| JP06240557 | EMBROIDERY MACHINE |
| WO/2011/033969 | DRIVE DEVICE FOR SEWING MACHINE SEWING FRAME |
| JP2003239167 | SEWING FRAME-DRIVING DEVICE OF SEWING MACHINE |
| 1. | An embroidery frame operating method of an embroidering machine having a needle, a needle driving means for driving the needle, an embroidery frame for moving a material to a necessary position with supporting the material, and an embroidery frame moving means for moving the embroidery frame in a necessary direction, the method comprising the steps of: accelerating said embroidery frame via said embroidery frame moving means; decelerating said accelerated embroidery frame said the embroidery frame moving means; deceleration synchronizing load applying, to said embroidery frame, a separate load for reducing an inertia force of said embroidery frame in synchronization with said decelerating step; and stopping said embroidery frame for a certain period of time. |
| 2. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the step of synchronizing with a deceleration synchronizing phase angle area within a certain scope of a principal axis motor of said needle driving means synchronizing with said decelerating step. |
| 3. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of transmitting a power of a principal axis motor of said needle driving means to a synchronizing axis synchronizing with said principal axis motor and, in synchronization with said decelerating step via a cam installed on said synchronizing axis, adjusting a tensile force of a load belt connected to said embroidery frame. |
| 4. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of transmitting a power of a principal axis motor of said needle driving means to a synchronizing axis synchronizing with said principal axis motor and, in synchronization with said decelerating step by operating a clutch via a cam installed on said synchronizing axis, connecting a load to a load belt connected to said embroidery frame. |
| 5. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of transmitting a power of a principal axis motor of said needle driving means to a synchronizing axis synchronizing with said principal axis motor and, in synchronization with said decelerating step via a cam installed on said synchronizing axis, adjusting an open and shut amount of a valve installed in a passage of a cylinder device connected to said embroidery frame. |
| 6. | The embroidery frame operating method of the embroidering machine as claimed in a claim among claims 3 to 5, further comprising the step of adjusting a tensile force of a timing belt of said needle driving means via the cam installed on said synchronizing axis. |
| 7. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor of said needle driving means and, in synchronization with said detected deceleration synchronizing phase angle area, driving a torque motor which drives a load belt connected to said embroidery frame. |
| 8. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor of said needle driving means and, in synchronization with said detected deceleration synchronizing phase angle area, driving a servo motor connected to an axis driven by a pulse motor of said embroidery frame moving means. |
| 9. | The embroidery frame operating method of the embroidering machine as claimed in claim 1, wherein said deceleration synchronizing load applying step comprises the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor synchronizing with said decelerating step and, in synchronization with said detected deceleration synchronizing phase angle area, operating a solenoid device which drives a load means connected to said embroidery frame. |
| 10. | The embroidery frame operating method of the embroidering machine as claimed in a claim among claims 1 to 9, wherein said accelerating step comprises a first accelerating step of accelerating said embroidery frame in an Xaxis direction via a first embroidery frame moving means and a second accelerating step of accelerating the embroidery frame in a Yaxis direction via a second embroidery frame moving means, wherein said decelerating step comprises a first decelerating step of decelerating said accelerated embroidery frame in the Xaxis direction via said first embroidery frame moving means and a second decelerating step of decelerating said accelerated embroidery frame in the Yaxis direction via said second embroidery frame moving means, and wherein said deceleration synchronizing load applying step comprises a first deceleration synchronizing load applying step for reducing a tensile force of said embroidery frame in the Xaxis direction in synchronization with said first decelerating step and a second deceleration synchronizing load applying step for reducing the tensile force of said embroidery frame in the Y axis direction in synchronization with said second decelerating step. |
| 11. | The embroidery frame operating method of the embroidering machine as claimed in a claim among claims 1 to 9, wherein the load applied to said deceleration synchronizing load applying step is dismissed at an ending point of said stopping step. |
| 12. | An embroidery frame operating apparatus of an embroidering machine having a needle, a needle driving means, having a principal axis motor, for driving the needle, and an embroidery frame for moving a material to a necessary position with supporting the material, the apparatus comprising: an embroidery frame moving means for moving said embroidery frame to the necessary position on an XY coordinate plane ; and in synchronization with a deceleration of said moved embroidery frame, a deceleration synchronizing load applying means that applies a separate load to said embroidery frame in order to reduce an inertia force of said moved embroidery frame. |
| 13. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises the principal axis motor of said needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of said embroidery frame, a synchronizing axis synchronizing with said principal axis motor, a power transmitting device for transmitting a power of said principal axis motor to said synchronizing axis, a load belt connected to said embroidery frame, and a cam, installed on said synchronizing axis, adjusting a tensile force of said load belt in synchronization with said deceleration synchronizing phase angle area. |
| 14. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises the principal axis motor of said needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of said embroidery frame, a synchronizing axis synchronizing with said principal axis motor, a power transmitting device for transmitting a power of said principal axis motor to said synchronizing axis, a load belt connected to said embroidery frame, a cam, installed on said synchronizing axis, synchronizing with said deceleration synchronizing phase angle area, and a clutch connecting said load to said load belt in synchronization with said deceleration synchronizing phase angle area via a predetermined load and said cam. |
| 15. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises the principal axis motor of said needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of said embroidery frame, a synchronizing axis synchronizing with said principal axis motor, a power transmitting device for transmitting a power of said principal axis motor to said synchronizing axis, a cylinder device connected to said embroidery frame, a cam installed on said synchronizing axis, and a valve for adjusting an open and shut amount of a passage connected to said cylinder device according to a revolving angle of said cam. |
| 16. | The embroidery frame operating apparatus of the embroidering machine as claimed in a claim among claims 13 to 15, wherein a tensile force of a timing belt decreases when said timing belt of said embroidery frame moving means starts to operate by being connected to the cam installed on said synchronizing axis and increases after an acceleration. |
