machine that sews a work cloth being moved by a user. The program includes instructions for detecting the work cloth, instructions for calculating a direction and a distance of movement of the work cloth as calculated movement data each time the work cloth is detected, the movement being determined based on a location where the work cloth was previously detected, and the movement data being in the form of two-dimensional coordinate data, instructions for storing the calculated movement data as stored movement data each time the movement data is calculated, instructions for specifying a line segment as a specified line segment based on the stored movement data, instructions for determining whether a stitch to be formed next will overlap with an already formed stitch when the work cloth is detected in a state where a sewing needle is above the work cloth, based on whether a line segment interconnecting a first position and a second position overlaps with the specified line segment or whether the specified line segment exists within a predetermined distance from the first position or the second position, the first position being a position on the work cloth below the sewing needle, and the second position being a most recent needle drop position, and instructions for performing an error correction operation if it is determined that the stitch that is to be formed next will overlap with the already formed stitch. 
         [0010]    Exemplary embodiments further provide a computer-readable recording medium storing a sewing machine control program for a sewing machine that sews a work cloth being moved by a user, the program including instructions for detecting a stitch formed on the work cloth, instructions for determining whether a stitch to be formed next will overlap with an already formed stitch, based on whether the detected stitch exists within a predetermined range determined on the basis of a first position or whether a line segment interconnecting the first position and a second position overlaps with the detected stitch, the first position being a position on the work cloth below a sewing needle when the stitch is detected in a state where the sewing needle is above the work cloth, the second position being a most recent needle drop position, and instructions for performing an error correction operation if it is determined that the stitch to be formed next will overlap with the already formed stitch. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Exemplary embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings in which: 
           [0012]      FIG. 1  is an overall perspective view of a sewing machine according to a first embodiment; 
           [0013]      FIG. 2  is a perspective view showing a needle bar up-and-down movement mechanism and a needle bar releasing mechanism in the sewing machine of  FIG. 1 ; 
           [0014]      FIG. 3  is an elevational view of major components showing the needle bar up-and-down movement mechanism and the needle bar releasing mechanism in the sewing machine of  FIG. 1 ; 
           [0015]      FIG. 4  is an explanatory illustration showing an operation of the needle bar releasing mechanism to release a needle bar; 
           [0016]      FIG. 5  is an explanatory illustration showing another operation of the needle bar releasing mechanism to release a needle bar; 
           [0017]      FIG. 6  is an explanatory illustration showing a further operation of the needle bar releasing mechanism to release a needle bar; 
           [0018]      FIG. 7  is an explanatory illustration showing an additional operation of the needle bar releasing mechanism to release a needle bar; 
           [0019]      FIG. 8  is a side view of major components showing a sewing needle, a presser foot, and an image sensor; 
           [0020]      FIG. 9  is a block diagram showing an electrical configuration of the sewing machine; 
           [0021]      FIG. 10  is a conceptual diagram showing storage areas provided in RAM; 
           [0022]      FIG. 11  is a table showing the configuration of a coordinate storage area in the RAM; 
           [0023]      FIG. 12  is a flowchart of main processing showing the operations of the sewing machine; 
           [0024]      FIG. 13  is an explanatory illustration showing a situation where a new stitch intersects with an already formed stitch; 
           [0025]      FIG. 14  is an explanatory illustration showing a situation where a new stitch is formed on an already formed stitch; 
           [0026]      FIG. 15  is a flowchart of determination processing which is performed in the main processing of  FIG. 12 ; 
           [0027]      FIG. 16  is an explanatory illustration of a method of calculating a distance between a line segment (stitches) and a point (needle drop point); 
           [0028]      FIG. 17  is an overall perspective view of the sewing machine according to a modification of the first embodiment; 
           [0029]      FIG. 18  is a block diagram showing the electrical configuration of the sewing machine according to a second embodiment; 
           [0030]      FIG. 19  is a conceptual diagram showing the configuration of the RAM according to the second embodiment; 
           [0031]      FIG. 20  is a flowchart showing the operations of the sewing machine according to the second embodiment; and 
           [0032]      FIG. 21  is an explanatory illustration showing one example of a shape of stitches formed by stippling stitching. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    The following describes first and second embodiments of the present disclosure with reference to the drawings. First, the first embodiment is described below with reference to  FIGS. 1-15 . The configuration of a sewing machine I in the first embodiment is described below with reference to  FIGS. 1-11 . 
         [0034]    The physical configuration of the sewing machine  1  in the present embodiment will be described below with reference to  FIG. 1 . The sewing machine I has a sewing machine bed  2  that extends in the right and left directions, a pillar  3  that is erected upward at the right end of the sewing machine bed  2 , and an arm  4  that extends leftward from the upper end of the pillar  3 . The left end of the arm  4  is referred to as a head portion  5 . The pillar  3  has on a front surface thereof a liquid crystal display (LCD)  10  having a touch panel  16  on its surface. The LCD  10  displays entry keys and the like for entering a pattern to be sewn, sewing conditions, etc. The user can select a desired pattern to be sewn, desired sewing conditions and the like by touching the positions corresponding to those entry keys on the touch panel  16 . The sewing machine  1  includes a sewing machine motor  79  (see  FIG. 9 ), a drive shaft  11  (see  FIG. 2 ), a needle bar  6  (see  FIG. 3 ), a needle bar up-and-down movement mechanism  22  (see  FIG. 2 ), a needle bar swinging mechanism  26  (see  FIG. 3 ), and a needle bar releasing mechanism  25  (see  FIG. 3 ). A sewing needle  7  (see  FIG. 2 ) is attached to the lower end of the needle bar  6 . The needle bar up-and-down movement mechanism  22  is configured to raise and lower the needle bar  6 . The needle bar swinging mechanism  26  is configured to swing the needle bar  6  in the right and left direction. The needle bar releasing mechanism  25  is configured to release the needle bar  6  from the driving force of the sewing machine motor  79 . 
         [0035]    The sewing machine bed  2  has a needle plate  80  disposed on an upper surface thereof. The sewing machine bed  2  includes a feed dog back-and-forth movement mechanism (not shown), a feed dog up-and-down movement mechanism (not shown), a feed adjustment pulse motor  78  (see  FIG. 9 ), and a shuttle mechanism (not shown). The feed dog back-and-forth movement mechanism and the feed dog up-and-down movement mechanism are configured to drive a feed dog (not shown). The feed adjustment pulse motor  78  adjusts a feed distance by which a work cloth is fed by the feed dog. The shuttle mechanism houses a bobbin with a wound bobbin thread. 
         [0036]    The head portion  5  has on a front surface thereof a sewing start switch  81  and a sewing stop switch  82 . The sewing start switch  81  is used to start sewing by starting the drive of the sewing machine motor  79 . The sewing stop switch  82  is used to stop sewing by stopping the driving of the sewing machine motor  79 . The sewing machine  1  has on a right side surface thereof a pulley (not shown) with which the drive shaft  11  is rotated by hand to move the needle bar up and down. 
