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Title:
ELECTRONIC CONTROL SYSTEM INSERTED ONTO SEWING MACHINES
Document Type and Number:
WIPO Patent Application WO/2017/095355
Kind Code:
A1
Abstract:
The invention relates to an electronic control system which ensures full synchronized operation of mechanisms and apparatuses such as puller, material feeding (stitching materials such as fabric, carpet, plastics, canvas, etc.. with machine), tape re-puller, smocking apparatus, additional transport mounted on sewing machines, in all cases (stich length and stich direction does not make difference) without needing any setting.

Inventors:
YILMAZ, Hakan (Halkali Merkez Mah. Camlikalti Mevkii Korulu Sok. Koru Sitesi A2 Blok Daire: 6 Kucukcekmece/Istanbul, TR)
Application Number:
TR2016/050481
Publication Date:
June 08, 2017
Filing Date:
December 02, 2016
Export Citation:
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Assignee:
YILMAZ, Hakan (Halkali Merkez Mah. Camlikalti Mevkii Korulu Sok. Koru Sitesi A2 Blok Daire: 6 Kucukcekmece/Istanbul, TR)
YILMAZ, Oktay (Halkali Merkez Mah. Camlikalti Mevkii Korulu Sok. Koru Sitesi A2 Blok Daire: 6 Kucukcekmece/Istanbul, TR)
UNLU, Gokhan (Halkali Merkez Mah. Camlikalti Mevkii Korulu Sok. Koru Sitesi A2 Blok Daire: 6 Kucukcekmece/Istanbul, TR)
International Classes:
D05B19/16; D05B27/22
Foreign References:
US4295435A1981-10-20
JPS61131788A1986-06-19
JP2006181166A2006-07-13
JPH0479986A1992-03-13
US4109596A1978-08-29
GB2177520A1987-01-21
US6871606B22005-03-29
US4295435A1981-10-20
Attorney, Agent or Firm:
DESTEK PATENT, INC (Lefkose Caddesi NM Ofispark B Blok No:36/5 Besevler, Bursa, TR)
Download PDF:
Claims:
CLAIMS

1 . A sewing machine which comprises an electronic control system, which is used in the textile sector and in homes, which performs the feeding operation by the feeding element (15) that the feeding mechanism or the needle feeding mechanism or the upper feeding mechanism has and where the said feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanism are together, and which comprises: a counterpart sensor (31 ) which is positioned on the main pulley (29) or on the main shaft (30) of the sewing machine or on a piece which directly or indirectly move the main pulley (29) or the main shaft (30) or on a preferred piece which produces the vertical motions of the feeding mechanism(s) with the motion it receives from the pieces the main pulley (29) or the main shaft (30) indirectly or indirectly moves, that is the main shaft (30) and which transfers this motion to the feeding element(s) (15),

a sensor (33) which is fixed at a position that senses the said counterpart sensor (31 ) and which sends a signal to a step motor driving embodiment when it senses the said counterpart sensor (31 ),

a counterpart signal generator (22),

a signal generator (23) which generates a signal in response to the motion of the said counterpart signal generator (22) and which transfers the signals it produces to a step motor driving embodiment,

a step motor driving embodiment which through a step motor driver (45) operates a step motor (4) that gives the motion needed to the mechanism that provides the motion of the material depending upon the content of the motion signal it receives from the signal generator (23) in the time intervals it receives signal from the sensor(33) during the time it receives signal from the said signal generator(23) and which during the time it receives signal from the signal generator(23), stops the operation of the step motor(4) through the said step motor driver (45) when the signal from the sensor (33) is stopped and does not operate the step motor (4) until signal is received again from the sensor(33), and which is characterized in that it comprises:

the said counterpart signal generator (22) which is fixed to one of the said feeding mechanisms, having the same motion with the circular or linear motions of the said feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanism of the sewing machine, the said signal generator (23) which is positioned opposite to the said counterpart signal generator (22) in a position that can sense the circular or linear motions of the counterpart signal generator (22) to produce signal according to the circular or linear motions of the said feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanism.

2. A sewing machine as claimed in Claim 1 , which is characterized in that the said step motor driving embodiment comprises PLC (46) which provides the control of the said step motor driver (45) according to the content of the signal it receives from the said signal generator (23) and the said sensor(33).