| 17. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises a connecting means connected to said embroidery frame, a torque motor for holding, if necessary, said connecting means, a deceleration synchronizing phase angle area detecting means which detects a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with said deceleration, and a torque motor controlling means for controlling an operation of said torque motor in synchronization with said detection of the deceleration synchronizing phase angle area. |
| 18. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises a servo motor connected to an axis driven by a pulse motor of said embroidery frame moving means, a deceleration synchronizing phase angle area detecting means to detect a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with said deceleration, and a servo motor controlling means for controlling an operation of said servo motor in synchronization with the detection of said deceleration synchronizing phase angle area. |
| 19. | The embroidery frame operating apparatus of the embroidering machine as claimed in claim 12, wherein said deceleration synchronizing load applying means comprises a load means connected to said embroidery frame, a solenoid device for operating said load means, a deceleration synchronizing phase angle area detecting means for detecting a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with said deceleration, and a solenoid device controlling means for controlling an operation of said solenoid device in synchronization with the detection of said deceleration synchronizing phase angle area. |
| 20. | The embroidery frame operating apparatus of the embroidering machine as claimed in a claim among claims 17 to 19, wherein said deceleration synchronizing phase angle area detecting means is an encoder which is installed on a peripheral surface of a principal axis, for driving said needle, driven by said principal axis motor. |
| 21. | The embroidery frame operating apparatus of the embroidering machine as claimed in a claim among claims 12 to 19, wherein said embroidery frame moving means comprises: a first embroidery frame moving means having a first moving body which constrains said embroidery frame in an Xaxis direction and allows the embroidery frame to move in a Yaxis direction, a first power transmitting member connected to said first moving body, and a first pulse motor for moving said first power transmitting member in the Xaxis direction according to an embroidery data; and a second embroidery frame moving means having a second moving body which constrains said embroidery frame in the Yaxis direction and allows the embroidery frame to move in the Xaxis direction, a second power transmitting member connected to said second moving body, and a second pulse motor for moving said second power transmitting member in the Yaxis direction according to the embroidery data, and wherein said deceleration synchronizing load applying means comprises a first deceleration synchronizing load applying means for applying a load to said embroidery frame in the Xaxis direction in synchronization with a deceleration of said embroidery frame in the Xaxis direction and a second deceleration synchronizing load applying means for applying a load to said embroidery frame in the Yaxis direction in synchronization with a deceleration of said embroidery frame in the Yaxis direction. |
2. Description of Related Art In general, an embroidering machine such as a computer embroidering machine for final products, a multi-head computer embroidering machine and a computer quilting machine largely comprises a sewing part for needlework and an embroidery frame part, substituting for manual work, for adjusting the movement of the embroidery frame by controlling an X-axis pulse motor and a Y-axis pulse motor by means of an embroidering machine controller according to a data inputted in a predetermined memory. That is, the embroidering machine in the present invention is a concept which includes not only the computer embroidering machine for final products, the multi-head computer embroidering machine and the computer quilting machine but also an apparatus similar thereto.
With holding a material unfolded, the embroidery frame is horizontally moved to a wanted position of an X-Y plane. An operational configuration of the embroidery frame is as follows.
A moving body, with supporting the embroidery frame, for allowing the embroidery frame to move in a single direction is fixed on a timing belt. The moving body and the timing belt are rectangular arranged in an X-axis direction and in a Y-axis direction, respectively. In the state that the embroidery frame is installed in the moving body, each pulse motor is driven by each belt connected to a pulley of the pulse motor driven by a pulse signal, so that the belt is pulled and pushed so as to horizontally move the embroidery frame in a wanted direction within a certain scope at a high velocity. Of course, while the embroidery frame is horizontally moved or stopped, the needle is moved upwardly and downwardly by the principal axis motor at a high velocity.
FIG. 1 is a perspective view of a generic multi-head embroidering machine.
With reference to FIG. 1, the generic multi-head embroidering machine 100 is briefly explained below. As shown, the multi-head embroidering machine comprises a body 112 of a long lateral shape. With holding a material, an embroidery frame 114 mounted on the body 112 is movable in the four directions, i. e., back, forth, right and left. The embroidery frame 114 is moved by a first pulse motor 116 mounted at an end of the body 112 and by a second pulse motor 118 mounted around a middle rear side of the body 112.
Above the embroidery frame 114, a plurality of needle driving devices
120 for moving needles upwardly and downwardly are long laterally arranged by the predetermined distance. The needle driving devices 120 are driven by a principal axis motor 124 which drives a principal axis 122. A thread guide 126 for guiding a thread is disposed above the needle driving devices 120. A driver box 128, a power source box 130 and a controller box 132 are disposed below the embroidery frame 114. A selection operating panel 134 for inputting a necessary data or for selecting an embroidery design is disposed around an upper right of the embroidery frame 114. A power source switch 138 is disposed on a lower leg 136 of the selection operating panel 134.
When necessary information is inputted and selected via the selection operating panel 134 and the power switch 138 is turned on, the principal axis is revolved by the principal axis motor 124 and accordingly the needle driving devices 120 move the needles upwardly and downwardly. Concurrently with this, the frame 114 is moved right and left, i. e., in the X-axis direction, by the first pulse motor 116, and back and forth, i. e., in the Y-axis direction, by the second pulse motor 118. Depending on the embroidery data corresponding to a selected design, a driving of the first and second pulse motors 116,118 is operated by a controlling means installed in the controller box 132.
FIG. 2 is a plan view of the multi-head embroidering machine roughly showing a driving of the embroidery frame. FIG. 3 is a cross section view showing a state in which the moving body for movably supporting the embroidery frame is installed. FIG. 4 is a perspective view showing a state in which the moving body is installed.
As represented in FIG. 2, a frame 114a, on which a material 115 is
fixed, movable in the back and forth direction and in the right and left direction is mounted on a body 112a of the multi-head embroidering machine. A plurality of needle driving devices 120a are spaced by the predetermined distance, and are laterally disposed above the upper frame 114a. Outside the frame 114a, there are provided a first pulse motor 116a for driving the frame 114a right and left, i. e., in the X-axis direction, and a second pulse motor 118a for driving the frame 114a back and forth, i. e., in the Y-axis direction.