         [0037]    Next, the needle bar up-and-down movement mechanism  22  will be described below with reference to  FIGS. 2-7 . As shown in  FIGS. 2 and 3 , the needle bar  6  is slidably supported by an upper support portion  341  and a lower support portion  342  of a needle bar support  34  in such a manner that the needle bar  6  can move up and down. At a position along the needle bar  6 , a needle bar pawl support  30  (see  FIG. 3 ) is fixed. The base end (upper end) of a needle bar pawl body  31  is pivotally supported by a pin  301  (see  FIG. 6 ) in such a manner that the needle bar pawl body  31  is pivotally movable (see  FIGS. 6 and 7 ). Below the needle bar pawl support  30 , a needle bar guide bracket  32  is connected to the needle bar  6  in such a manner that the needle bar guide bracket  32  can move up and down with respect to the needle bar  6 . 
         [0038]    A thread take-up crank  27  is fitted to the end of the drive shaft  11 , and a needle bar crank rod  29  is coupled via a crank pin  28  which projects laterally from the thread take-up crank  27 . A boss  291  of the needle bar crank rod  29  and a shaft  322  which protrudes from the needle bar guide bracket  32 , are coupled in such a manner that the boss  291  can be rotated with respect to the shaft  322 . As shown in  FIG. 6 , an engagement pawl portion  312  formed at the end (lower end) of the needle bar pawl body  31  can be engaged with and disengaged from a concaved locking portion  321  formed in the needle bar guide bracket  32 . Further, a torsion spring (not shown) is connected to the base end of the needle bar pawl body  31 , so that its spring force acts to hold the engagement pawl portion  312  and the locking portion  321  in an engaged state. If the drive shaft  11  is rotated by the driving of the sewing machine motor  79  while the engagement pawl portion  312  is engaged with the locking portion  321  as shown in  FIG. 6 , the rotation of the drive shaft  11  is transmitted as up-and-down movement to the needle bar guide bracket  32  via the thread take-up crank  27  and the needle bar crank rod  29 . The up-and-down movement of the needle bar guide bracket  32  is transmitted via the needle bar pawl body  31  and the needle bar pawl support  30  to move the needle bar  6  up and down. A thread take-up lever (not shown) coupled to the thread take-up crank  27  moves up and down in conjunction with the rotation of the drive shaft  11 . 
         [0039]    The needle bar swinging mechanism  26  is described below. The needle bar support  34  is hung and supported at its upper end  343  by a support shaft  35  that is fixed to a frame (not shown) of the sewing machine  1  so that the needle bar support  34  can be moved rotationally. Further, the lower end of the needle bar support  34  is urged in an arrow A direction by a spring (not shown). As shown in  FIG. 3 , the needle bar swinging lever  36  (not shown in  FIG. 2 ) is axially supported by a support shaft  361  that is fixed to the frame of the sewing machine  1 . The lower end of  362  of the needle bar swinging lever  36  is in contact with the side surface of the lower end  344  of the needle bar support  34 . 
         [0040]    As shown in  FIG. 2 , a needle bar swinging-and-releasing pulse motor  43  (hereinafter simply referred to as pulse motor  43 ) is fixed to the frame of the sewing machine  1 . A cam body  37 , which includes a needle bar swinging cam portion  371  and a needle bar releasing cam portion  372 , is fixed to the rotary shaft of the pulse motor  43  in such a manner as to rotate integrally with the rotary shaft. As shown in  FIG. 3 , the needle bar swinging cam portion  371  of the cam body  37  contacts a contacting portion  363  connected at the upper end of the needle bar swinging lever  36 . When the pulse motor  43  operates to rotate the needle bar swinging cam portion  371  in an arrow E direction, the contacting portion  363  of the needle bar swinging lever  36  is pressed by the needle bar swinging cam portion  371  and moved rotationally in an arrow C direction. As a result, the lower end  344  of the needle bar support  34  is pressed in an arrow B direction against the biasing force of the spring. Conversely, when the needle bar swinging cam portion  371  is rotated in an arrow F direction in  FIG. 3 , the lower end  344  of the needle bar support  34  is moved in an arrow A direction. 
         [0041]    Next, the configuration of the needle bar releasing mechanism  25  is described below. As shown in  FIGS. 2 and 3 , a support shaft  40  and the needle bar  6  are supported on the needle bar support  34 , in parallel. A releasing lever  41  is supported by the support shaft  40  so that the releasing lever  41  can be moved rotationally. A flared portion  411  formed at one end of the releasing lever  41  can contact an overhang portion  311  of the needle bar pawl body  31  (see  FIG. 4 ). Further, a pin-like cam follower  412  that protrudes downward from the other end of the releasing lever  41  can contact the needle bar releasing cam portion  372  of the cam body  37  (see  FIG. 4 ). 
         [0042]    A coil portion of a torsion coil spring  42  is supported around the support shaft  40 . A fixing end extending from the coil portion of the torsion coil spring  42  is fixed to the flared portion  411  of the releasing lever  41  to urge the releasing lever  41  in a direction in which the cam follower  412  can contact with the needle bar releasing cam portion  372 . Therefore, when the cam body  37  is rotated by the pulse motor  43 , the needle bar releasing cam portion  372  contacts the cam follower  412  so that the releasing lever  41  may be moved clockwise around the support shaft  40  against the biasing force of the torsion coil spring  42  (see  FIGS. 4 and 5 ). Therefore, the flared portion  411  presses the overhang portion  311  of the needle bar pawl body  31  in the right-hand direction in  FIGS. 4 and 5 . Consequently, the needle bar pawl body  31  is pivotally moved in a direction in which the engagement pawl portion  312  is disengaged from the locking portion  321  of the needle bar guide bracket  32  (see  FIGS. 6 and 7 ). As such, the needle bar pawl support  30  and the needle bar guide bracket  32  are released from a state (engaged state) where they are coupled in a driving relation to each other. The flared portion  411  of the releasing lever  41  extends over a range within which the needle bar pawl body  31  moves up and down when the needle bar pawl body  31  is engaged with the needle bar guide bracket  32 . It is thus possible to release the needle bar  6  irrespective of the vertical position of the needle bar  6 . 
         [0043]    Between the needle bar pawl support  30  and the upper end of the needle bar support  34 , a tension spring  38  is disposed to constantly urge the needle bar  6  upward. The tension spring  38  pulls the needle bar  6  up to a top dead center position if the needle bar pawl support  30  and the needle bar guide bracket  32  are released from the state in which they are coupled in a driving relation to each other, as shown in  FIG. 7 . Thus, the needle bar  6  stays in a standby state at the top dead center position when the needle bar  6  is released. 
