Description APPARATUS AND METHOD FOR CONTROLLING SPANGLE

SUPPLIER

Technical Field

[1]

[2] The present invention relates to a spangle supplier,and more particularly, to an apparatus and method for controlling a spangle supplier, in which control signals for spangle are received not from the main CPU of the embroidery machine but from the sensors or solenoids of the embroidery machine, which are installed in the respective heads, and the solenoid valve or the stepping motor is driven by the signal processed through the control unit, so that the spangle supplier can be smoothly controlled regardless of the different kinds of embroidery machines with the different signal systems and the different year and make thereof, or the kinds of automated single/ multiple embroidery machines.

Background Art

[3]

[4] Generally, embroidered basic fabric using spangles of small pieces in various forms has more value added than simple embroidered basic fabric using yarns of various colors.

[5] These spangles are material usually applied to basic fabric, clothing, shoes, and accessories for women. The spangles are formed of polyvinyl chloride (PVC) or pure polyester, and produced in the form of a tape.

[6] To provide these spangles, a spangle supplier moves a spangle tape at a predetermined speed and cuts the spangles into individual pieces. After being cut, the spangles are sewed and attached to the basic fabric.

[7] Conventionally, a spangle supplier made by a different manufacturer than that of an embroidery machine has a signaling system incompatible with the embroidery machine. Consequently, it is very difficult for the spangle supplier and the embroidery machine to share signals. Additionally, even if signals are compatible between the machines, the main CPU of the embroidery machine needs to process all the signals in order to control the spangle supplier with respect to a plurality of heads in the embroidery machine. Thus, an overload is frequently generated in the main CPU of the embroidery machine, and peripheral devices including the CPU can break down in the worst-case scenario.

[8] Additionally, in a conventional method for controlling the spangle supplier, there is the problem of a design limitation in that a thread is continuously drawn to allow only

a running stitch when the spangle supplier must switch operating processes without cutting a yarn.

[9] Moreover, when resuming the spangle embroidery after a power failure or a process termination, an operator needs to manually readjust the starting point since the new starting point is different from the original starting point.

[10] Accordingly, the present invention is directed toan apparatus and method for controlling spangle supplierthat substantially obviates one or more problems due to limitations and disadvantages of the related art. Disclosure of Invention

Technical- Problem

[11] n object of the present invention is to providean apparatus and method for controlling a spangle supplier, in which control signals for spangle are received not from the main CPU of the embroidery machine but from the sensors or solenoids of the embroidery machine, which are installed in the respective heads, and a solenoid valve or a stepping motor is driven by the signal processed through the control unit, so that the spangle supplier can be smoothly controlled regardless of the different kinds of embroidery machines with the different signal systems and the different year and make thereof, or the kinds of automated single/multiple embroidery machines.

[12] Another object of the present invention is to provide an apparatus and method for controlling a spangle supplier, capable of solving the problem of a design limitation by programming the spangle supplier to wait in an ascended state through a control unit. Specifically, when moving to another working point after the cut process, the movement is achieved not by the running stitches but by the jump, thereby solving the problem of the design limitation.

[13] A further another object of the present invention is to provide an apparatus and method for controlling a spangle supplier, capable of automatically setting a spangle tape, which is provided to the spangle supplier, at an accurate cutting position when re- supplying a power after the power is off.

[14] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

Technical- Solution

[15] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the apparatus includes: a

sensor unit having a needlebar position sensor for detecting a needlebar position and outputting a detection signal to the control unit, an initial position sensor for detecting an initial position of a stepping motor and outputting a detection signal to the control unit, and a main-shaft rotation sensor for detecting a cycle of the needlebar; a key button unit having a reset button for initializing the control unit, a forward button for forwarding the spangle tape by rotating a driving shaft of the stepping motor in a forward direction, a reverse button for reversing the spangle tape by rotating the driving shaft of the stepping motor in a reverse direction, and an up/down button for driving a cylinder to ascend/descend a bottom portion of the spangle supplier; the control unit for processing each signal from the sensor unit, the key button unit and the embroidery machine, and outputting control signals of the spangle supplier; the stepping motor driven to move the spangle tape according to the control signal from the control unit; anda solenoid valve for ascending/descending a cylinder by the control unit receiving a solenoid signal from the embroidery machine and determining an ascending/descending timing of the cylinder, whereinthe control unit moves the spangle supplier in a predetermined distance each time when a jump solenoid signal is inputted from the embroidery machine.

