阅读说明：本技术 缝纫机 (Sewing machine ) 是由 今村雄介 近藤宏史 于 2020-03-27 设计创作，主要内容包括：本发明涉及一种缝纫机,该缝纫机能够以区分缝制不良的种类的方式进行告知。缝纫机从线张力检测机构的检测结果获取面线的张力。缝纫机基于所获取的面线的张力,对是否发生了缝制不良进行判断。在缝纫机判断为发生了缝制不良时,由缝纫机对所发生的缝制不良进行判别。在所判别出来的缝制不良包括断线、跳针和收线不良中的任一者时,缝纫机与缝制不良的种类相应地,分别以单独告知的方式进行告知。(The invention relates to a sewing machine, which can inform in a mode of distinguishing the types of poor sewing. The sewing machine acquires the tension of the upper thread from the detection result of the thread tension detection mechanism. The sewing machine judges whether sewing failure occurs based on the acquired tension of the upper thread. When the sewing machine judges that the sewing failure occurs, the sewing machine judges the occurred sewing failure. When the identified sewing failure includes any one of broken thread, skip stitch and take-up failure, the sewing machine informs the types of the sewing failure separately.)

1. A sewing machine (1) has:

a needle bar (11) equipped with a needle (10) through which an upper thread can be inserted, the needle bar being capable of moving up and down; and

a drive section (27) that drives the needle bar,

the sewing machine is driven by the driving part to sew,

the sewing machine is characterized in that the sewing machine is provided with a sewing machine,

the sewing machine has:

a first acquiring part (91) for acquiring the tension of the upper thread in the sewing process;

a detection unit that detects a sewing failure including at least a thread breakage, a stitch skipping, and a thread take-up failure based on the tension acquired by the first acquisition unit; and

and a first control part which informs the types of the sewing defects detected by the detection part through an informing part in a mode of independent informing.

2. The sewing machine of claim 1,

the sewing machine also has a first counting part which counts the number of times of the vertical movement of the needle bar,

the first control unit counts the number of times the needle bar moves up and down during a period from the start of sewing by the drive unit to the detection of the sewing failure by the detection unit by the first counting unit when the detection unit detects the sewing failure, and notifies the needle bar by the notification unit.

3. The sewing machine of claim 2,

the sewing machine has:

a cloth feeding mechanism capable of feeding cloth;

a stopping section for stopping the feed of the cloth by the cloth feeding mechanism when the detecting section detects the sewing failure;

a determining unit that determines, after the stopping unit stops the conveyance of the fabric, a moving amount and a moving direction in which the fabric moves during a period from the detection of the sewing failure to the stop of the conveyance of the fabric; and

and a second control unit that conveys the cloth by the cloth feeding mechanism in a direction opposite to the movement direction determined by the determination unit, in accordance with the movement amount determined by the determination unit.

4. Sewing machine as in any of claims 1 to 3,

the informing part is a display part (25, 221) which displays the type of the sewing failure independently.

5. Sewing machine as in any of claims 1 to 4,

the notification unit has light emitting units (210A, 200B, 200C) capable of blinking,

the sewing machine further comprises a second counting part for counting the number of times of the detection part detecting the sewing failure,

the first control unit notifies the user by blinking the light emitting unit the number of times counted by the second counting unit.

6. Sewing machine as in any of claims 1 to 5,

the sewing machine has: a base unit (2); a support column part (3) extending upward from the base part; and a boom section (4) extending from the column section so as to face the base section,

the needle bar is provided at a tip end portion (5) of the arm portion so as to be movable up and down, the needle bar protrudes downward from a lower end of the tip end portion,

the notification portion is provided at the lower end of the distal end portion and has a light emitting portion that can be lit,

the first control unit provides notification by lighting the light emitting unit when the detection unit detects the sewing failure.

7. Sewing machine as in any of claims 1 to 6,

the sewing machine further includes a third control unit configured to stop the driving unit and stop sewing when the sewing failure detected by the detection unit is the broken thread.

8. Sewing machine as in any of claims 1 to 7,

the sewing machine has a first setting unit that informs whether or not the sewing failure is individually set for each sewing failure by the informing unit.