         [0044]    On the other hand, if the cam follower  412  is separated from the needle bar releasing cam portion  372  by driving of the pulse motor  43 , the biasing force of the torsion coil spring  42  causes the flared portion  411  of the releasing lever  41  to move rotationally in such a direction as to be separated from the overhang portion  311  of the needle bar pawl body  31 . Accordingly, by a torsion spring (not shown), the engagement pawl portion  312  of the needle bar pawl body  31  is locked to the locking portion  321  of the needle bar guide bracket  32 , as shown in  FIG. 6 . As a result, the engagement pawl portion  312  and the locking portion  321  are coupled in a driving relation to each other. This coupling operation is performed at the top dead center position of the needle bar  6 . 
         [0045]    As described above, the needle bar releasing mechanism  25  and the needle bar swinging mechanism  26  are configured to be operated by the driving of the pulse motor  43 . The operations to release and swing the needle bar  6  can be controlled by causing a later-described CPU  61  to execute a program. 
         [0046]    Next, an image sensor  50  disposed in the sewing machine  1  will be described below with reference to  FIG. 8 . The image sensor  50  includes a CCD camera and a control circuit, and captures an image with the CCD camera at predetermined lapses of time. The control circuit compares the most recently taken image and a currently taken image to pick up a portion commonly included in both images, and then provides values that represent a direction and a distance of the movement of the target based on a range of the commonly included portion and its position in the images. In the present embodiment, as shown in  FIG. 8 , a frame (not shown) of the sewing machine  1  is fitted with a support frame  51 . The image sensor  50  is attached to the support frame  51  at a position where the image sensor  50  can capture an image of an area including a needle drop point of the sewing needle  7  and its vicinity. The needle drop point herein refers to a point at which a work cloth is stuck through by the sewing needle  7  attached to the needle bar  6  when the needle bar  6  is moved downward by the needle bar up-and-down movement mechanism  22  (see  FIG. 1 ). A presser foot  47 , which holds down the work cloth, is attached to a presser holder  46 , which is fixed to the lower end of a presser bar  45 . The presser foot  47  and the presser holder  46  are made of a transparent resin so that images of stitches can be taken through them. 
         [0047]    Next, the electrical configuration of the sewing machine  1  is described below with reference to  FIG. 9 . As shown in  FIG. 9 , a body  60  of the sewing machine  1  includes a CPU  61 , a ROM  62 , a RAM  63 , an EEPROM  64 , a card slot  17 , an external access RAM  68 , an input interface  65  and an output interface  66  which are connected to each other by a bus  67 . A sewing start switch  81 , a sewing stop switch  82 , a touch panel  16 , a lower-needle-position sensor  89 , and the image sensor  50  are connected to the input interface  65 . Drive circuits  71 ,  72 ,  74  and  75  are connected to the output interface  66 . The drive circuit  71  drives the feed adjustment pulse motor  78 . The drive circuit  72  drives the sewing machine motor  79 , which is used to rotate the drive shaft  11 . The drive circuit  74  drives the pulse motor  43 , which is used to swing or release the needle bar  6 . The drive circuit  75  drives the LCD  10 . 
         [0048]    The CPU  61  conducts main control over the sewing machine  1 , to perform a variety of computations and processing in accordance with a control program stored in a control program storage area of the ROM  62 , which is a read only memory device. The RAM  63 , which is a random access memory, is provided with various storage areas as required for storing the results of various computations by the CPU  61 . The sewing start switch  81  and the sewing stop switch  82  are button type switches. The lower-needle-position sensor  89 , which detects a rotation phase of the drive shaft  11 , is configured to output an ON signal when the needle bar  6  is lowered from a higher needle position down to a lower needle position as the drive shaft  11  revolves. The higher needle position herein refers to a position at which the tip of the sewing needle  7  is above the upper surface of the needle plate  80 , i.e., above the work cloth. The lower needle position herein refers to a position where the tip of the sewing needle  7  is below the upper surface of the needle plate  80 . 
         [0049]    Next, storage areas in the RAM  63  are described below with reference to  FIG. 10 . As shown in  FIG. 10 , the RAM  63  has a stitch counter storage area  631 , a coordinate storage area  632 , and a movement amount storage area  633 . The RAM  63  also has additional storage areas other than those illustrated. The stitch counter storage area  631  stores a stitch counter that counts the number of stitches when the coordinates of a stitch are recorded. The coordinate storage area  632  stores the coordinates of a stitch. The movement amount storage area  633  stores a movement amount of a work cloth that is outputted by the image sensor  50 . 
         [0050]    Next, the coordinate storage area  632  in the RAM  63  will be described below with reference to  FIG. 11 . The coordinate storage area  632  stores coordinates array R, which is a two-dimensional array showing a trajectory-of stitches. The coordinates array R includes an x-coordinate and a y-coordinate. The subscript of the two-dimensional array begins with “0”. The n&#39;th array is herein expressed as R n  (X n , Y n ). This means that the n&#39;th array has an x-coordinate of X n  and a y-coordinate of Y n . Further, a point represented by the coordinates in the array R n  is herein expressed as p n . In the 0&#39;th array, a position of the work cloth before the start of sewing, i.e., (0, 0), is stored as a reference position. The first and subsequent arrays sequentially store the coordinates that represent the positions of needle drop points with respect to the reference position. Thus, the n&#39;th array stores the coordinates of the n&#39;th needle drop point. 
         [0051]    Next, the operations of the sewing machine  1  will be described below with reference to  FIG. 12 . Processing in  FIG. 12  starts when the startup of sewing is instructed by the operation of the sewing start switch  81 . In this processing, position information of stitches is recorded as coordinate information. Then, it is continually monitored whether a stitch to be formed overlaps with an already formed stitch when the sewing needle  7  is at the higher needle position and is to be lowered down to form the stitch on a work cloth. If having determined that the&#39;stitches would overlap, the needle bar  6  is released from the power of the sewing machine motor  79  (needle bar releasing) so that the sewing needle  7  does not operate, thus controlling the sewing machine  1  not to form stitches. 
         [0052]    First, in step  1  (S 1 ) an initial value of 0 is stored in the stitch counter storage area  631  of the RAM  63  to initialize a stitch counter n. Then, in step  2  (S 2 ) the CPU  61  accesses the image sensor  50 . When accessed, the image sensor  50  captures an image at startup which serves as a reference. In step  3  (S 3 ) initial values for the coordinates array R n , i.e., (X 0 =0, Y 0 =0), are stored into the coordinates array R 0 . In step  4  (S 4 ) the sewing machine motor  79  starts revolving. 