[16] In apparatus for controlling a spangle supplier, which includes at leas one needle mounted on at least one head, a needlebar for supporting the needle, and a control unit, mounted on a embroidery machine with a thread adjuster and a tread snatcher, for moving and cutting a spangle tape and controlling a spangle supplier to provide spangles sewn by the needle, a sensor unit includes: a needlebar position sensor for detecting a position of a needlebar of the embroidery machine and outputs a detection signal; an initial position sensor for detecting an initial position of a stepping motor and outputs a detection signal to the control unit, and a main-shaft rotation sensor for detecting a rotation/stop of a main shaft. A key button unit includes a reset button for initializing the control unit, a forward/reverse button for forwarding/reversing a spangle tape by rotating a driving shaft of the stepping motor in a forward/reverse direction, and an up/down button for driving a cylinder to ascend/descend a bottom portion of the spangle supplier. A control unit processes signals inputted from the sensor unit, the key button unit and the embroidery machine and outputs control signals of the spangle supplier. A stepping motor is driven by the control signal to move the spangle tape. An ascending/descending jump solenoid of the cylinder receives a jump signal from the embroidery machine and automatically determines an ascending/descending timing of the cylinder. The control unit moves the spangle supplier by a predetermined distance every when the jump signal is inputted from the embroidery machine.

[17] The control unit includes: a power unit for converting power supplied from a power

supply and providing the power into each of the units; a signal input unit for receiving a digital signal through the sensor unit, the key button unit and the solenoid unit, changing a voltage level of the digital signal, and filtering the digital signal; a signal process unit for generating a control signal to drive the stepping motor in an appropriate timing or to control the solenoid valve through the signal output unit by analyzing input signals of the sensor unit, the key button unit, and the solenoid unit through the signal input unit; a signal output unit for changing a level of the digital signal to operate the stepping motor or the cylinder; and a stepping motor drive unit electrically connected to the stepping motor, the stepping motor drive unit repeatedly moving a predetermined distance according to a moving direction or a pulse signal, which is previously set to drive the stepping motor according to the control signal through from the signal process unit to the signal output unit.

[18] Input signals of the control unit includes: a jump solenoid signal, a wiper solenoid signal, and a cut solenoid signal inputted from the embroidery machine; a needlebar position detection signal detected from the needlebar position sensor; a stepping motor initial position detection signal detected from the initial position detection sensor; a main-shaft rotation detection signal detected from the main-shaft rotation detection sensor; an initialization signal for initializing the control unit through the reset button; a forward signal for rotating the stepping motor in a forward direction through the forward button; a reverse signal for rotating the stepping motor in a reverse direction through the reverse button; and an up/down signal for ascending/descending the cylinder through the up/down button by an input signal of the key button operated by a user.

[19] The output signal of the control unit includes: a pulse signal for controlling a direction of the stepping motor or informing a moving distance; a low-power control signal for power saving when not in use; a cylinder drive signal for ascending/ descending the cylinder; and a status output signal for displaying a status indicator LED to an exterior such that a user monitors a normal operation status, a power saving status, and other error status of the control unit.

[20] The control unit further includes a toggle switch for suspending unnecessary heads and putting the spangle supplier on a standby mode without conveying the spangle in a spangle embroidery process of more than two embroidery machines.