9. The sewing machine according to any one of claims 1 to 8,

the detecting section detects the sewing failure based on a relationship between a detection reference set for each sewing failure and the tension,

the detection reference can be inputted for each sewing failure by using an input part,

the sewing machine further includes a second setting unit for setting the detection reference inputted by the input unit.

Technical Field

The present invention relates to a sewing machine.

Background

Japanese laid-open patent publication No. 132188 of 1995 discloses a sewing apparatus capable of detecting and notifying a thread breakage. When the tension of the upper thread is changed, the thread take-up spring is contacted with the limit pin or leaves the limit pin. In the sewing process, the upper thread generates periodic tension variation. When the thread is broken, the tension of the upper thread can not be changed. At this time, the thread take-up spring is continuously in contact with the limit pin. At this time, the sewing device causes the display part to display the needle with broken thread in the multi-needle sewing.

The sewing failure generated in the sewing process includes stitch skipping, poor line winding and the like besides the broken line. The sewing device can not inform sewing failure except broken thread. Therefore, it is difficult for the operator to perform appropriate processing according to the type of defective sewing.

Disclosure of Invention

Problems to be solved by the invention

The invention aims to provide a sewing machine capable of informing in a mode of distinguishing types of sewing defects.

The sewing machine of claim 1 comprises: a needle bar equipped with a needle capable of inserting an upper thread, the needle bar being capable of moving up and down; and a drive unit that drives the needle bar, wherein the sewing machine is driven by the drive unit to perform sewing, and the sewing machine is characterized by comprising: a first acquiring part for acquiring the tension of the upper thread in the sewing process; a detection unit that detects a sewing failure including at least a thread breakage, a stitch skipping, and a thread take-up failure based on the tension acquired by the first acquisition unit; and a first control part which informs the types of the sewing defects detected by the detection part through an informing part in a mode of independent informing.

The sewing machine notifies the types of the sewing defects individually. Therefore, the sewing machine can inform the user by distinguishing the type of the sewing failure.

In the sewing machine according to claim 2, the sewing machine may further include a first counting unit that counts a number of times the needle bar moves up and down, and the first control unit may count, when the detection unit detects the poor sewing, a number of times the needle bar moves up and down in a period from when the driving unit starts sewing to when the detection unit detects the poor sewing, by the first counting unit, and notify the notification unit of the number of times the needle bar moves up and down. The operator can easily grasp the sewing failure occurrence position.

In the sewing machine according to claim 3, the sewing machine may further include: a cloth feeding mechanism capable of feeding cloth; a stopping section for stopping the feed of the cloth by the cloth feeding mechanism when the detecting section detects the sewing failure; a determining unit that determines, after the stopping unit stops the conveyance of the fabric, a moving amount and a moving direction in which the fabric moves during a period from the detection of the sewing failure to the stop of the conveyance of the fabric; and a second control unit that conveys the cloth by the cloth feeding mechanism in a direction opposite to the movement direction determined by the determination unit, in accordance with the movement amount determined by the determination unit. The sewing machine can make the cloth move back to the position where sewing is not good. Therefore, the operator can easily restart the sewing from the sewing failure occurrence place.

In the sewing machine according to claim 4, the notification unit may be a display unit that displays the type of the defective sewing alone. The sewing machine can inform the user by using the display part in a mode of distinguishing the types of the sewing defects. Therefore, the operator can easily grasp the type of the sewing failure.

In the sewing machine according to claim 5, the notification unit may include a light emitting unit that can blink, the sewing machine may further include a second counting unit that counts the number of times the detection unit detects the defective sewing, and the first control unit may notify the notification unit by blinking the light emitting unit by the number of times counted by the second counting unit. The operator can easily grasp the number of sewing failure occurrences. Therefore, the operator can conveniently grasp the abnormity of the sewing machine according to the frequency of poor sewing.

In the sewing machine according to claim 6, the sewing machine may further include: a base portion; a pillar portion extending upward from the base portion; and a needle bar provided at a distal end portion of the arm portion so as to be movable up and down, the needle bar protruding downward from a lower end of the distal end portion, wherein the notification portion is provided at a lower end of the distal end portion and includes a light emitting portion that can be lit, and the first control portion notifies by lighting the light emitting portion when the detection portion detects the sewing failure. The operator can observe the occurrence of poor sewing conveniently. Therefore, the operator can conveniently grasp the abnormality of the sewing machine by identifying the occurrence of the sewing failure.