3. A sewing machine as claimed in Claim 1 , which is characterized in that the said step motor driving embodiment comprises an electronic control circuit (48) which provides the control of the said step motor driver (45) according to the content of the signal it receives from the said signal generator (23) and the said sensor(33). 4. A sewing machine as claimed in Claim 1 , which is characterized in that the said step motor driving embodiment comprises a frequency divider (47) use in controlling of the said step motor driver (45) according to the content of the signal it receives from the said signal generator (23) and the said sensor(33). 5. A sewing machine as claimed in Claim 1 , which is characterized in that in the said electronic control mechanism, the turn signal which the step motor (4) should produce for the set stitch length is defined in the said step motor driver (45), in all cases where the feeding element(s) (15) affect the material, whether it is forward or backward motion, whether the stitch length setting is changed by an element that is positioned on the sewing machine and that changes the stitch length setting or the stitch length or the forward-backward direction is instantaneously changed by a lever arm (26) positioned on the sewing machine.

Description:
Electronic control system inserted onto sewing machines

DESCRIPTION

Technical Field

The present invention relates to a system to be used in electronic control of new apparatus and accessory mechanisms (new generation puller, gathering apparatus, additional transport etc.), which could not be used in some machines employed in the textile sector and at homes until the invention of existing systems and apparatus such as puller, tape prepuller, additional feeding and the electronic control system that is the subject matter of the present invention, which realizes the feeding operation by a feeding element of the feeding mechanism, which can be mounted on all machines such as single needle lock stitcher, double needle lock stitcher, chain stitch machine, zigzag sewing machine, overlook machine, interlock machine, lock sewing machine, belt machine, bridge machine, feed off the arm chain stitcher, blind stitcher machine, etc. State of the Art Technology

The devices and the accessory mechanisms that are the subject matter of the present invention should operate fully synchronized with the machined they are connected to because the sewing of the desired quality can only be performed when this synchronized operation is ensured. This target is partially reached in the most advanced systems being used today; however, electronic information to the step motors that drive these devices and the accessory mechanisms are being obtained from the wrong place (the main shaft of the machine and the attached balancing pulley). In systems installed with method some inevitable shortcomings have occurred. Despite difficult use and high costs of these systems, full proficiency has not been reached. For example, if the puller device mounted on a single needle lock stitcher is of a commonly used mechanical structure, the wheel that performs the pulling operation of the material (for example fabric, carpet, plastics, canvas, etc.) can turn only in the forward direction of the stitch and when a backward stitch is necessary, the wheel is lifted upwards to prevent distortion in the stitch since the mechanism cannot turn the wheel upwards. If the puller device is made with step motor controlled electronically, the puller wheel can turn backwards during backward stitch but the machine must have electronic backward stitch (zigzag) accessory, thus it must be an electronic single needle lock stitcher of high cost. When the lever arm used to manually and instantaneously change the stitch length and the stitch direction (forward and backward), known colloquially as the zigzag arm, again the wheels should be lifted up to prevent the distortion of the stitch. In addition, when the stitch length setting of the machine is changed, the pulling distance of all the existing systems, whether they are mechanical or electronic, must also be re-arranged each time to operate synchronously with the machine. The conditions explained here are valid when a puller device is connected to a single needle lock stitcher.

In addition, in all machines, the stitch length of which can be arranged, when the length setting is changed, it is necessary that the mounted device is also re-synchronized.

In the prior art search, US Patent Application No US6871606 was found. This Application relates to a method and device for arranging material conveyance in a sewing machine or an embroidery machine. In the system disclosed in this application, the electronic information is provided by a motion or position sensor on the material being stitched. Another patent application is the US Patent Application No US4295435. This application relates to a puller machine, which comprises a wheel turned by a step motor operated according to the electric pulses produced by a sensor sensing the main shaft of the sewing machine. In the existing systems mentioned in this application, the electronic information is taken from the wrong point that is from the main pulley or shaft of the machine, as mentioned earlier.

Consequently, due to the disadvantages mentioned above and due to the insufficiency of the existing solutions on the issue, an advancement in the related technical field is necessary.