FIGS. 3 and 4 show configurations of transmitting a power of the first and second pulse motors 116a, 118a to the frame 114a.
As shown in FIG 3 and 4, the frame 114a holding the material 115 is movably installed in and along the groove of a guide 117, and is supported by the moving body 121 fixed on a timing belt 119. A roller 123 allowing the frame 114a to move either in the X-axis direction or in the Y-axis direction is parallel disposed on the moving body 121 at a predetermined distance. That is, with being supported on the moving body 121 having the roller 123, the frame 114a is freely movable within a predetermined scope, i. e., in the right and left direction by the first pulse motor 116a and in the back and forth direction by the second pulse motor 118a. While the frame 114a is moved toward a necessary position along a horizontal plane, a needle 125 is repeatedly moved upwardly and downwardly by the principal axis motor.
FIG. 5 is a diagram illustrating a stroke of a needle bar operating the needle. FIG. 6 is a graph showing speed changes of the pulse motor related to the stroke of the needle bar in FIG. 5. FIG. 7 is a graph showing speed changes of a corresponding frame to a pulse motor speed.
In FIG. 5, when an upper dead point of the needle bar operating the needle is set for an angle of 0°, a single stroke consists of an angle of 360°, the needle pierces a material held by the frame at around an angle of 100°, and the needle is escaped from the material at around an angle of 260°. That is, an upper scope ranges from the angle of 260° at which the needle is escaped from the material to the angle of 100° at which the needle pierces the material again after passing the upper dead point. This upper scope is a scope that the frame is movable as the needle is out of the material. A lower scope ranges from the angle of 100° at which the needle pierces to the angle of 260° from which the needle is escaped again. This lower scope is a scope that the frame is not movable as the needle is piercing into the material. The diagram of FIG. 5 is identical with a single stroke of the principal axis motor which drives the needle via the needle bar. Of course, all the embroidering machines do not have the same stroke as above. An angle at which the needle is pierced into and escaped from the material can be changed.
Referring to FIG. 6, the driving speed changes of the pulse motor corresponding to the stroke as shown in FIG. 5 can be understood. That is, the pulse motor for moving the frame is accelerated at the angle of 260° that the needle is escaped from the material, and stops an operation at the angle of 100° that the needle pierces the material by reducing the speed again when reaching the upper dead point. The pulse motor then repeats the preceding process by stopping the operation up until the needle is escaped from the material and by being accelerated again at the angle of 260° that the needle is escaped from the material.
That is, an oblique-lined scope between the angle of 0° as the upper dead point and the angle of 100° at which the needle pierces the material is a deceleration synchronizing phase angle area in which the speed is reduced.
And also, the angle of 260° at which the needle is escaped from the material is an acceleration starting phase angle.
Of course, a variety of changes according to a property of the motor or types of the embroidering machine might be made to an acceleration starting point of the pulse motor, a decelerating point thereof, and an accelerating point after deceleration. For instance, depending on a capability of the pulse motor, the motor may be driven to start to accelerate at the upper dead point of the angle of 0°, to accelerate up to an angle of 50°, to start to decelerate at the angle of 50°, and to stop at the angle of 100°. This driving operation may also change the deceleration synchronizing phase angle area described in this invention.
In general, the embroidering machine is driven at 500-800 rpm. A time for conveying the frame within a single stroke is (60 seconds/driving rpm) X (200°/360°) and a time for stopping the frame within a single stroke is (60 seconds/driving rpm) X (160°/360°). That is, when a driving speed of the embroidering machine is 750 rpm, the time for conveying the frame within the single stroke is (60 seconds/750 rpm) X (200°/360°) = 0.04444 seconds, and the time for stopping the frame is (60 seconds/750 rpm) X (160°/360°) = 0.03556 seconds. Unlike general sewing work in which a material is continuously proceeded toward a single direction, work of the embroidering machine has something to do with a design for which a certain area of the
material is filled with letters or drawings, so that a satin stitch of a return movement is required to perform the work. Therefore, the frame performs the return movement by repeatedly alternating the time for conveying the frame and the time for stopping the frame as calculated above.
The moving speed of the frame corresponding to the speed of the pulse motor is marked with a dotted line in FIG. 7. As understood from FIG. 7, when the speed of the frame follows the driving speed of the pulse motor at a predetermined interval, the frame has a great speed toward the proceeding direction by the looseness and elasticity of the timing belt, the pulse motor and the frame and by the inertia of the frame although the driving of the pulse motor stops at the stopping time and the stopping time ends. Therefore, the frame far exceeds the stopping point.
As a result, when the needle is piercing the material, embroidery quality becomes lowered as the frame is out of alignment with the predetermined position due to the inertia of the frame. Of course, when the frame proceeds in a single direction when the needle is piercing the material, embroidery quality is lowered in that the frame is out of alignment with the predetermined position due to the inertia.
Further, a load of the pulse motor increases in proportion to the increase of frame weight, or to which the driving speed of the principal axis motor, i. e., the driving speed of the needle, exceeds 1000 rpm, for example.
And also, as the driving speed increases, the speed of the frame increases in that the time for conveying the frame is shortened, and the inertia of the frame increases in that the time for stopping the frame is shortened. Of course,
when the weight of the frame increases, the frame far exceeds the point at which the frame stops as the inertia increases although the time is not shortened. Accordingly, the driving of the frame requires almost the square of the strengths proportionate to the speed of the frame. This is further explained in FIG. 8.
FIG. 8 is a graph showing speed changes of a pulse motor corresponding frame when the driving speed of the principal axis motor is increased more than that in FIGS. 6 and 7.