         [0053]    In step  5  (S 5 ) a determination is made as to whether the output of the lower-needle-position sensor  89  is an ON signal, which indicates that the sewing needle  7  is at the lower needle position. When the sewing needle  7  is at the lower needle position (YES at S 5 ), the sewing needle  7  pierces the work cloth so that the work cloth cannot be moved. Therefore, it is not necessary to detect a movement amount of the work cloth. Therefore, the determination is repeated at S 5  until the lower-needle-position sensor  89  outputs an OFF signal, which indicates that the sewing needle  7  is not at the lower needle position (NO at S 5 ). 
         [0054]    When the lower-needle-position sensor  89  outputs an OFF signal to indicate that the sewing needle  7  is not at the lower needle position (NO at S 5 ), it means that the sewing needle  7  has been pulled out of the work cloth, and thus the work cloth can be moved. Therefore, a position at which the lowered sewing needle  7  is to pierce the work cloth next time becomes the ending point of the next stitch. The stitch counter n is incremented by “1” (S 6 ). More specifically, 1 is added to the initial value 0 so that the stitch counter n becomes 1. Then, in step  7  (S 7 ) coordinate values of the coordinates array R n−1  are stored in the coordinates array R n . More specifically, the values of R 0  (0, 0) are stored in R 1 . 
         [0055]    In step  8  (S 8 ) a determination is made as to whether the output of the lower-needle-position sensor  89  is an ON signal, which indicates that the sewing needle  7  is at the lower needle position (S 8 ). When the output of the lower-needle-position sensor  89  is an OFF signal, which indicates that the sewing needle  7  is not at the lower needle position (NO at S 8 ), it means that the sewing needle  7  is not pierced into the work cloth, so the work cloth is still moving. Therefore, in step  9  (S 9 ) the CPU  11  accesses the image sensor  50  to acquire an amount of movement as measured from a position at the time of the previous access and stores the amount in the movement amount storage area  633 . The movement amounts in the x-direction and the y-direction acquired from the image sensor  50  are written as the X and Y coordinates, respectively. The movement amount acquired from the image sensor  50  is added to R n , and R n  is updated in step  10  (S 10 ). Specifically, X n =X n +X and Y n =Y n +Y are obtained. The updated R n  represents the current position of the sewing needle  7 . 
         [0056]    In step  11  (S 11 ) a determination is made as to whether a stitch to be formed by interconnecting a point represented by R n  and a point represented by R n−1  overlaps with any one of the stitches formed so far if the sewing needle  7  is currently pierced into the piece of work cloth. More specifically, determination is made as to whether a line segment P n−1 p n , which interconnects points p n−1  and p n , overlaps with any one of line segments p 0 p 1 , p 1 p 2 , . . . , and p n-2 p n−1 . The determination processing at S 11  will be described in detail later with reference to a flowchart in  FIG. 15 . Then in step  12  (S 12 ) a determination is made as to whether it was determined that the stitches overlap with each other in the determination processing at S 11 . In this case, because n=1 and thus no stitch has been formed, there is no stitch to be compared. Consequently, it has been determined that there are no overlapping stitches in the determination processing at S 11  (NO at S 12 ). Thus, the process returns to S 8 . 
         [0057]    When the output of the lower-needle-position sensor  89  is obtained as an ON signal, indicating that the sewing needle  7  is at the lower needle position through the repetitive performance of the processing of S 8 -S 12  (YES at S 8 ), the repetition of the processing of S 8 -S 12  is stopped and the process advances to step  13  (S 13 ). In other words, the updating of the coordinates array R n  is ended when the sewing needle  7  is pierced into the work cloth and positioned at the lower needle position. Accordingly, the coordinates immediately before the sewing needle  7  is pierced into the work cloth are employed as the values of the coordinates array R n . Because the processing of S 8 -S 12  are continually repeated by the CPU  61 , there is no problem to employ those coordinates as those of a needle drop point when making determination of a stitch overlap. 
         [0058]    At S 13 , a determination is made as to whether the sewing stop switch  82 is operated (S  13 ). If the sewing stop switch  82  is not operated (NO at S  13 ), the process returns to S 5  to wait until the sewing needle  7  is again moved from the lower needle position (YES at S 5 ). If an OFF signal is obtained as the output of the lower-needle-position sensor  89 , indicating that the sewing needle  7  is moved from the lower needle position (NO at S 5 ), the stitch counter n is incremented by  1  to provide a count of  2  (S 6 ). Then, the values of the coordinates array R n−1  are stored into the coordinates array R n  (S 7 ). More specifically, the values of R 1  are stored in R 2 . The process then advances to S 8 . In such a manner, the processing of S 5 -S 13  is repeated. 
         [0059]    When the processing of S 5 -S 12  is repeated and it is determined that the line segment p n−1 p n  that interconnects points p n−1  and p n  overlaps with any one of line segments p 0 p 1 , p 1 p 2 , . . . , and p n−2 p n−1 , that is, the stitches overlap if the sewing needle  7  is lowered from the current position to form a stitch (YES at S 12 ), an error correction operation is performed. In the error correction operation, at step  14  (S 14 ) the needle bar releasing mechanism  25  is operated to release the needle bar  6  from the power of the sewing machine motor  79 . More specifically, the pulse motor  43  is driven to rotate the cam body  37 . When the cam body  37  is rotated to be in a state as shown in  FIG. 5 , the needle bar releasing cam portion  372  presses the cam follower  412 . Consequently, the releasing lever  41  moves clockwise as shown in  FIG. 5  against the biasing force of the torsion coil spring  42 . As a result, the flared portion  411  of the releasing lever  41  pivotally moves the overhang portion  311  of the needle bar pawl body  31  upward to release the needle bar pawl support  30  and the needle bar guide bracket  32  from the state in which they are coupled in driving relation to each other. After the needle bar  6  is released, the sewing machine motor  79  is stopped in step  15  (S  15 ) and the processing ends. If the sewing stop switch  82  is operated (YES at S  13 ), the sewing machine motor  79  is stopped (S 15 ) and the processing is ended. 
         [0060]    Now, determination processing on the stitch overlap at S 11  is described below with reference to  FIGS. 13-15 . When stitches overlap, it means that one stitch and another stitch pass through the same point. There are two cases when stitches overlap. The first case is when two stitches intersect with each other (endpoints of two line segments are not on one straight line), as shown in  FIG. 13 . The second case is when two stitches are oriented in the same direction (endpoints of two line segments are on one straight line), as shown in  FIG. 14 . As mentioned above, the coordinates of the needle drop point p n  are stored in the coordinates array R n  in advance and are expressed as (x-coordinate, y-coordinate)=(X n , Y n ). 