[21] According to another aspect of the present invention, there is provided a method for controlling a spangle supplier, including the steps of: initializing a control unit and a position of a spangle tape provided by a spangle supplier after power is on and supplied to the control unit from a power supply; supplying spangles if the signal of the needlebar position sensor is on, and suspending all control functions of the spangle supplier if a signal of the needle position sensor is off after the initialization of the

control unit is finished; descending a bottom portion of the spangle supplier to supply spangles by driving the cylinder when the spangle supplier is disposed above a position of the needlebar and a signal of the needlebar position sensor is on, and ascending the cylinder toward a neutral position when the signal of the needlebar position sensor is off; and setting a jump flag when a jump solenoid signal is inputted by an embroidery machine or a additional floppy disk and informs a timing of mounting the spangles, and resetting a jump flat after driving a stepping motor to mount the spangles on a embroidery basic fabric when the jump solenoid signal is off.

[22] The step of initializing the control unit includes the steps of: initializing variable values or various register values used in the control unit; initializing an output value of a stepping driver control signal used for driving a stepping motor; and setting an accurate initial position of a spangle tape supplied to the spangle supplier by driving the stepping motor.

Advantageous Effects

[23] According to the present invention, the control signals for spangle are received not from the main CPU of the embroidery machine but from the sensors or solenoids of the embroidery machine, which are installed in the respective heads. Then, the solenoid valve or the stepping motor is driven by the signal processed through the control unit. Therefore, the spangle supplier can be smoothly controlled regardless of the different kinds of embroidery machines with the different signal systems and the different year and make thereof, or the kinds of automated single/multiple embroidery machines.

[24] Additionally, by keeping the body of the spangle supplier waiting in an ascended state, a general embroidery process is not interrupted during cutting off the power, cutting the thread, replacing the needlebar, and terminating the spangle process. Moreover, when moving to another working point, the movement is achieved not by the running stitches but by the jump, thereby solving the problem of the design limitation.

[25] Furthermore, when re-supplying power after the power is off,aposition of the spangle tape supplied to the spangle supplier can be set automatically.

Description Of Drawings

[26]

[27] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:

[28] Fig. 1 is a block diagram illustrating a controlling apparatus of a spangle supplier according to an embodiment of the present invention;

[29] Fig. 2 is a block diagram of a sensor unit in Fig. 1 ;

[30] Fig. 3 is a block diagram of a key button unit in Fig. 1 ;

[31] Fig. 4 is a block diagram of a solenoid unit in Fig. 1 ;

[32] Fig. 5 is a schematic view of a controlling apparatus connected to a spangle supplier according to an embodiment of the present invention; and

[33] Fig. 6 is a flow chart illustrating a sequential control process of a spangle supplier according to an embodiment of the present invention.

Best Mode

[34]

[35] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[36] Fig. 1 is a block diagram illustrating a controlling apparatus of a spangle supplier,

Fig. 2 is a block diagram of sensor unit shown in Fig. 1, Fig. 3 is a block diagram of a key button unit shown in Fig. 1, Fig. 4 is a block diagram of a solenoid unit shown in Fig. 1, and, Fig. 5 is a schematic view of a controlling apparatus connected to a spangle supplier.

[37] First, an apparatus for controlling a spangle supplier 40 includes a sensor unit 21, a key button unit 23, a solenoid unit 24, a control unit 30, a stepping motor 41, and a solenoid valve 50. The control unit 30 analyzes and processes signals from the key button unit 23 and the solenoid unit 24. Additionally, the stepping motor 41 and the solenoid valve 50 are driven according to the processed signals outputted from the control unit 30.

[38] Referring to Figs 2 and 5, the sensor unit 21 includes a needlebar position sensor

21 A for detecting a position of a needlebar 6, an initial position sensor 2 IB for detecting an initial position of the stepping motor 41, a main-shaft rotation sensor 21C for detecting an operation of one cycle in up and down directions of the needlebar 6.