In the sewing machine according to claim 7, the sewing machine may further include a third control unit configured to stop the driving unit and stop the sewing when the sewing failure detected by the detection unit is the broken thread. The operator can deal with the disconnection as early as possible.

In the sewing machine according to claim 8, the sewing machine may further include a first setting unit that sets whether or not the notification unit notifies the sewing failure individually for each sewing failure. The operator does not need to be aware of a sewing defect that is of less importance to the operator. Therefore, the sewing machine can restrain the bothersome feeling of the operator.

In the sewing machine according to claim 9, the detection unit may detect the sewing failure based on a relationship between a detection reference set for each type of the sewing failure and the tension, and the detection reference may be input for each type of the sewing failure by an input unit, and the sewing machine may further include a second setting unit that sets the detection reference input by the input unit. The operator does not need to be aware of a sewing defect that is of less importance to the operator. Therefore, the sewing machine can restrain the bothersome feeling of the operator.

Drawings

Fig. 1 is an overall perspective view of the sewing machine 1.

Fig. 2 is an overall perspective view of the sewing apparatus 100.

Fig. 3 is a partially enlarged view of the head 5.

Fig. 4 is a partially enlarged view of the panel portion 220.

Fig. 5 is an electrical block diagram of the sewing machine 1.

Fig. 6 is a flowchart of the sewing process.

Fig. 7 is a flow chart following fig. 6.

Fig. 8 is a flow chart following fig. 7.

Fig. 9 is a flowchart of the processing in the case of defective sewing.

Fig. 10 is a flowchart of the process at the time of disconnection.

Fig. 11 is a flowchart of the process at the time of stitch skipping.

Fig. 12 is a flowchart of the processing when the wire take-up is defective.

Detailed Description

A sewing machine 1 according to an embodiment of the present invention will be described. The following description uses the left and right, front and back, and up and down shown by arrows in the drawings.

Referring to fig. 1 to 3, the structure of the sewing machine 1 will be described. The sewing machine 1 has a table 9 and a sewing device 100. An opening 9A is provided in the upper surface of the table 9. The right front portion of the table 9 has a panel portion 220. The sewing device 100 has a base 2, a column 3, and an arm 4. The base part 2 is fitted at the opening 9A, and the base part 2 extends in the left-right direction. The housing part 2 is equipped with a needle plate 7 on the upper surface. The operator places the cloth on the bed 2 and the needle plate 7. The needle plate 7 has a needle receiving hole 8 and a feed dog hole 14. The pin receiving hole 8 has a circular shape in plan view. The feed sprocket 14 has a long diameter in the front-rear direction, and the feed sprocket 14 is located at the left, rear, right, and front of the needle accommodating hole 8, respectively. The column part 3 extends upward from the right end of the seat part 2. The arm portion 4 extends leftward from the upper end of the column portion 3 and faces the upper surface of the base portion 2. The arm unit 4 has a first input unit 24 and a first display unit 25 at a substantially central portion in the left-right direction of the front surface. The first input portion 24 is three input buttons. The operator inputs various instructions by operating the first input unit 24 while looking at the first display unit 25. The arm part 4 has a thread passing rod (Japanese vertical rod) 20 protruding upward on the left side of the upper surface. The thread take-up lever 20 is penetrated by the upper thread 6 drawn out from the thread spool.

The arm portion 4 includes an upper shaft 15 and a main motor 27 (see fig. 5) therein. The upper shaft 15 extends in the left-right direction and is connected to an output shaft of the main motor 27 via an upper shaft pulley. The upper shaft pulley is fixed to the right end of the upper shaft 15. The arm portion 4 has a head portion 5 at a left end portion. The head 5 protrudes downward from the arm 4 and faces the needle plate 7 from above. The head 5 supports the needle bar 11 so that the needle bar 11 can move up and down. The lower end of the needle bar 11 is fitted with a needle 10 and projects downward from the head 5. The needle bar 11 is connected to the upper shaft 15 by an up-and-down movement mechanism. The needle bar 11 is moved up and down by the up-down movement mechanism in accordance with the rotation of the upper shaft 15. The needle 10 moves up and down together with the needle bar 11 while holding the needle thread 6 (see fig. 3) passing through the needle eye. The needle 10 can be passed through the needle-receiving hole 8. The lower end of the movable range of the needle 10 is a bottom dead center.