         [0061]    When the two line segments (a first line segment and a second line segment) intersect with each other, as in the first case, the following two conditions are satisfied at the same time. The first condition is that a straight line which includes the first line segment should intersect with the second line segment. The second condition is that a straight line which includes the second line segment should intersect with the first line segment. For example, the first line segment is a line segment that goes through the determination processing (a line segment interconnecting the new needle drop point p n  and the previous needle drop point p n−1 ) and the second line segment is any one of the already formed line segments p 0 p 1 , p 1 p 2 , . . . , and p n-2 p n−1 . 
         [0062]    For example, of the line segments shown in  FIG. 13 , the coordinate arrays are stored as R 0  (0, 0), R 1  (20, 0), R 2  (39.9, 1.7), R 3  (58, 10.2), R 13  (56.6, −4.2), and R 14  (42.5, 10). 
         [0063]    As shown in  FIG. 15 , in the determination processing, at step  21  (S 21 ) the initial value 0 is stored as variable m used to specify the second line segment. Then, in step  22  (S 22 ) a determination is made as to whether the first condition is satisfied, that is, whether a straight line that includes the first line segment p n p n−1  intersects with the second line segment p m p m+1 , i.e., line segment p 0 p 1 . The straight line that includes the first line segment p n p n−1  is hereinafter referred to as a first straight line. 
         [0064]    The equation for the first straight line can be expressed by (X n−1 −X n ) (y−Y n−1 )+(Y n−1 −Y n )(−x+X n−1 )=0. Coordinates of two needle drop points that form the second line segment are respectively substituted into the left side (X n−1 −X n )(y−Y n−1 )+(Y n−1 −Y n ) (−x+X n−1 ). A value obtained by substituting the coordinates of one of the two needle drop points that comes earlier in order is R 1 , and a value obtained by substituting the coordinates of the other needle drop point that comes later in order is R 2 . When the signs of those values are both negative, the two needle drop points that form the second line segment are present in a coordinate region below the first straight line. On the other hand, when the signs of those values are both positive, the two needle drop points that form the second line segment are present in a coordinate region above the first straight line. Therefore, if the sign of R 1 *R 2  is negative, the first straight line extends between the two needle drop points that form the second line segment. In other words, the first straight line and the second line segment intersect with each other. 
         [0065]    In the example shown-in  FIG. 13 , n=14. Therefore, R 1  can be calculated by substituting coordinates (X 0 , Y 0 ) of point p 0  into x and y in (X 13 −X 14 )(y−Y 13 )+(Y 13 −Y 14 ) (−x+X 13 ). R 2  can also be calculated by substituting coordinates (X 1 , Y 1 ) of point p 1 . Then, a determination is made as to whether the sign of R 1 *R 2  is negative. In the example shown in  FIG. 13 , since the respective coordinates arrays are R 0  (0, 0), R 1  (20, 0), R 13  (56.6, −4.2), and R 14  (42.5, 10), R 1 =(56.6−42.5)(0−(−4.2))+(−4.2-10)(−0+56.6)=−744.5. Thus, the sign of R 1  is negative. Further, R 2 =(56.6−42.5)(0−(−4.2))+(−4.2−10) (−20+56.6)=−460.5. Thus, the sign of R 2  is also negative. Therefore, R 1 *R 2  takes on a positive value, and thus it is determined that the first straight line and the second line segment do not intersect with each other (NO at S 22 ). The process then advances to step  24  (S 24 ). 
         [0066]    At S 24 , a determination is made as to whether the first and second line segments are on the same straight line and overlap with each other, i.e., whether they are in the exemplary state shown in  FIG. 14  (S 24 ). If R 1  and R 2  used in the determination on an intersection at S 22  are both 0, the first and second line segments are on the same straight line. Therefore, a determination is made as to whether R 1 =R 2 =0 (S 24 ). If R 1 =R 2 =0 does not hold true (NO at S 24 ), the first and second line segments are not on the same straight line. Therefore, the process advances to step  26  (S 26 ), and  1  is added to variable m to make it 2, in order to specify the second line segment that goes through the determination processing next (S 26 ). Then, in step  27  (S 27 ) a determination is made as to whether the value of variable m is larger than n−2, i.e., whether the determination on intersection has been made on all the second line segments. In the example of  FIG. 13 , n−2=12 and m=2, so that it is determined that determination on an intersection has not yet been made on all the second line segments (NO at S 27 ). The process then returns to S 22 . 
         [0067]    If R 1 =R 2 =0, the first and second line segments are on the same straight line (YES at S 24 ). Further, in step  25  (S 25 ) a determination is made as to whether the two line segments overlap with each other. Specifically, a determination is made as to whether the x-coordinate X m  of an endpoint p m  of the second line segment p m p m+1  is present between the respective x-coordinates X n  and X n−1  of the endpoints p n  and p n−1  of the first line segment p n p n−1  (S 25 ). More specifically, a determination is made as to whether X n ≦X m ≦X n−1  or X n−1 ≦X m ≦X n . If X m  is present between X n  and X n−1 , the first and second line segments are on the-same straight line and overlap with each other (YES at S 25 ). Therefore, in step  29  (S 29 ) it is determined that the stitches overlap and the processing is ended. 
         [0068]    On the other hand, if X m  is not present between X n  and X n−1 , the two line segments do not overlap with each other (NO at S 25 ). Therefore, the process advances to step  26  (S 26 ), and 1 is added to variable m to make it 2 in order to determine the next line segment (S 26 ). Then at step  27  (S 27 ) it is determined whether the determination of an intersection has been made on all the second line segments. If the determination has not been made on all of the second line segments (NO at S 27 ), the process returns to S 22  to determine whether the next second line segment intersects with the first straight line (S 22 ). The processing of S 22 -S 27  is then repeated. 
         [0069]    In the example shown in  FIG. 13 , when variable m=2, it is determined at S 22  that the second line segment intersects with the first straight line (YES at S 22 ). In this case, the target for the determination is the second line segment p 2 p 3 . Since the respective coordinates arrays are R 2  (39.9, 1.7) and R 3  (58, 10.2), R 1 =(56.6−42.5)(1.7−(−4.2))+(−4.2−10)(−39.9+56.6)=−153.95. Thus, the sign of R 1  is negative. Further, R 2 =(56.6−42.5)(10.2−(−4.2))+(−4.2−10)(−58+56.6)=222.92. Thus, the sign of R 2  is positive. Therefore, R 1 *R 2  takes on a negative value and it is thus determined that the second line segment intersects with the first straight line (YES at S 22 ). In this case, the first condition is satisfied. 
         [0070]    Next, it is determined whether the second condition is satisfied. Specifically, in step  23  (S 23 ) a determination is made as to whether a straight line including the second line segment p m p m+1  intersects with the first line segment p n p n−1 . The straight line including the second line segment p m p m+1  is hereinafter referred to as a second straight line. 