That is, the graphs illustrated in FIGS. 6 and 7 represent a speed when the principal axis motor is driven at 750 rpm. On an assumption that a feeding distance of the pulse motor in a single stroke is the same as in FIGS. 6 and 7, when the driving speed of the principal axis motor is increased up to 1000 rpm, the accelerating and decelerating speeds of the pulse motor and the accompanied accelerating and decelerating speeds of the frame dramatically change as shown in FIG. 8. When a driving speed of the principal axis motor, i. e., a driving speed of the needle, is 1000 rpm, the time for which the frame is movable is (60 seconds/1000 rpm) X (200°/360°) = 0.03333 seconds, and the time for which the frame should stop is (60 seconds/1000 rpm) X (160°/360°) = 0.02667 seconds. In order to move the frame by a distance identical to the distance of the driving speed at 750 rpm within such a short period of time, the pulse motor should be rapidly accelerated and decelerated at a faster speed than the above example, and accordingly the inertia applied to the frame becomes bigger.
An area marked with dots between a time axis and a speed line of the
pulse motor is a distance at which the frame should be moved. In order to make the moving distance of the frame identical to the feeding distance of the driving speed at 750 rpm as shown in FIG. 7, a slant of the speed change in the frame and the driving of the pulse motor becomes very steep as represented in FIG. 8. The frame still has a speed even far beyond the point at which the frame should stop. Accordingly, embroidery quality is lowered.
As well, as the speed by the inertia remains in the frame at a newly accelerating point (260°), a bigger power is required to reverse accelerate the frame. And also, when the weight of the frame increases, the frame far exceeds the point at which the frame should stop as the inertia increases although the time is not shortened.
Due to the reasons explained above, the conventional embroidering machine is driven at about 500-800 rpm even though the driving speed of the principal axis motor, i. e., the driving speed of the needle, can be raised. That is, in accordance with the driving speed of the principal axis, the frame is possibly driven at a high speed above 800 rpm, for example, 1000 rpm.
However, when the speed of the pulse motor increases more, the inertia caused by the weight of the frame becomes so great at a point at which the frame should stop after the frame is rapidly accelerated and then decelerated that there arises a problem that the capacity of the pulse motor should be enlarged.
When the speed of the pulse motor is increased forcibly, a great inertia affects the frame at the point that the frame should be stopped, and the frame passes the stopping point due to the looseness and elasticity of the belt, the
pulse motor and the frame. In this case, as the needle of the embroidering machine which moves upwardly and downwardly at a high speed does not stop, embroidering work happens at a position out of the alignment with the planned stopping point, so that the embroidery quality is also lowered. On the other hand, noise and vibration caused by the inertia of the frame occur severely.
Summary of the Invention The present invention has been made to solve the problems of the prior art, and accordingly, it is a first object of the present invention to provide an embroidery frame operating method of an embroidering machine capable of dramatically increasing the driving speed of an embroidery frame, improving embroidery quality, and little generating noise and vibration.
A second object of the present invention is to provide an apparatus for performing the operating method of the present invention.
The first object of the present invention will be achieved by an embroidery frame operating method of an embroidering machine having a needle, a needle driving means for driving the needle, an embroidery frame for moving a material to a necessary position with supporting the material, and an embroidery frame moving means for moving the embroidery frame in a necessary direction, the method comprising the steps of accelerating the embroidery frame via the embroidery frame moving means, decelerating the accelerated embroidery frame via the embroidery frame moving means, deceleration synchronizing load applying, to the embroidery frame, a separate
load for reducing an inertia force of the embroidery frame in synchronization with the decelerating step, and stopping the embroidery frame for a certain period of time.
It is preferable to comprise the deceleration synchronizing load applying step in synchronization with a deceleration synchronizing phase angle area within a certain scope of a principal axis motor of the needle driving means synchronizing with the decelerating step.
The deceleration synchronizing load applying step comprises the steps of transmitting a power of a principal axis motor of the needle driving means to a synchronizing axis synchronizing with the principal axis motor and, in synchronization with the decelerating step via a cam installed on the synchronizing axis, adjusting a tensile force of a load belt connected to the embroidery frame.
The deceleration synchronizing load applying step may comprise the steps of transmitting a power of a principal axis motor of the needle driving means to a synchronizing axis synchronizing with the principal axis motor and, in synchronization with the decelerating step by operating a clutch via a cam installed on the synchronizing axis, connecting a load to a load belt connected to the embroidery frame.
In a case that the load is insufficient by means of adjusting the tensile force of the load belt, a way of connecting the load with use of a clutch may be used.
The deceleration synchronizing load applying step may comprise the steps of transmitting a power of a principal axis motor of the needle driving
means to a synchronizing axis synchronizing with the principal axis motor and, in synchronization with the decelerating step via a cam installed on the synchronizing axis, adjusting an open and shut amount of a valve installed in a passage of a cylinder device connected to the embroidery frame.
The deceleration synchronizing load applying step may comprise the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor of the needle driving means and, in synchronization with the detected deceleration synchronizing phase angle area, driving a torque motor which drives a load belt connected to the embroidery frame.
The embroidery frame operating method of the embroidering machine may further comprise the step of adjusting a tensile force of a timing belt of the needle driving means via the cam installed on the synchronizing axis.
The deceleration synchronizing load applying step comprises the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor of the needle driving means and, in synchronization with the detected deceleration synchronizing phase angle area, driving a servo motor connected to an axis driven by a pulse motor of the embroidery frame moving means.
The deceleration synchronizing load applying step comprises the steps of detecting a deceleration synchronizing phase angle area of a principal axis motor synchronizing with the decelerating step and, in synchronization with the detected deceleration synchronizing phase angle area, operating a solenoid device which drives a load means connected to the embroidery frame.