Objective of the Invention

The present invention, inspired from the current situation, aims to solve the disadvantages mentioned above and to ensure by the method found some novelties which have not been possible to utilize up to now. In the method performed by the system that is the subject of the present invention, the signal generator is mounted to a suitable section of the feeding mechanism, which section creates the horizontal motion of the feeding mechanism and carries it to the material to be stitched. This way signal is produced and the accurate pulling time interval information of these signals that will start and stop the step motor (This information varies depending on the need of the apparatus or the device to be controlled to operate synchronously with the machine. For example, when smocking is desired in a single needle lock stitcher with needle transport, the feeding element must be used in the time interval when it does not affect the material to be stitched in addition to the time interval when it affects) are taken by the sensor from the parts, the position of which are determined in the main pulley and main shaft of the machine and in the pieces that directly or indirectly move these (such as the pulley and shaft of the motor that drives the machine) or that these directly or indirectly move (in the pieces that produce the vertical movements of the feeding mechanism with the motion it receives from the an additional pulley that moves parallel to the main pulley and transfers it to the feeding element (these pieces vary depending on the type of the machine)) and which are mounted an counterpart sensor. Then, these signals are used as desired (In the installed system, it is ensured that the signal taken from the sensor is conveyed to the driver of the step motor to start and stop the step motor. But as seen in Figure 11 , it is possible that the signals received from the signal generator and the said sensor are connected to a control circuit (pic, frequency divider, electronic circut, etc) or to a control box that comprises (a control box that can drive the step motor etc.) all of these before the step motor driver with an alternative connection and that after the signals are processed as desired, the step motor is started and stopped. The important point here is that the information received from the sensor is used to stop and start the motor.) The system that is the subject of the present invention in all machines which perform the feeding by a feeding element that the feeding mechanism has. In virtue of the method performed by the system that is the subject of the present invention, if a puller device is mounted to a single needle lock stitcher, as illustrated in the technical drawings, as this device is mounted to the machine for the first time its synchrony with the machine will be made only once and then this device will perform the pulling operation by mimicking the feeding element by processing the information received from the horizontal motion of the feeding mechanism of the machine with no error and not needing re-setting in both forward and backward stitches. In addition, contrary to all other control methods, when the stitch length setting of the machine is changed, the pulling device will automatically continue fully synchronized operation, without any re-setting, in virtue of the accurateness of the method used. Even when an electronic apparatus to change the forward-backward direction of the stitch (zigzag apparatus) or a lever arm to instantaneously change the forward-backward direction and the length setting of the stitch is used, which is the most difficult to control, the device being controlled with the said new system will continue perfect operation, without the need to lift the wheel, as is never possible in the state of the art, costly systems due to the error of the method being currently used.

To apply the apparatus or mechanisms to be controlled by the system of the present invention to machines, these machines do not need any electronic motor or apparatus. The system of the present invention can be applied to all stitches, electronic or mechanic, which perform the feeding operation through a feeding element.

In virtue of the system of the present invention, some new systems that are impossible to be made with the methods being currently used can also be applied to machines. For example, performing smocking with a machine with needle transport or rendering an additional transport capacity to a machine with needle transport. Such examples can be increased according to need.

To achieve the objectives mentioned above, a sewing machine which can be used in the textile sector or at home and which performs the feeding operation through a feeding element that the feeding mechanism or the needle feeding mechanism or the upper feeding mechanism has or through feeding elements in the sewing machines which have the said the feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanisms together has been developed. The said sewing machine comprises an electronic control system which comprises: a counter sensor which is positioned on the main pulley or on the main shaft of the sewing machine or on a piece which directly or indirectly move the main pulley or the main shaft or on a preferred piece which produces the vertical motions of the feeding mechanism(s) with the motion it receives from the pieces the main pulley or the main shaft indirectly or indirectly moves, that is the main shaft and which transfers this motion to the feeding element(s),

- a sensor which is fixed at a position that senses the said counterpart sensor and which sends a signal to a step motor driving embodiment when it senses the said counterpart sensor,

- a counterpart signal generator,

- a signal generator which generates a signal in response to the motion of the said counterpart signal generator and which transfers the signals it produces to a step motor driving embodiment,

a step motor driving embodiment which through a step motor driver operates a step motor that gives the motion needed to the mechanism that provides the motion of the material depending upon the content of the motion signal it receives from the signal generator in the time intervals it receives signal from the sensor during the time it receives signal from the said signal generator and which during the time it receives signal from the signal generator, stops the operation of the step motor through the said step motor when the signal from the sensor is stopped and does not operate the step motor until signal is received again from the sensor and in addition: the said counterpart signal generator which is fixed to one of the said feeding mechanisms, having the same motion with the circular or linear motions of the said feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanism of the sewing machine, the said signal generator which is positioned opposite to the said counterpart signal generator in a position that can sense the circular or linear motions of the counterpart signal generator to produce signal according to the circular or linear motions of the said feeding mechanism or the said needle feeding mechanism or the said upper feeding mechanism.

In a preferred embodiment of the invention, the sewing machine is characterized in that the said step motor driving embodiment comprises PLC (Programmable Logic Controller) which provides the control of the said step motor driver according to the content of the signal it receives from the said signal generator and the said sensor.

In a preferred embodiment of the invention, the sewing machine is characterized in that the said step motor driving embodiment comprises electronic control circuit which provides the control of the said step motor driver according to the content of the signal it receives from the said signal generator and the said sensor.

In a preferred embodiment of the invention, the sewing machine is characterized in that the said step motor driving embodiment comprises frequency divider use in controlling of the said step motor driver according to the content of the signal it receives from the said signal generator and the said sensor.