         [0071]    Like the first straight line, an equation for the second straight line can be expressed as (X m+1 −X m )(y−Y m+1 )+(Y m+1 −Y m )(−x+X m+1 )=0. The coordinates of two needle drop points p n  and p n−1  that form the first line segment p n p n−1  are substituted into the left side (X m +1−X m )(y−Y m+1 )+(Y m+1 −Y m )(−x+X m+1 ). A value obtained by substituting the coordinates of the needle drop point p n−1  is R 3 , and a value obtained by substituting the coordinates of the needle drop point p n  is R 4 . When the signs of those values are both negative, the two needle drop points that form the first line segment are present in a coordinate region below the second straight line. On the other hand, when the signs of those values are both positive, the two needle drop points are present in a coordinate region above the second straight line. Therefore, if the sign of R 3 *R 4  is negative, the second straight line extends between the two needle drop points that form the first line segment, i.e., the second straight line and the first line segment intersect with each other. 
         [0072]    In the example shown in  FIG. 13 , since R 3 =(39.9)(−4.2−1.7)+(1.7−10.2) (−56.6−39.9)=248.74, the sign of R 3  is positive. Further, since R 4 =(39.9)(10−1.7)+(1.7−10.2)(−42.5−39.9)=−128.13, the sign of R 4  is negative. Therefore, R 3 *R 4  takes on a negative value, and it is determined that the second straight line intersects with the first line segment (YES at S 23 ). In other words, the second condition also is satisfied. Accordingly, in step  29  (S 29 ) it is determined that the stitches overlap. 
         [0073]    If having determined that the first line segment and the second straight line do not intersect with each other (NO at S 23 ), the process advances to S 26 , and 1 is added to variable m to make it 2 in order to make determination on the next second line segment (S 26 ). Then, determination is made as to whether the determination on intersection has been made on all the second line segments (S 27 ). If determination has not yet been made on all of the second line segments (NO at S 27 ), the process returns to S 22  to determine whether the next second line segment intersects with the first straight line (S 22 ). 
         [0074]    If none of the second line segments pmpm+1 intersects with the first straight line and, further, they are not on the same straight line (NO at S 22  and NO at S 24 , NO at S 22 , YES at S 24 , NO at S 25 , and YES at S 27 ), in step  28  (S 28 ) it is determined that the stitches do not overlap. If it is determined that the second line segment p m p m+1  and the first straight line intersect with each other but there is no second line segment p m p m+1  to make the second straight line which intersects with the first line segment p n p n−1  (YES at S 22 , NO at S 23  and YES at S 27 ), it is also determined that the stitches do not overlap (S 28 ). 
         [0075]    In such a manner, in the determination processing at S 11  ( FIG. 15 ) in the main processing shown in  FIG. 12 , the coordinates array R stored in the coordinate storage area  632  is referenced, and it is determined whether a stitch to be formed by interconnecting a point indicated by R n−1  and a point where the sewing needle  7  is to be pierced into the work cloth at this point in time overlaps with any one of stitches formed so far. 
         [0076]    As described above, in the sewing machine  1  of the first embodiment, the coordinates of the needle drop points are stored beforehand in the coordinates array R. Then, while the sewing needle  7  is not at the lower needle position, continual monitoring is made as to whether stitches overlap. More specifically, it is continually monitored to determine whether a line segment interconnects a position at which the sewing needle  7  is to be lowered from the current position and a position at which the sewing needle  7  is most recently pulled out from the work cloth (most recent needle drop point), that is, whether the line segment p n p n−1 , overlaps with any one of the line segments that indicate stitches formed so far (line segments p 0 p 1 , p 1 p 2 , . . . , and p n−2 p n−1 ). If it is determined that the line segments overlap with each other, the needle bar releasing mechanism  25  releases the needle bar  6  from power due to the driving of the sewing machine motor  79 , thereby operations of the sewing needle  7  are stopped. 
         [0077]    Therefore, the stitches can be prevented from overlapping with each other. It is thus possible to avoid making a mistake of overlapping stitches when, for example, a stippling stitch is formed by free-motion sewing, for which overlapping stitches may be considered unattractive. 
         [0078]    The sewing machine  1  in the above-described embodiment may be modified as follows. For example, in the first embodiment, a CCD camera is employed in the image sensor  50 . The image sensor  50 , however, only needs to be capable of detecting a movement distance and a movement direction of a work cloth. Optionally, the camera may be a CMOS camera. 
         [0079]    In the above-described embodiment, a determination is made as to whether a stitch to be formed, which interconnects a point indicated by R n−1  and a point at which the sewing needle  7  is to be pierced into the work cloth from the current position, overlaps with any one of the stitches formed so far. Based on the determination, the stitches can be prevented from overlapping with each other (S 11  in  FIG. 12 ). However, this determination may not include whether the stitches (line segments) overlap with each other. For example, it may be determined whether there is any stitch (line segment) among the stitches (line segments) formed so far that has a predetermined range within which the coordinates position p n  of the sewing needle  7  is present. In this case, if a stitch already exists in the predetermined range when the sewing needle  7  is pierced into the work cloth, i.e., if a stitch exists in the vicinity of the needle drop point p n , the error correction operation (releasing of the needle bar  6 ) may be performed. 
         [0080]    One example of the determination on whether there is a stitch in the predetermined range is described below with reference to  FIG. 16 . In this example, a distance between line segment AB and point C, which is not present on line segment AB, as shown in  FIG. 16 , is considered. A distance between point C and one of the points on line segment AB that is nearest to point C is taken as distance L. The relationships between line segment AB and point C are divided into three cases shown in  FIG. 16 . In the first case, the intersection point T of line segment AB and a perpendicular line drawn from point C to straight line AB is on line segment AB (point C 2  and intersection point T 2 ). In the second case, intersection point T is not present on line segment AB, and is closer to point A than to point B (point C 1  and intersection T 1 ). In the third case, intersection point T is not present on line segment AB, and is closer to point B than to point A (point C 3  and intersection T 3 ). 
         [0081]    As shown in  FIG. 16 , in the first case where intersection point T 2  is on line segment AB, length L C2  of a perpendicular line drawn from point C 2  to straight line AB is taken as distance L between line segment AB and point C. In the second case where intersection point T 1  is not on line segment AB and is closer to point A, which is one of the endpoints of line segment AB, length L C1  of line segment A C1  interconnecting point C 1  and point A is taken as distance L between line segment AB and point C. In the third case where intersection point T 3  is not on line segment AB and closer to point B, which is the other endpoint of line segment AB, length L C3  of line segment B C3  interconnecting point C 3  and point B is taken as distance L between line segment AB and point C. 
         [0082]    In the determination process, the position of intersection point T is first determined. An amount of change in x and an amount of change in y along line segment AB can be defined as dx=X B −X A  and dy=Y B −Y A , respectively. Then, the coordinates of intersection T of straight line AB and the perpendicular line drawn from point C to straight line AB can be expressed as T(X A +dx*t, Y A +dy*t). In this case, if 0≦t≦1, intersection point T is present on line segment AB. If t&lt;0, intersection T is present outside of point A of line segment AB along straight line AB. If 1&lt;t, intersection T is present outside of point B of line segment AB along straight line AB. 