What is preferable is that the accelerating step comprises a first accelerating step of accelerating the embroidery frame in an X-axis direction
via a first embroidery frame moving means and a second accelerating step of accelerating the embroidery frame in a Y-axis direction via a second embroidery frame moving means, that the decelerating step comprises a first decelerating step of decelerating the accelerated embroidery frame in the X- axis direction via the first embroidery frame moving means and a second decelerating step of decelerating the accelerated embroidery frame in the Y- axis direction via the second embroidery frame moving means, and that the deceleration synchronizing load applying step comprises a first deceleration synchronizing load applying step for reducing a tensile force of the embroidery frame in the X-axis direction in synchronization with the first decelerating step and a second deceleration synchronizing load applying step for reducing the tensile force of the embroidery frame in the Y-axis direction in synchronization with the second decelerating step.
The load applied to the deceleration synchronizing load applying step is dismissed at an ending point of the stopping step.
The second object will be achieved by an embroidery frame operating apparatus of an embroidering machine having a needle, a needle driving means, having a principal axis motor, for driving the needle, and an embroidery frame for moving a material to a necessary position with supporting the material, the apparatus comprising an embroidery frame moving means for moving the embroidery frame to the necessary position on an X-Y coordinate plane, and, in synchronization with a deceleration of the moved embroidery frame, a deceleration synchronizing load applying means that applies a separate load to the embroidery frame in order to reduce an
inertia force of the moved embroidery frame.
The deceleration synchronizing load applying means comprises the principal axis motor of the needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of the embroidery frame, a synchronizing axis synchronizing with the principal axis motor, a power transmitting device for transmitting a power of the principal axis motor to the synchronizing axis, a load belt connected to the embroidery frame, and a cam, installed on the synchronizing axis, adjusting a tensile force of the load belt in synchronization with the deceleration synchronizing phase angle area. It is preferable that a thick and wide material is used for the load belt.
The deceleration synchronizing load applying means comprises the principal axis motor of the needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of the embroidery frame, a synchronizing axis synchronizing with the principal axis motor, a power transmitting device for transmitting a power of the principal axis motor to the synchronizing axis, a load belt connected to the embroidery frame, a cam, installed on the synchronizing axis, synchronizing with the deceleration synchronizing phase angle area, and a clutch connecting the load to the load belt in synchronization with the deceleration synchronizing phase angle area via a predetermined load and the cam. That deceleration synchronizing load applying means may be used to supplement to a case in which the load of the load applying means adjusting the tensile force of the load belt by use of the cam is insufficient.
The deceleration synchronizing load applying means comprises the
principal axis motor of the needle driving means having a deceleration synchronizing phase angle area synchronizing with the deceleration of the embroidery frame, a synchronizing axis synchronizing with the principal axis motor, a power transmitting device for transmitting a power of the principal axis motor to the synchronizing axis, a cylinder device connected to the embroidery frame, a cam installed on the synchronizing axis, and a valve for adjusting an open and shut amount of a passage connected to the cylinder device according to a revolving angle of the cam.
A tensile force of a timing belt decreases when the timing belt of the embroidery frame moving means starts to operate by being connected to the cam installed on the synchronizing axis and increases after an acceleration.
The deceleration synchronizing load applying means comprises a connecting means connected to the embroidery frame, a torque motor for holding, if necessary, the connecting means, a deceleration synchronizing phase angle area detecting means which detects a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with the deceleration, and a torque motor controlling means for controlling an operation of the torque motor in synchronization with the detection of the deceleration synchronizing phase angle area.
The deceleration synchronizing load applying means comprises a servo motor connected to an axis driven by a pulse motor of the embroidery frame moving means, a deceleration synchronizing phase angle area detecting means to detect a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with the deceleration, and a servo motor
controlling means for controlling an operation of the servo motor in synchronization with the detection of the deceleration synchronizing phase angle area.
If necessary, the deceleration synchronizing load applying means may comprise a load means connected to the embroidery frame, a solenoid device for operating the load means, a deceleration synchronizing phase angle area detecting means for detecting a certain deceleration synchronizing phase angle area of the principal axis motor synchronizing with the deceleration, and a solenoid device controlling means for controlling an operation of the solenoid device in synchronization with the detection of the deceleration synchronizing phase angle area.
As a deceleration synchronizing phase angle area detecting means, it is preferable to use an encoder which is installed on a peripheral surface of a principal axis, for driving the needle, driven by the principal axis motor.
What is preferable is that the embroidery frame moving means comprises: a first embroidery frame moving means having a first moving body which constrains the embroidery frame in an X-axis direction and allows the embroidery frame to move in a Y-axis direction, a first power transmitting member connected to the first moving body, and a first pulse motor for moving the first power transmitting member in the X-axis direction according to an embroidery data; and a second embroidery frame moving means having a second moving body which constrains the embroidery frame in the Y-axis direction and allows the embroidery frame to move in the X-axis direction, a second power transmitting member connected to the second moving body, and
a second pulse motor for moving the second power transmitting member in the Y-axis direction according to the embroidery data, and that the deceleration synchronizing load applying means comprises a first deceleration synchronizing load applying means for applying a load to the embroidery frame in the X-axis direction in synchronization with a deceleration of the embroidery frame in the X-axis direction and a second deceleration synchronizing load applying means for applying a load to the embroidery frame in the Y-axis direction in synchronization with a deceleration of the embroidery frame in the Y-axis direction.
Drawings FIG. 1 is a perspective view of a generic multi-head embroidering machine.
FIG. 2 is a plan view of the multi-head embroidering machine roughly showing the driving of the embroidery frame.
FIG. 3 is a cross section view showing a state in which a moving body for movably supporting the frame is installed.
FIG. 4 is a perspective view showing a state in which the moving body is installed.
FIG. 5 is a diagram illustrating a stroke of a needle bar which operates a needle.
FIG. 6 is a graph showing speed changes of a pulse motor related to the stroke of the needle bar in FIG. 5.
FIG. 7 is a graph showing the speed changes of a corresponding frame
to a pulse motor speed.
FIG. 8 is a graph showing the speed changes of a pulse motor corresponding frame when the driving speed of a principal axis motor is increased more than that in FIGS. 6 and 7.
FIGS. 9 and 10 are block diagrams explaining a concept of the embroidery frame operating method and apparatus of the embroidering machine according to the present invention.