In a preferred embodiment of the invention, the sewing machine is characterized in that in the said electronic control mechanism, the turn signal which the step motor should produce for the set stitch length is defined in the said step motor driver, in all cases where the feeding element(s) affect the material, whether it is forward or backward motion, whether the stitch length setting is changed by an element that is positioned on the sewing machine and that changes the stitch length setting or the stitch length or the forward-backward direction is instantaneously changed by a lever arm positioned on the sewing machine.

The structural and characteristics features and all advantages of the present invention will be more clearly understood by the figures given below and the detailed disclosure referencing these figures and hence, assessment of the invention should be made considering these figures and the detailed disclosure.

Figures That Will Help Understanding the Invention Figure 1 : Two-dimensional view of the sewing machine from the left side in which the system of the present invention is used.

Figure 2: Two-dimensional view of the sewing machine from the right side in which the system of the present invention is used.

Figure 3: Front view of the sewing machine in which the system of the present invention is used. Figure 4: Detailed view of Figure 3 part A, which shows the stitch length setting numerator and the lever arm.

Figure 5: The time schedule of a single needle lock stitcher to which the system of the present invention was applied.

Figure 6: 2-Dimensional left side view of the puller mechanism mounted to a sewing machine controlled by the system of the present invention, showing some angle and diameter values.

Figure 7: Drawing showing the feeding gear, connection rod, horizontal motion trunnion, horizontal motion shaft, signal generator, counterpart signal generator and some angles and distance values of the connection apparatus in the feeding mechanism of the sewing machine in which the system of the present invention is used.

Figure 8: The operation diagram of the system of the present invention.

Figure 9: The main pulley, turn direction of the main pulley, sensor and counterpart sensor in the sewing machine in which the system of the present invention is used. Figure 10: Drawing showing the main pulley, sensor, counterpart sensor and other parts in an overlock machine in which the system of the present invention is used. Figure 11 : An alternative operation diagram of the system of the present invention.

Explanation of the References of Pieces

1 . Machine body

2. Cylinder

3. Cylinder connection rod

4. Step motor

5. Step motor pulley

6. Trigger belt

7. Wheel

8. Connection apparatus

9. Stitch plate

10. Cylinder arm

1 1 . Stitch needle

12. Needle bar

13. Presser bar

14. Stitch presser foot Feeding element

Vertical motion trunnion

Vertical motion shaft

Feeding shaft

Horizontal motion trunnion

Horizontal motion shaft

Counterpart signal generator connection apparatus

Counterpart signal generator

Signal generator

Counterpart signal generator connection apparatus fixing element

Machine lower body

Lever arm

Stitch length numerator

Wheel fixing element

Main pulley

Main shaft

Counterpart Sensor

Sensor connection apparatus

Sensor

Lever arm motion transfer rod

Time interval for the upward and downward motion of the feeding element in the main pulley with respect to reference point

Forward-backward time interval in the main pulley with respect to reference point when the feeding element is down

The upward and downward time interval of the feeding element in the main pulley with respect to reference point

Forward-backward time interval on the main pulley with respect to reference point when the feeding element is up

Wheel belt connection pulley

Reference point

Step motor driver

PLC

Frequency divider

Electronic control circuit h : Length that the wheel pulls the material to be sititched

θ 2 : The angle that the horizontal motion trunnion will turn when the material is pulled for the length

θ 3 : Turning angle of the connection apparatus of the counterpart signal generator θ 4 : The angle that the wheel must turn to pull the material for length

θ 5 : Turning angle of the step motor pulley

D 4 : Wheel diameter

D 5 : Diameter of the step motor pulley

d 4 : Diameter of the connection pulley of the wheel belt

s 3 : Amount of motion of the counterpart signal generator

z 2 : Distance between the centre of the horizontal motion shaft and the connection centre of the feeding rod of the horizontal motion trunnion

z 3 : Distance between the horizontal motion shaft centre and the counterpart signal generator to ensure s 3 value

The drawings are not drawn to scale and the details that are not necessary to understand the present invention may have been omitted. In addition, elements that are at least significantly equivalent or that have at least significantly equivalent functions are shown with the same number.

Detailed Disclosure of the Invention

In this detailed disclosure, the preferred embodiments of the system of the present invention are disclosed only for better understanding of the subject.

The functions of the preferred elements that the sewing machine which uses the electronic control system of the present invention comprises are given below:

- The cylinder (2) ensures that the wheel (7) presses the material and that the wheel (7) is lifted up and lowered down.

The cylinder connection rod (3) is the piece which fixes the cylinder (2) to the machine body (1 ).

The step motor (4) is the element which ensures control through the signals produced and which turns the wheel (7) to which it is connected to move the material forward and backward. The step motor pulley (5) is the piece on which the trigger belt (6) is mounted.