         [0083]    Variable t can be obtained as follows. Since line segment TC and line segment AB are perpendicular to each other, the inner product of their vectors is 0. That is, (dx, dy)·(X A +dx*t−X C , Y A +dy*t−Y C )=0 is established. This equation may be rearranged as (dx 2 +dy 2 )t+dx(X A −X C )+dy(Y A −Y C )=0. Supposing that dx 2 +dy 2 =a and dx(X A −Y C )+dy(Y A −Y C )=b, the equations can be expressed as a*t+b=0, and t=−b/a can be obtained. The values of a and b are expressed by the coordinates of point A, B, and C and as such, can be calculated, referring to the coordinates of array R. 
         [0084]    If t&lt;0, point C has a position relationship of point C 1  shown in  FIG. 16 . Accordingly, distance L between line segment AB and point C is distance L C1  between point A and point C 1 . Specifically, distance L C1  is a positive square root of (X A −X C ) 2 +(Y A −X C1 ) 2 . Further, if t&gt;0, point C has a position relationship of point C 3  shown in  FIG. 16 . Accordingly, distance L between line segment AB and point C is distance L C3  between point B and point C 3 . Specifically, distance L C3  is a positive square root of (X B −X C3 ) 2 +(Y B −Y C3 ) 2 . 
         [0085]    Further, if 0≦t≦1, point C has a position relationship of point C 2  shown in  FIG. 16 . Supposing that intersection point T 2  is at (X T2 , Y T2 ), distance L C2  is a positive square root of (X A −X T2 ) 2 +(Y A −Y T2 ) 2 . It should be noted that X T2 =X A +dx*t=X A +dx*(−b/a) and Y T2 =Y A +dy*t=Y A +dy*(−b/a). The values of a and b are expressed by the coordinates of point A, B, and C, and as such, can be calculated referencing the coordinates array R. 
         [0086]    Thus, calculated distance L is compared with a preset reference distance. If distance L is not larger than the reference distance, it is determined that there is already a stitch in a predetermined range so the needle bar releasing processing is performed. As the reference distance, a predetermined value (e.g., 3 mm etc.) may be stored in advance. Further, the reference distance may be determined in accordance with a stitch length (pitch). For example, the reference distance may be the same as the stitch length, 1.5 times as long as the stitch length, or longer than the stitch length by  2 mm. The reference distance may be stored in the ROM  62  or the EEPROM  64  or written into the program. Further, a menu for setting a reference distance may be displayed on the LCD  10  so that the user can enter a numeral on the touch panel  16  or select one of several preset numerals. If the user is permitted to set the reference distance, the user can employ a desired distance. Therefore, the user can adjust the numeral by, for example, selecting a small value if stitch trajectories come close to each other, and may select a large value if stitch trajectories do not come close to each other. 
         [0087]    Further, rather than determining whether there is any one such stitch among the stitches formed thus far where the coordinates position p n  of the sewing needle  7  is present in the predetermined range, determination may be made as to whether the last needle drop point (coordinates position p n−1 ) is in the predetermined range. 
         [0088]    Further, in the first embodiment, if stitches are expected to overlap with each other, the needle bar releasing mechanism  25  releases the needle bar  6  from driving power of the sewing machine motor  79  as an error correction operation, thereby stopping the operations of the sewing needle  7 . However, the error correction operation is not limited to releasing the needle bar  6 . For example, revolving of the sewing machine motor  79  may be stopped to stop the operations of the sewing needle  7 . In this case, even after the revolving of the sewing machine motor  79  is stopped, several stitches may be formed through inertia. Nevertheless, the sewing machine motor  79  will be stopped faster than in a case where the user operates the sewing stop switch  82  after the user finds a stitch overlap. Therefore, even if stitches overlap with each other, the number of the overlapping stitches may be reduced. Further, rather than stopping the revolving of the sewing machine motor  79 , the sewing machine motor  79  may be slowed down, i.e., the sewing speed may be decreased. 
         [0089]    Further, the error correction operation may involve notification rather than stopping or slowing down the operations of the sewing needle  7 . As shown in  FIG. 17 , an alarm lamp  83  may be provided to the sewing machine  100 , so that it would light up or blink if stitches are expected to overlap with each other. The alarm lamp  83  might be disposed in the vicinity of a position at which the sewing needle  7  is stuck into a work cloth (needle drop point). For example, the alarm lamp  83  may be disposed at the lower end portion of the front surface of the head  4 , as shown in  FIG. 17 . The alarm lamp  83  may be connected to the output interface  66  so that it may light up in accordance with an instruction from the CPU  6   1 . Further, as shown in  FIG. 17 , a speaker  84  may be fitted to the sewing machine  100  so as to produce an alarm sound or a reminder message. The speaker  84  may also be connected to the output interface  66 . Further, these notification operations may be combined with other error correction operations, such as stopping of the operations of the sewing needle  7 , slowing down of the sewing speed, or releasing of the needle bar  6 . 
         [0090]    Next, a second embodiment will be described below with reference to  FIGS. 17-21 . In the second embodiment, a sewing machine  100  includes a CCD camera  53 , which captures an image in the vicinity of a needle drop point. If there is a stitch in the image captured, it is determined that a stitch is already present near an expected sewing position, and so there is a possibility of stitch overlapping. In this case, a sewing machine motor  79  is stopped to stop the operations of a sewing needle  7  so that sewing is stopped. The physical configuration of the sewing machine  100  in the second embodiment is much the same as that of the sewing machine  1  in the first embodiment, and so the explanation is omitted here. In the first embodiment, the sewing machine  1  includes the image sensor  50  (see FIG:  8 ). In the second embodiment, as shown in  FIG. 17 , the sewing machine  100  further includes a color sensor  52  that detects a thread color. The color sensor  52  is fitted into the spool housing  20 , to which a thread spool  21  used in sewing is attached. 
         [0091]    Next, the electrical configuration of the sewing machine  100  is described below. The electrical configuration of the sewing machine  100  also is much the same as that of the sewing machine  1  in the first embodiment (see  FIG. 9 ). In the sewing machine  1 , the CCD camera  53  is connected to the input interface  65 . In the sewing machine  100 , the color sensor  52  is also connected to the input interface  65 . The CCD camera  53  and the color sensor  52  capture images as required by the CPU  61 , and input thread color data detected from the captured image to the input interface  65 . 