[39] Additionally, referring to Fig. 3, the key button unit 23 includes a reset button 23A for initializing the control unit 30, a forward button 23B for forwarding a spangle tape 1 by rotating a driving shaft of the stepping motor 41 in a forward direction, a reverse button 23C for reversing the spangle tape 1 by rotating the driving shaft of the stepping motor 41 in a reverse direction, and an up/down button 23D for driving a cylinder to ascend/descend a bottom portion 44 of the spangle supplier 40 shown in Fig. 5.

[40] The solenoid unit 24 includes a jump solenoid 24A for receiving a jump signal of an embroidery machine, a wiper solenoid 24B for receiving a timing of wiping a thread while cutting the thread, and a cut solenoid for receiving a cut signal of the thread.

[41] The control unit 30 includes a power unit 31, a signal input unit 32, a signal process

unit 33, a signal output unit 34, and a motor drive unit 35. The respective units of the control unit 30 will now be described. [42] First, the power units 31 converts 24V DC supplied from an external power supply

10 into 5 V DC that can be used in the control unit 30, and provides the 5 V DC into each unit. [43] Additionally, the signal input unit 32 receives a signal through the sensor unit 21, the key button unit 23 and the solenoid unit 24, and changes a voltage level of the signal, and also plays a role in filtering the signal for a convenient use. At this time, the input signals from the exterior of the control unit 30 are separated from an internal control signal by a photo coupler (not shown). [44] The signal process unit 33 drives the stepping motor 41 in an appropriate timing by analyzing signals from the signal input unit 32, or generates an on/off signal to drive the solenoid valve 50. [45] Input signals received by the signal process unit can be divided into largely three types. [46] First, signals inputted from the embroidery machine are a signal of the jump solenoid 24A, a signal of the wiper solenoid 24B, and a signal of the cut solenoid 24C. [47] Second, sensor signals from the exterior of the control unit 30 are a detection signal for a needlebar position, which is detected through the needlebar position sensor 2 IA, a detection signal for an initial position of the stepping motor 41, which is detected through the initial position sensor 2 IB, and a detection signal for a main-shaft rotation, which is detected through the main-shaft rotation sensor 21C. [48] Third, there is a key button input signal operated by a user through the key button unit 23. The key button input signals are an initialization signal for initializing the control unit 30 through the reset button 23A, a forward signal for forwarding the stepping motor 41 through the forward button 23B, a reverse signal for reversing the stepping motor 41 through the reverse button 23B, and a up/down signal for ascending/ descending the cylinder 43 through the up/down button 23D. [49] Moreover, the signal process unit processes input signals and then outputs signals to the exterior of the control unit. The output signals are largely divided into three types. [50] First, most of the output signals are used to control the stepping motor drive unit 35.

That is, a pulse signal is used to control a direction of the stepping motor 41 and to inform a moving distance. A low-power control signal is used for power saving when the spangle supplier is not in use. [51] Second, a cylinder drive signal is used to control the ascending/descending of the cylinder 43. [52] Third, a status output signal is used for outputting a status indicator LED (60) in order that a user can monitor a status of the control unit 30 such as a normal operation

status, a low-power status, and other error statuses.

[53] Additionally, output signals from the signal output unit 34 and the signal input unit

32 are digital signals. The signal output unit 34 changes a level of an output voltage, and uses an internal control signal to operate the stepping motor 41 and other devices in the exterior of the control unit 30.

[54] Moreover, the stepping motor 41 is electrically connected to the stepping motor drive unit 35. The stepping motor drive unit 35 has a function to drive the stepping motor 41 according to a control signal through from the signal process unit 33 to the signal output unit 34, and repeatedly moves the stepping motor 41 in a constant distance according to a predefined moving direction or a pulse signal.

[55] The above-described connection relationship between each unit can be summarized as the driving of the stepping motor 41 according to an external input signal. Each time an input signal from an embroidery machine, especially a signal of the jump solenoid 24 A, is inputted, a main function is to move the stepping motor 41 in a predetermined distance. The other signals are used to operate additional functions.

[56] Reference numerals 5, 45 and 46 represent a needle, a driving roller for moving a spangle tape, and a cutter for cutting a spangle tape, respectively.