The trigger belt (6) is the piece which transfers the motion it receives from the step motor (4) to the wheel belt connection pulley (43).

The wheel (7) is the piece which moves the material forward and backward by turning on the material.

The connection apparatus (8) is the piece which fixes the step motor (4) and the wheel (7) to the cylinder (2).

The stitch plate (9) is the piece on which the material to be stitched moves.

The cylinder arm (10) is the piece which moves the wheel (7) up and down.

The stitch needle (11 ) is the needle that does the stitching function.

The needle bar (12) is the shaft to which the stitch needle (11 ) is connected.

The stitch presser foot (14) is the piece which presses on the material.

The presser bar (13) is the piece to which the stitch presser foot (14) is connected.

The feeding element (15), although known as the feeding gear in the sector, is the piece which moves the material to be stitched by pulling it (There may be only one feeding element (15) in a normal lock stitcher at the lower part or there may be two according to the type of the stitcher, one up and one down. As the feeding element (15) generally gears are used but again according to the type of the stitcher, "needle" may also be used. For example, in a sewing machine with needle transport, the lower feeding element (15) is a "gear" while the upper feeding element is the "needle"). The vertical motion trunnion (16) is the piece which transfers the movement of the vertical motion shaft (17) to the feeding shaft (18).

The vertical motion shaft (17), is the piece which produces the vertical motion of the feeding element (15) and which transfers the motion it receives from the eccentric piece connected to the main shaft (30) by an arm to the vertical motion trunnion (16) and to the feeding shaft (18) through the vertical motion trunnion (16).

The feeding shaft (18) is the piece which moves in an elliptical path in the forward or backward direction by the motion it receives from the vertical motion trunnion (16) and the horizontal motion trunnion (19). The feeding element (15) is fixed to the feeding shaft (18). Hence, the feeding element (15) moves the material to perform the feeding operation. The horizontal motion trunnion (19) is the piece which conveys the motion of the horizontal motion shaft (20) to the feeding shaft (18).

The horizontal motion shaft (20) is the shaft which receives motion from the main shaft (30) and which conveys the feeding mechanism motion the stitch length of which is determined through the stitch length numerator (27) and the position of the lever arm (26) to the feeding shaft (18) through the horizontal motion trunnion (19).

- The counterpart signal generator connection apparatus (21 ) is the piece which fixes the counterpart signal generator (22) which is the counterpart of the signal generator (23) to the horizontal motion shaft (20).

- Concerning the counterpart signal generator (22): The counterpart signal generator (22) is suitably fixed to the feeding mechanism and conveys the circular or linear motion of the feeding mechanism (according to the place it is connected) to the signal generator (23). Hence, the signal generator (23) produces signal in response to the motion of the counterpart signal generator (22). Similarly, if the counterpart signal generator (22) is connected to a mechanism with circular motion, the stitcher and the mechanism should be synchronized at the first installation, as it is here. The most accurate signal amount required is obtained by changing the distance of the counterpart signal generator (22) to the centre of the motion and thus the synchronization is performed.

- Concerning the signal generator (23): A pulse generator or encoder can be used as a signal generator (23). The signal generator (23) senses the circular motion of the counterpart signal generator (22) that moves together with the horizontal motion shaft (20) and produces electronic signals. The signal generator (23) has various types. In the system of the present invention, preferably, is an encoder that can sense circular and linear movements. The signal generator (23) produces the square wave signals that the step motor driver (45) needs. The signal generator (23) has a magnetic structure and facilitates mounting since it has very small dimensions. The greatest advantage of the magnetism of the signal generator (23) is that it is not affected by grease and dust. The signal producing efficiency, precision and speed of signal generator (23) used here can conveniently meet the requirements of the system being controlled. - The counterpart signal generator connection apparatus fixing element (24) is a piece such as screw, etc. and it fixes the counterpart signal generator connection apparatus (21 ) to the horizontal motion shaft (20).

- The machine lower body (25) is the part on which the material to be stitched moves.

- The lever arm (26) is the piece that instantaneously changes the stitch length and the forward and backward direction of the stitch manually.

- The stitch length numerator (27) is the piece that sets the stitch length.

The wheel fixing element (28), is a piece that fixes the wheel (7) to the connection apparatus (8) such as a screw, etc.

- The main pulley (29) operates the stitcher, turning by the motion it receives from the motor or by the motion given manually.

The main shaft (30) is the shaft which turns with the main pulley (29) connected to it and conveys this turning to the other mechanisms of the machine.

- The counterpart sensor (31 ) has generally a metal structure depending on the sensor (33) used. The counterpart sensor (31 ) is the piece which is mounted at a desired part on the main pulley (29) and ensures that the sensor (33) senses the desired motion at the correct time.