         [0092]    Now, storage areas provided in a RAM  63  are described below with reference to  FIG. 19 . As shown in  FIG. 19 , the RAM  63  has a thread color storage area  638 , an image storage area  639 , and a pixel information storage area  640 . The RAM  63  has other storage areas other than those shown in  FIG. 19 . The thread color storage area  638  stores data of a thread color detected by the color sensor  52 . The image storage area  639  stores an image of a work cloth (hereinafter referred to as a work cloth image) taken by the CCD camera  53 . The pixel information storage area  640  stores information that indicates a pixel that is determined to have the same color as the thread color in the most recent two work cloth images (a current image and a last image). The information indicating the pixel is hereinafter referred to as stitch pixel information. 
         [0093]    Next, the operations of the sewing machine  100  are described below with reference to  FIG. 20 . Processing shown in  FIG. 20  starts when a sewing start switch  81  is operated to instruct start-up of sewing. As shown in  FIG. 20 , in step  41  (S 41 ) a thread color is detected (S 41 ). Specifically, data of the thread color detected by the color sensor  52  is stored as RGB-values in the thread color storage area  638 . 
         [0094]    Subsequently, in step  42  (S 42 ) a sewing machine motor  79  starts revolving to begin sewing. Then, in step  43  (S 43 ) a determination is made as to whether a sewing stop switch  82  is operated. If the sewing stop switch  82  is not operated (NO at S 43 ), in step  44  (S 44 ) an image of the vicinity of the needle drop point is captured by the CCD camera  53 , and a work cloth image is stored in the image storage area  639 . Then, in step  45  (S 45 ) a determination is made as to whether there is a stitch in the work cloth image. 
         [0095]    Specifically, the last stitch pixel information stored in the pixel information storage area  640  is updated by the current stitch pixel information. Then, RGB-values of each of the pixels of the work cloth image are compared with the RGB-values of the thread color stored in the thread color storage area  638 . If the respective RGB-values are in a predetermined allowable range, they are considered to agree with each other. For example, if the R-value of the thread color is 125 and the R-value of the pixel in the work cloth image is in the range of ±3, that is, between 122 and 128, it is determined that their respective R-values agree with each other. In such a manner, information that indicates that the pixels whose RGB-values are all determined to agree with those of the thread color is stored as the current stitch pixel information in the pixel information storage area  640  in the RAM  63 . If there are at least a predetermined number of the pixels that are stored in the pixel information storage area  640  as the number of those that agree with the thread color in RGB-values, it is determined that there is a stitch in the work cloth image. The predetermined number may be either a constant percentage (1%, 0.5%, etc.) of all the pixels in a work cloth image or a fixed value. The fixed value, if employed, may vary with the resolution of a work cloth image. 
         [0096]    Even if there is a stitch, there is no problem if the stitch has been formed most recently. That is, if the work cloth image has at least the predetermined number of pixels having the same color as the thread color, determination is made as to whether the stitch has been formed most recently. This determination is made by comparing the last stitch pixel information and the current stitch pixel information with each other. If a ratio at which the pixels indicated by the last stitch pixel information and the pixels indicated by the current stitch pixel information agree in at least a predetermined percentage, it may be considered that images of the same stitch have been captured. Accordingly, the percentage at which the pixels agree is calculated and, if it is at least a predetermined value (e.g., 50%), the stitch that is present in the work cloth image has been formed most recently. In such a case, it is determined that there is no stitch in the work cloth image. 
         [0097]    If it is determined at S 45  that there is a stitch in the work cloth image-(YES at S 45 ), the revolving of the sewing machine motor  79  is stopped to stop the operations of the sewing needle  7 , and sewing is stopped at step  46  (S 46 ). Then, the present processing is ended. If it is determined at S 45  that there is no stitch (NO at S 45 ), the process returns to S 43  and the processing of S 43 -S 45  is repeated. If the sewing stop switch  82  is operated during the processing (YES at S 43 ), the present processing is ended. 
         [0098]    As described above, in the sewing machine  100  in the second embodiment, if a stitch exists in the vicinity of a needle drop point, revolving of the sewing machine motor  79  is stopped in the error correction operation. Even after the revolving of the sewing machine motor  79  is stopped, several stitches may be formed because the operations of the needle bar  6  do not stop immediately. Nevertheless, the sewing machine motor  79  will be stopped faster than in a case where the user operates the sewing stop switch  82  after the user finds a stitch overlap. Therefore, even if stitches overlap with each other, the number of the overlapping stitches may be reduced so that fewer stitches may need to be unraveled, thereby mitigating the job of unraveling by the user. 
         [0099]    The sewing machine  100  in the second embodiment may be modified as follows. For example, in the second embodiment, the sewing machine motor  79  is stopped to stop sewing in an error correction operation. However, the error correction operation is not limited to stopping the sewing machine motor  79 . As in the first embodiment, the operations of the sewing needle  7  may be stopped by releasing the sewing needle  6  from driving power of the sewing machine motor  79  by using the needle bar releasing mechanism  25 . Other error correction operations such as those described in the first embodiment also may be employed. 
         [0100]    In the present embodiment, a determination is made as to whether there is a stitch in a predetermined range of a work cloth. It may be determined whether the stitch overlaps with any one of already formed stitches. In this case, if a line segment interconnecting an ending point of a most-recently formed stitch and a needle drop point overlaps with a detected stitch, it may be determined that the stitches overlap. 
         [0101]    In the second embodiment, the color sensor  52  is attached to the spool housing  20 . The attachment position, however, is not limited to this configuration. The attachment position may be anywhere, as long as it is possible to detect a thread set along a thread hooking path from the thread spool  21  to the sewing needle  7 . Further, instead of detecting a thread color by the color sensor  52 , the RGB-values of the thread colors of a plurality of thread kinds may be stored in advance in the EEPROM  64  or the ROM  62  in the sewing machine  100 . In such a case, the thread colors may be displayed on the LCD  10  and selected by the user via the touch panel  16 . When the LCD  10  is not colored, the color names and the thread part numbers may be displayed so that the user can select a desired thread color. 
         [0102]    Further, in the second embodiment, a stitch is detected on the assumption that the entirety of a work cloth image taken by the CCD camera  53  is within a predetermined range. However, the predetermined range may not be the entirety of the work cloth image, but may be only a part of the work cloth. For example, it is possible to use only such part of an image taken by the CCD camera  53  as necessary to be in a needle traveling direction from a needle drop point. In such a case, the most-recently formed stitch will not be detected. Further, in the second embodiment, images are continually taken by the CCD camera  53  to determine whether there is a stitch. However, there cannot be an already formed stitch when sewing is started, so that the CCD camera may be set to capture nothing within a predetermined lapse of time after the startup of sewing. Further, rather than taking images continually, the images may be taken at every predetermined lapse of time (e.g., 0.2s) to determine whether there is a stitch. Further, the CCD camera  53  may be replaced by a CMOS camera.

Technology Category: d