[57] Referring to Fig. 6, a method for controlling a spangle supplier will now be described. Fig. 6 is a flowchart illustrating a controlling method of a spangle supplier according to an embodiment of the present invention.

[58] In step Sl, after power is on, the power is supplied to the control unit 30 from the power supply 10, and then the control unit 30 is initialized.

[59] That is, the initialization is largely divided into three processes. First, the setup of variable values or register values used internally is initialized. Then, a control signal output value of the stepping driver 35 for driving the stepping motor 41 is initialized. Finally, the stepping motor 41 is driven to set an accurate initial position of the spangle tape 1.

[60] In this case, the signal process unit 33 processes a signal inputted through the initial position sensor 2 IB. Next, the setting of the accurate initial position of the spangle tape 1 is executed by driving the stepping motor 41 through the stepping motor drive unit 35 according to predetermined processes.

[61] In step S2, after the initialization is finished, whether to execute an entire control loop is determined using a signal received from the needlebar position sensor 2 IA.

[62] In this case, if the signal of the needlebar position sensor 21 A is off, all control functions of the spangle supplier are suspended because it is considered that the spangle supplier is not mounted on a position of the needlebar. On the contrary, if the signal of the needlebar position sensor 21An is on, all control functions of the spangle supplier are operated normally because it is considered that the spangle supplier is

mounted on a position of the needlebar.

[63] Also, a position of the cylinder is determined according to the signal detected from the needlebar position sensor 21a. That is, when the signal of the needlebar position sensor 21a is on, it is considered that the spangle supplier is mounted on a position of the needlebar, so that the bottom portion 44 is descended to install spangles according to driving of the cylinder 43. In step S4, when the signal of the needlebar position sensor 21a is off, the cylinder 43 is ascended toward the neutral position of the cylinder 43.

[64] In step S5 and S6, if it is determined in step S2 that the spangle supplier is mounted on the position of the needlebar and the signal of the jump solenoid in the embroidery is on, it is recognized as a preparation timing for supplying spangles and a jump flag variable is set. In steps S7 and S8, if the set value of the jump flag is set in a state in which the signal input of the jump solenoid is in off-state, it is determined as a timing when the signal of the jump solenoid is terminated, so that the stepping motor is rotated. In step S9, the spangles are supplied and the jump flag variable is reset.

[65] When an unnecessary head 3 is suspended by a toggle switch 25 in a spangle embroidery process of more than two embroidery machines, the suspended head 3 does not generate the signal of the jump solenoid, and the mounted spangle supplier waits in the suspended state without transferring the spangles.

[66] In step SlO, the key button signal generated by the user manipulation is received and corresponding functions are performed. In step SIl, an internal status of the control unit 30 is outputted such that the user can monitor the status of the control unit 30. In this manner, the control process of the spangle supplier is completed.

[67] All the above operations are repeated with an infinite loop until the power is cut off.

Finally, a control of the spangle supplier is completed when the power is off.

[68] According to the present invention, the control signals for spangle are received not from the main CPU of the embroidery machine but from the sensors or solenoids of the embroidery machine, which are installed in the respective heads. Then, the solenoid valve or the stepping motor is driven by the signal processed through the control unit. Therefore, the spangle supplier can be smoothly controlled regardless of the different kinds of embroidery machines with the different signal systems and the different year and make thereof, or the kinds of automated single/multiple embroidery machines.

[69] Additionally, by keeping the body of the spangle supplier waiting in an ascended state, a general embroidery process is not interrupted during cutting off the power, cutting the thread, replacing the needlebar, and terminating the spangle process. Moreover, when moving to another working point, the movement is achieved not by the running stitches but by the jump, thereby solving the problem of the design limitation.

[70] Furthermore,when re-supplying power after the power is off,aposition of the spangle tape supplied to the spangle supplier can be set automatically.

[71] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Industrial Applicability

[72] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.