FIG. 11 is a block diagram showing an example of the embroidery frame operating method of the embroidering machine according to the present invention.
FIG. 12 is a plan view showing a state of applying a load belt to a deceleration synchronizing load applying means.
FIG. 13 is a cross section view showing a state in which the load belt of FIG. 12 is installed.
FIG. 14 is a plan view showing a state of applying a cylinder device to the deceleration synchronizing load applying means.
FIG. 15 is a plan view showing a state that a clutch is applied to the deceleration synchronizing load applying means.
FIG. 16 is a block diagram showing another example of the embroidery frame operating apparatus of the embroidering machine according to the present invention.
FIG. 17 is a block diagram explaining another example according to the present invention.
FIG. 18 is a plan view partially showing an example of installing a
torque motor and a connecting means as in FIG. 17.
FIG. 19 is a flow chart explaining an embroidery frame operating process of the embroidering machine according to the present invention.
FIG. 20 is a flow chart explaining the operating process of the embroidery frame during the process of FIG. 19.
FIG. 21 is a graph showing the speed changes of the embroidery frame according to the driving speed change of the pulse motor in a case to which the present invention has not been applied.
FIG. 22 is a graph showing the speed changes of the embroidery frame according to the change of the deceleration synchronizing load to apply to the embroidery frame and the driving speed change of the pulse motor according to the present invention.
Detailed Description of the Preferred Embodiments Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
FIGS. 9 and 10 are block diagrams explaining a concept of the embroidery frame operating method and apparatus of the embroidering machine according to the present invention.
As represented in FIG. 9, the concept of the method and apparatus 200 according to this invention is that, when an embroidery frame 210 is driven by an embroidery frame moving means 220, a load is applied to the embroidery frame 210 by a deceleration synchronizing load applying means 250 in synchronization with a point at which the frame 210 is decelerated to
reduce an inertia force of the frame 210. This concept of the present invention may be variously embodied according to a method of synchronizing with the deceleration of the embroidery frame 210 and applying a load to the embroidery frame 210.
FIG. 10 is more embodied than FIG. 9. It is preferable that the embroidery frame moving means 220 comprises a first embroidery frame moving means 220a for driving the embroidery frame 210 in the X-axis direction and a second embroidery frame moving means 220b for driving the embroidery frame 210 in the Y-axis direction. It is preferable that the deceleration synchronizing load applying means 250 comprises a first deceleration synchronizing load applying means 250a for applying a load of the X-axis direction to the embroidery frame 210 so as to correspond to the embroidery frame 210 decelerating in the X-axis direction, and a second deceleration synchronizing load applying means 250b for applying a load of the Y-axis direction to the embroidery frame 210 so as to correspond to the embroidery frame decelerating in the Y-axis direction.
FIG. 11 is a block diagram showing an example of the embroidery frame operating method of the embroidering machine according to the present invention. FIG. 12 is a plan view showing a state of applying a load belt to the deceleration synchronizing load applying means of FIG. 11. FIG. 13 is a cross section view showing a state installed the load belt of FIG. 12. FIG. 14 is a plan view showing a state of applying a cylinder device to the deceleration synchronizing load applying means of FIG. 11. FIG. 15 is a plan view showing a state applied a clutch to the deceleration synchronizing load
applying means of FIG. 11.
As understood from FIGS. 11 to 14, first and second pulse motors 226a, 226b are connected to the embroidery frame 210 via timing belts 221a, 221b.
A controlling means 230 is connected to the first and second pulse motors 226a, 226b via motor drivers 228a, 228b as shown in FIG. 11. That is, the controlling means 230 reads an embroidery data determined by an embroidery design stored in a memory, applies a controlling signal accompanied with a form of pulse to the motor drivers 228a, 228b, and respectively drives the first and second pulse motors 226a, 226b according to the applied controlling signal. Accordingly, timing belts 221 a, 221 b on which the moving body explained in FIGS. 3 and 4 is fixed pull or push the embroidery frame 210, thereby moving the embroidery frame 210 to a necessary position on a horizontal plane.
As shown in FIGS. 12 and 13, load belts 251 a, 251 b on which the moving bodies 252a, 252b are respectively fixed are connected to the embroidery frame 210 and to synchronizing axes 261 a, 261 b via cams 256a, 256b. The synchronizing axes 261 a, 261 b are connected to the principal axis motor 271 via a power transmitting device 266. Of course, the power transmitting device 266 should be a material which does not cause a slip in the timing belts and the gear. It is preferable that a thick and wide material is used for the load belts 251 a, 251 b.
The cylinder device 280 as represented in FIG. 14 can be used instead of the load belts 251 a, 251 b. That is, in a state that the embroidery frame 210 is movable by the pulse motor 228 which moves the timing belts 221 on which
the moving body 222 is fixed, a load can be applied to the embroidery frame 210 in synchronization with a deceleration synchronizing phase angle area like the principal axis motor 271 by adjusting an open and shut amount of a valve 286 operating the cylinder device 280 by a movement of the cam 256 installed on the synchronizing axis 261 by fixing the moving body 284 supporting the embroidery frame 210 on an end of the cylinder rod 282. That is, it is preferable that the configuration of a cam curve is such that the valve 286 starts to be shut when the cam 256 is at the decelerating point, i. e., at which the needle is at the upper dead point, and is shut most at the point that the needle pierces the material, and the valve 286 starts to re-open in this state and is open most right before the needle is accelerated by escaping from the material. The valve 286 should be open and shut by an electronic control.
That is, the power of the principal axis motor 271 for driving the needle is transmitted to the synchronizing axes 261,261 a, 261 b via the power transmitting device 266. Accordingly, as the synchronizing axes 261,261a, 261 b and the cams 256,256a, 256b installed thereon are revolvingly driven, the load is applied to the embroidery frame 210 in synchronization with the above-explained deceleration synchronizing phase angle area via the load belts 251 a, 251 b or the cylinder device 280. The size and timing of the load to be applied to the embroidery frame 210 via the load belts 251 a, 251 b or the cylinder device 280 will be determined by a shape of the cams 256,256a, 256b.