- The sensor connection apparatus (32) is the piece that fixes the sensor (33) to the machine body (1 ).

- The sensor (33) senses the counterpart sensor (31 ) mounted on the main pulley (29). When the sensor (30) senses the mentioned counterpart sensor (31 ), the step motor driver (45) starts using the turning signals it receives from the signal generator (23) and the step motor (4) operates and turns the wheel (7).

The lever arm motion transfer rod (34) conveys the motion of the lever arm (26) to the feeding mechanism.

- The wheel belt connection pulley (43) is the piece that conveys the motion of the step motor (4) to the wheel (7).

The puller mechanism preferably comprises the following elements among the above mentioned ones: cylinder (2), - cylinder connection rod (3),

- step motor (4),

- step motor pulley (5),

- trigger belt (6),

- wheel (7),

- connection apparatus (8),

- cylinder arm (10),

- wheel fixing element (28),

- wheel belt connection pulley (43).

The feeding mechanism preferably comprises the following elements again among the above mentioned ones:

Feeding element (15),

- vertical motion trunnion (16),

- vertical motion shaft (17),

- feeding shaft (18),

horizontal motion trunnion (19),

- horizontal motion shaft (20).

This is the mechanism that is the essential part of the invention. The electronic signal generator (23) and the counterpart signal generator (22) that is its counterpart are mounted to a suitable part of the feeding mechanism or the feeding mechanisms according to the type of the stitcher. This way, electronic signals are produced from the actual motion that affects the material. The electronic control system of the present invention is based on this. Although the feeding mechanism preferably comprises these elements, some feeding mechanisms may not comprise all these elements (The said feeding mechanism varies according to the type of the stitcher. For example, in a sewing machine with needle transport the feeding mechanism comprises two parts. Since in this sewing machine the stitch needle does the same motion with the feeding element (15), this part is named as the needle feeding mechanism in the catalogue of this sewing machine in addition to the feeding mechanism. Another example is the overlock machine with upper transport. The overlock machine with upper transport also has a feeding element positioned at the upper part in addition to the feeding element. As in the previous example of the sewing machine with needle transport, this feeding element can perform the same motion with the lower feeding element. This part is named as the upper feeding mechanism in the catalogues of the machines having this type of upper feeding elements in addition to the feeding mechanism. The feeding mechanism mentioned in the present application represents the feeding, needle feeding and upper feeding mechanisms of the sewing machines of different types. The counterpart signal generator (22) is mounted to a preferred part of the mentioned mechanisms and produces the signal needed from these parts.) On the other hand, the electronic control system comprises the following indispensable parts: - counterpart signal generator (22), (magnet is preferred here as the counterpart signal generator (22) but different types also exist)

- signal generator (23),

- counterpart sensor (31 ),

- sensor (33),

- step motor driver (45) and the elements the positions of which are different according to the existing technique are as follows: - signal generator (23),

- counterpart signal generator (22).

The electronic control system of the invention can be applied to all industrial and home- type sewing machines that perform the feeding operation through a feeding element (15). For example, this system may be used in the control of

- Stitcher pulling apparatus

- tape pre-puller apparatus

- new generation transport systems or can ensure smocking with some sewing machines. In addition, many mechanisms which comprise a motor and which are desired to operate synchronously with the machine as needed can be controlled with this electronic control system. The operation principle of the electronic control system of the present invention is as follows in the most general sense: There is a counterpart sensor (31 ) on the main pulley (29) or on the main shaft (30) of the machine or on a preferred one (here the main pulley (29) is preferred) of the pieces (the pieces that make the vertical movements of the feeding mechanism with the motion received from the needle bar (12) and the main shaft (30) and convey it to the feeding element (15) (these pieces vary according to the type of the machine)) which directly or indirectly move these (such as the pulley and the shaft of the motor that gives motion to the machine) or which these directly or indirectly move. The sensor (33) is fixed on the machine body (1 ) at a position that can sense the counterpart sensor (31 ). The sensor (33) senses the counterpart sensor (31 ) on the main pulley (29), and as motioned above, conveys the information concerning when the step motor (4) will turn to the PLC (46), frequency divider (47), electronic control circuit (48) or to the step motor driver (45) preferred here; thus, the effect period of the controlled pulling mechanism on the material to be stitched is determined. When the direction of the stitch is changed as forward or backward or when the stitch length is changes, this period will never change. Independent of whether the sensor (33) senses the counterpart sensor (31 ), the signal generator (23) of the machine continuously produces signal as long as there is motion according to the motion (to left or right) of the counterpart signal generator (22) fixed on the feeding mechanism. The signal generator (23) sends the signals it produces to the step motor driver (45) preferred here. The step motor driver (45) also receives information from the sensor (33). The step motor driver (45) operates the step motor (4) up to the distance the feeding element (15) affects the material and in the direction that the feeding element (15) affects the material, during the time it receives signal from the signal generator (23), in the time intervals it receives signal from the sensor (33), according to the number and direction of the motion signal received from the signal generator (23). The step motor driver (45) stops the step motor (4) when the signal from the sensor (33) ceases during the time it receives signal from the signal generator (23) and does not operate the step motor (4) until the signal from the sensor (33) comes again. Thus, the following problems occurring in the state of the art technique are eliminated:

• the necessity to re-set the stitch length of the mounted apparatus when the stitch length of the machine is changed, the necessity to cease the contact of the controlled apparatus with the material to be stitched when the stitch direction is being controlled by an electronic zigzag apparatus,

the necessity to cease the contact of the controlled apparatus with the material when the lever arm (26) that is used to instantaneously change the stitch direction and distance,

the problem of not being able to use some apparatuses on some machines due to the abovementioned shortcomings. Below, what kind of a calculation should be made for a lock stitcher to synchronize the feeding element (15) with the wheel (7) is explained in order to prevent non- harmonious movement of the feeding element (15) with the wheel (7) when the stitch length numerator (27) used for setting the stitch length of the sewing machine is set to various values, when the lever arm (26) is used to instantaneously change the stitch direction and distance and in all such cases.

If the puller apparatus controlled by the electronic control system of the present invention is to be used in a single needle lock stitcher, the technical specifications of the sewing machine, the puller apparatus and the technical elements to be used in the control system such as the signal generator (23), step motor (4) etc. must be identified. These are preferably as follows, respectively:

The distance 11 ; in a single stitch determined as a reference by the stitch length numerator (27), the distance that the feeding element (15) pulls the material is determined as 2mm,

The distance Z2; as can be seen in Figure 7, the distance between the centre of the horizontal motion shaft (20) and the connection centre of the feeding shaft (18) of the horizontal motion trunnion (19) is determined as 35mm, The micro step feature is used to ensure that the step motor (4) is turned 360 degrees against 1600 turn signal [n5] so that the step motor driver (45) and the step motor (4) operate more precisely and trouble-free,

The period length of the EPU signal generator (23) is determined as 2mm, The number of signals produced by the i3 signal generator (23) in one period is determined as 64 turn signals. • The diameter D5 of the step motor pulley (5) is determined as 18mm,

• The diameter of the d4 puller wheel belt connection pulley (43) is determined as 10mm,

• The diameter of the D4 puller wheel (7) is determined as 20mm.

In the light of the data we have, if the material is to be pulled by distance 11 , it must be ensured that the wheel (7) must pull the material by length 11 to provide synchronization. The wheel (7) must turn with the angle θ 4 to pull the material for the L1 distance, as can be seen in Figure 6.

360/ j

πϋ 4

According to the technical features given above, the angle θ 4 is found as 11 .46 degrees.

In equation 1 above, D 4 is the diameter of the wheel (7). θ 4 is in degrees angle. Then, the turning angle θ 5 of the step motor pulley (5) is calculated using the below equation:

According to the technical features given above, the angle θ 5 is found as 6.37 degrees.

In equation 2 above, d 4 is the diameter of the Wheel belt connection pulley (43) and D 5 is the diameter of the step motor pulley (5). The stitch number of the step motor (4) we used was 200 in 360° turn normally but it was increased to 1600 using the micro step feature of the step motor driver (45). In virtue of this, high precision and accuracy was obtained. In this case, for every turn signal the step motor (4): 360' 360

Ps = = 0.225 0 / adim

1600 (3)

According to the features given above, g 5 is found as 0.225 degrees/stitch. It makes a turn of 0.225°. In the expression above, n 5 is the number of stitches that the step motor (4) makes in a 360° turn. g 5 is the angular resolution of the step motor (4) obtained by the step motor driver (45). The number of signals i 5 that the signal generator (23) (encoder) must produce for the step motor (4) to turn by angle θ 5 is calculated by the equation:

According to the features given above, i 5 is found as 28.3 signals.

Thus, the number of signals that the signal generator (23) must produce is determined. Now, we have the number of signals that the puller mechanism needs to pull the material for 2mm.

The angle θ 2 must be found to determine the angle of motion when the horizontal motion shaft (20), on which the counterpart signal generator (22) is mounted, the horizontal motion trunnion (19) attached to it and the feeding element (15) move the 11 distance.

180 /,

(5) π z 2 According to the features given above, θ 2 is found as 3.27 degrees.