As shown in FIG. 15, in a state that the load belts 251 a, 251 b on which the moving bodies 252a, 252b supporting the embroidery frame 210 are fixed
are installed to race, the load may be applied to the embroidery frame 210 by use of the cylinders 280a, 280b operated by the cams 256a, 256b and the clutches 282a, 282b operated by the cylinders 280a, 280b. Of course, this method can be configured in combination with the above-explained load belt method as represented in FIG. 12.
The above method of adjusting the load of the load belt by the cam can be reverse applied to the pulse motor. When starting, the pulse motor cannot rapidly start as the timing belts 221 a, 221 b operate as a load due to a plurality of timing belts 221 a, 221 b connected between the pulse motor and the embroidery frame. To improve this problem to the effect that the driving speed of the embroidering machine can be increased, a tensile force of the timing belts 221 a, 221 b is slightly lowered by use of the cam in order to reduce the belt load when the pulse motor starts, and the starting speed of the pulse motor is increased by raising the tensile force when the speed is accelerated.
That is, although ends of the timing belts 221 a, 221 b as in FIG. 12 are connected to the synchronizing axes 261 a, 261 b on which the cams 256a, 256b are installed as shown in FIG. 13, the cam curve and the phase are formed in accordance with a degree of adjusting the tensile force.
FIG. 16 is a block diagram showing another example of the embroidery frame operating apparatus of the embroidering machine according to the present invention. The embroidery frame moving means 220 in FIG. 16 is the same as above.
The deceleration synchronizing load applying means 250 as represented in FIG. 16 is to apply a load to the embroidery frame 210 by
operating the load means 254a, 254b with solenoid devices 265a, 265b instead of the cams installed on the synchronizing axes mentioned above.
As understood from FIG. 16, the embroidery frame 210 connects the load means 254a, 254b corresponding to the load belt, the cylinder device and the clutch as explained above. The load means 254a, 254b connect the solenoid devices 265a, 265b. The solenoid devices 265a, 265b consecutively connect a solenoid device controlling means 264 and a deceleration synchronizing phase angle area detecting means 268. The deceleration synchronizing phase angle area detecting means 268 is to detect the deceleration synchronizing phase angle area from the principal axis motor 271, the principal axis synchronizing therewith, the needle bar, or the movement of the needle, and may use a technology of the prior art using an encoder or a needle height detecting sensor.
That is, concurrently with moving the embroidery frame 210 to a necessary position by the embroidery frame moving means 220, the deceleration synchronizing phase angle area of the principal axis motor 271 is detected by the deceleration synchronizing phase angle area detecting means 268 which comprises a controlling means of the principal axis motor 271, or the encoder installed on the peripheral surface of the principal axis, or a sensor for detecting a certain revolving angle of the needle bar, or the needle height detecting sensor for detecting the height of the needle. When the detected signal is applied to the solenoid device controlling means 264, the solenoid device controlling means 264 operates the solenoid devices 265a, 265b in synchronization with the applied detecting signal of the deceleration
synchronizing phase angle area. Accordingly, the solenoid devices 265a, 265b operate the load means 254a, 254b in synchronization with the deceleration synchronizing phase angle area of the principal axis motor 271, so that a load is applied to the embroidery frame 210 in synchronization with the deceleration synchronizing phase angle area of the principal axis motor 271. Occasionally, it is possible to configure that a separate load is connected to the axes of the pulse motors 226a, 226b in synchronization with the deceleration synchronizing phase angle area of the principal axis motor 271.
FIG. 17 is a block diagram explaining another example according to the present invention, and FIG. 18 is a plan view partially showing an example of installing a torque motor and a connecting means as in FIG. 17.
The configuration and operation process of the embroidery frame moving means 220 in FIG. 17 is identical to that in FIG. 11.
Unlike the example of FIG. 11, the deceleration synchronizing load applying means 250 detects an accelerating point and a decelerating point by use of the deceleration synchronizing phase angle area detecting means 268 comprising the encoder or the needle height detector instead of the synchronizing axes 261,261 a, 261 b. The torque motors 258a, 258b are configured better with a servo motor in order to assist the embroidery frame 210 in accelerating at the accelerating point, i. e., when the needle is out of the material, and in order to apply the load to the embroidery frame 210 at the decelerating point. More concretely examining this through FIG. 18, the embroidery frame 210 is movable by fixing the moving body 222 supporting
the embroidery frame 210 on the timing belt 221 driven by the pulse motor 226.
The embroidery frame 210 and the torque motor 258 are connected via a connecting means 253 comprising the timing belt on which the moving body 252 is fixed as explained above. As known from FIG. 17, a torque motor controlling means 263 is connected via torque motor drivers 259a, 259b. The torque motor controlling means 263 connects the deceleration synchronizing phase angle area detecting means 268 such as the encoder for detecting the deceleration synchronizing phase angle area from the principal axis motor 271, the principal axis, the needle bar or the movement of the needle, and the needle height detector.
That is, while the embroidery frame 210 repeats the process of accelerating, decelerating and stopping and the process of accelerating, decelerating and stopping toward the reverse direction by the embroidery frame moving means 220, a predetermined detecting signal of the deceleration synchronizing phase angle area is applied to the torque motor controlling means 263 by detecting the deceleration synchronizing phase angle area of the principal axis motor 271 via a controlling data of the controlling means for controlling the principal axis or the encoder installed on the peripheral surface of the principal axis or the needle height detecting sensor. The torque motor controlling means 263 applies the torque in a predetermined size to the axes of the torque motors 258a, 258b by controlling the torque motors 258a, 258b via the motor drivers 259a, 259b according to the applied detecting signal of the deceleration synchronizing phase angle area. Accordingly, the connecting means 253a, 253b apply the load to the embroidery frame 210 in
synchronization with the deceleration synchronizing phase angle area. As mentioned above, when a servo motor with an excellent performance is used as the torque motors 258a, 258b, the speed accelerating of the embroidery frame 210 may be assisted at the accelerating point and the load may be applied to the embroidery frame 210 at the decelerating point. Occasionally, the speed accelerating of the embroidery frame 210 at the acceleration point may be assisted by connecting the servo motor directly to the axis driven by the pulse motor 226, and the load may be applied to the embroidery frame 210 at the decelerating point.
FIG. 19 is a flow chart explaining an embroidery frame operating process of the embroidering machine according to the present invention.
With reference to FIGS. 9 to 18, the process of embodying the method of the present invention is explained as follows.
When the power switch is turned on after the preparation of a design selection is complete, the principal axis motor 271 starts to operate (Step 1), and accordingly the needle repeats the upwardly and downwardly moving operation (Step 2) via the needle bar around which the principal axis connected to the principal axis motor 271 is revolved (Step 3).
In the meantime, each pulse motor, i. e., stepping motor, 226,226a, 226b starts to operate concurrently with the start of the principal axis motor 271 (Step 4). After rapidly accelerating for a short period of time (Step 5), the pulse motors, i. e., stepping motors, 226,226a, 226b stop after rapidly decelerating (Step 6) (Step 7). The pulse motor, i. e., stepping motor, repeats the above process after stopping for a short period of time (Step 8).
On the other hand, a question as to whether it is a deceleration synchronizing phase angle area or not is determined by the principal axis motor 271, the principal axis synchronizing therewith, the needle bar, or the movement of the needle or by the synchronizing axes 261,261 a, 261 b synchronizing with the principal axis motor 271, and when the answer is in the affirmative, a deceleration synchronizing load is applied to the embroidery frame (Step 10). Step 10 is performed at the point that the pulse motors 226, 226a, 226b decelerate. Of course, Step 10 is not strictly supposed to be performed concurrently with the upper dead point 0° at which the pulse motors 226,226a, 226b start to decelerate, but may be performed after being delayed for a certain period of time. It is preferable that the accordingly applied load is continuously applied right before the pulse motors 226,226a, 226b start to accelerate, i. e., during which the pulse motors 226,226a, 226b stop after decelerating, and the load may be dismissed before that. That is, the question as to whether it is an acceleration synchronizing phase angle area or not is continuously determined after the load application, and when the answer is in the affirmative, the load (Step 12) is dismissed and the above process is repeated.
After the process is complete, the principal axis motor 271 is stopped (Step 13) and at the same time the pulse motor, i. e., stepping motor, is stopped to finish (Step 14).
FIG. 20 is a flow chart explaining the operating process of the embroidery frame during the process of FIG. 19.
That is, the embroidery frame 210 is accelerated with following the
acceleration of the pulse motors 226,226a, 226b at a predetermined interval (Step 15). When the pulse motors 226,226a, 226b rapidly decelerate, the embroidery frame 210 is decelerated with following the deceleration of the pulse motors 226,226a, 226b at a predetermined interval (Step 16).
Concurrently with this, when the deceleration synchronizing load applying means 250 applies the load for reducing the moving inertia of the embroidery frame 210 in synchronization with decelerating (Step 10), the embroidery frame 210 stops at an approximate point of the stopping point of the pulse motors 226,226a, 226b (step 17), repeats the above process for a predetermined period (Step 18), and stops the operation after completion.
FIG. 21 is a graph showing speed changes of the embroidery frame according to the driving speed change of the pulse motor in a case that the present invention has not been applied. FIG. 22 is a graph showing speed changes of the embroidery frame depending on the change of the deceleration synchronizing load applied to the embroidery frame and the accompanied driving speed change of the pulse motor according to the present invention.
In FIGS. 21 and 22, the full lines represent the speed change of the pulse motors 226,226a, 226b and the dotted lines represent the speed change of the embroidery frame 210. As understood from a deceleration synchronizing load applying curve marked in the upper part of FIG. 22, the deceleration synchronizing load is applied at around the upper dead point (0°) of the needle bar at which the pulse motors 226,226a, 226b start to decelerate, and is dismissed at around the acceleration starting point (260°) at which the pulse motor starts to accelerate.
As explained above, as the driving speed of the principal axis motor increases from 750 to 1000 rpm, the time at which the embroidery frame 210 is instantaneously movable decreases from 0.04444 to 0.03333 seconds.
However, as the distance that the embroidery frame should move for the moment is identical, a slant between the driving speed change of the pulse motors 226,226a, 226b and the speed change of the embroidery frame 210 becomes very steep. When the present invention is not applied, the embroidery frame 210 maintains the speed Va by the inertia up to the point (260°) at which the embroidery frame should be accelerated toward a reverse direction by far exceeding the stopping point as represented in FIG. 21.
Accordingly, a great power is required to accelerate the embroidery frame 210 in the reverse direction. On the other hand, as known from FIG. 22, when the present invention is applied, the embroidery frame stops before the acceleration starting point (260°) toward the reverse direction, so that the speed becomes 0 at the point (260°) of accelerating. That is, the embroidery frame 210 can be accelerated in the reverse direction with a less power than before.
The embroidery frame operating method of the embroidering machine and the apparatus for performing the operating method according to the present invention can be applied not only to the multi-head embroidering machine as explained above, but also to the embroidering machine for final products or the computer quilting machine although there is a slight difference in the method of holding the material for embroidering, or the final products.
Industrial Applicabilitv As known from the above explanations, when the embroidery frame operating method of the embroidering machine and the apparatus for performing the operating method according to the present invention is used, productivity of the embroidering machine and precision of embroidery can be improved by dramatically increasing the driving speed of the embroidery frame.
As well, durability of the embroidering machine and working conditions are improved as the noise and vibration occurred can be dramatically decreased by adding a great power to turn the directions of the embroidery frame. Moreover, embroidery products of high quality can be produced by precisely controlling the stopping position of the embroidery frame.
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