In equation 5, z2 is the distance between the centre of the horizontal motion shaft (20) and the connection centre of the feeding shaft (18) of the horizontal motion trunnion (19). Since the counterpart signal generator connection apparatus (21 ) is fixed to the horizontal motion shaft (20), the turn angle of the horizontal motion trunnion (19) is equal to the turn angle θ 2 .

3.27 degrees = 3.27 degrees

As mentioned above, the signal generator (23) chosen must operate with magnetic operation principle so that it is not affected by grease and dust. The signal generator (23) must sense both directions and produce a signal to be able to produce signal from the turn of the horizontal motion shaft (20) in both directions. The period length (EPU) of the signal generator (23) we use is 2 mm. The number of signals generated by the signal generator (23) at this period length i 3 =64. (Here, the number of signals that the preferred signal generator (23), stated as 64, is completely a choice. This resolution can be optionally be chosen between 6 signals and 8192 signals in a 2mm period. Thus, the signal for each apparatus desired to be controlled with the system of the present invention can easily be produced.) In order to meet the i 5 value, which is the number of signals required, considering the resolution of the signal generator (23), the s 3 value, which is the amount of motion of the counterpart signal generator (22) is calculated.

^EPU

h

According to the values specified, the s 3 value is calculated as 0.88 mm. In order to complete the synchronization, the counterpart signal generator (22) is fixed at z 3 distance to the centre of the Horizontal motion shaft (20) so that it produces 28 turn signals to the signal generator (22) in response to an angular movement of 3.27 degrees. The said z 3 distance is calculated by the below equation.

(8) According to the values specified, z 3 is calculated as 15.48mm.

The counterpart signal generator connection apparatus (21 ) is fixed according to the z 3 distance and its synchronization with the feeding element (15) of the wheel (7) is ensured.

In the next stage, the information that the feeding element (15) starts affecting the material and ends such effect must be conveyed to the PLC (46), frequency divider (47), electronic control circuit (48) or as preferred here to the step motor driver (45) by the sensor (33). To convey this message correctly, the sensor (33) must be mounted to a suitable place. In such a case we must look at the timing table at Figure 5. As Figure 5 shows, the most suitable place for this is the main pulley (29). The reason for this is that when sewing machine in a tour takes a reference point, it will make all its movements in the next tour with respect to the same reference point and that almost all main pulleys (29) of the sewing machines turn only in one direction, provided that changes with the model of the machine. For example, let us turn the main pulley (29) in the direction of turn until the stitch needle (11 ) comes to the topmost position and at this very moment let us mark the opposite of the position of the reference point (44) on the machine body (1 ) and turn the main pulley (29) again and again; we will see that the stitch needle (11 ) is in the topmost position where the reference points meet. This will be the same for the lowermost position of the stitch needle (11 ) and all movements of the feeding element (15). In all of the existing models, information is received in this way. Therefore, let us mount the sensor (33) below the main pulley (29) as seen in Figure 2. Then, let us take the point at which the sensor (33) senses as the reference point (44) and mount the counterpart sensor (31 ) to the corresponding point of the reference point (44) in the turning direction of the main pulley (29) on the main pulley (29), at the actual pulling time of the material by the feeding element (15), that is the forward-backward time interval on the main pulley with respect to the reference point when the feeding element is up (42). Now, in all cases that the feeding element (15) influences the material, whether forward or backward, whether the stitch length setting is changed by the stitch length numerator (27) or the stitch length or the forward- backward direction is instantaneously changed by the lever arm (26), the correct timing information will be received from the sensor. (In all of the existing models, in fact, the signal generator (23) has produced a signal for the timing information and turning the step motor (4) from this part, from which the actual material pulling time, that is the information of forward-backward time interval on the main pulley with respect to the reference point when the feeding element is up (42) should be received and a wrong path has been followed. The calculation explained above is given only as an example, because in some sewing machines the feeding mechanism may not comprise pieces such as horizontal motion trunnion (19), etc. or in some mechanisms which must operate synchronously with the feeding mechanism, which the electronic control system controls and which are moved by the step motor (4) they are attached to there may not be a wheel (7). A trigger belt (6) or conveyor band may be used in the mechanism to feed the material (fabric, carpet, etc.) instead of the wheel (7). However, the wheel (7), trigger belt (6) and the conveyor band are given only as examples. What is important is ensuring the movement of the material. What is important in the calculation above is the synchronization of the feeding element (15) and the machine with the accessory mechanisms and apparatus, when the stitch length numerator (27) used to set the stitch length of the sewing machine is set to different values, in order to prevent non- harmonious motion of the accessory mechanisms and apparatus (a puller apparatus is explained in this detailed disclosure) which should be synchronized with the feeding element (15) and the machine, and is that the settings necessary for this calculation is determined in the step motor driver (45).