The base unit 2 includes therein a shuttle, a thread cutting mechanism 17 (see fig. 5), and a cloth feeding mechanism. The shuttle is provided below the needle plate 7 and houses a bobbin around which a lower thread is wound. The shuttle has a tip, and can be rotated by power of the main motor 27, and catches the upper thread 6 passing through the eye of the needle 10 with the tip, and interweaves the upper thread 6 with the lower thread. The thread cutting mechanism 17 includes a fixed blade, a movable blade, and a thread cutting solenoid 17A (see fig. 5). The movable blade is connected to the tangent line electromagnetic element 17A. The movable knife is moved relative to the fixed knife by driving the thread cutting solenoid 17A, and the thread cutting mechanism 17 cuts the surface thread 6 and the ground thread by cooperation of the movable knife and the fixed knife.

The cloth feeding mechanism includes upper and lower cloth feeding shafts, a cloth feeding table, cloth feeding teeth 13, a horizontal cloth feeding shaft, and a cloth feeding motor 123 (see fig. 5). The upper and lower cloth feed shafts extend in the right and left direction inside the machine base 2 and are connected to the upper shaft pulleys via belts. The cloth feeding table is arranged to be capable of swinging and is connected with the upper and lower cloth feeding shafts. When the up-down feed shaft is rotated by the driving force of the main motor 27, the feed table moves in the up-down direction. The feed dog 13 is supported on the feed table. The horizontal feed shaft extends in the left-right direction at a position forward of the upper and lower feed shafts, and connects the feed motor 123 and the feed table. When the horizontal cloth feeding shaft is rotated by the driving force of the cloth feeding motor 123, the cloth feeding table moves in the front-rear direction. The cloth feeding table swings as the main motor 27 and the cloth feeding motor 123 are driven, and the cloth feeding teeth 13 protrude from or retreat into the cloth feeding sprocket holes 14. The cloth feed dog 13 moves in the front-rear direction while protruding upward from the cloth feed dog hole 14, and feeds the cloth.

As shown in fig. 3, the head 5 includes a sub thread gripper 26, a main thread gripper 60, a thread guide 21, a thread tension detection mechanism 130, a thread take-up lever 23, a guide hook 29, and the like in this order from the thread spool to the upstream side of the feed path of the upper thread 6 of the needle 10.

The sub-chuck 26 is provided at the upper right portion of the front surface of the head 5. The main gripper 60 is provided below the sub gripper 26 and is a front surface of the head 5. The sub-gripper 26 and the main gripper 60 respectively give tension to the upper thread 6. The sub-gripper 26 applies tension to the surface thread 6, which is required when the surface thread 6 and the lower thread are cut by the thread cutting mechanism 17. The main thread gripper 60 adjusts the tension applied to the upper thread 6 in accordance with the sewing operation of the sewing device 100. The wire guide 21 is provided on the left of the main wire gripper 60. The thread guide 21 folds back the upper thread 6 passing through the main thread gripper 60 toward the thread tension detecting mechanism 130 and the thread take-up lever 23. The wire tension detecting mechanism 130 is fixed to a recess 5A recessed rearward from the front surface of the head 5 by a screw 90, and is located at a vertical position between the sub wire gripper 26 and the main wire gripper 60. The line tension detecting mechanism 130 includes a magnetic sensor 105 (see fig. 5). The thread tension detecting means 130 can detect the tension acting on the upper thread 6, that is, the upper thread tension, based on the output voltage of the magnetic sensor 105. The thread take-up lever 23 is provided on the left side of the sub-gripper 26 and has a through hole 23A through which the upper thread 6 passes. The thread take-up lever 23 moves up and down in accordance with the driving of the main motor 27. The guide hook 29 is provided on the left of the wire tension detecting mechanism 130. The guide hook 29 guides the upper thread 6 passing through the through hole 23A of the thread take-up lever 23 toward the needle bar 11.

The header 5 has a header amplifier 200 and a protrusion 210. The head amplifier 200 is provided on the rear upper surface of the head 5. On the upper front surface of the head amplifier 200, a disconnection LED200A, a jumper LED200B, and a take-up LED200C are provided in this order from the right. The disconnection LED200A, the jumper LED200B, and the take-up LED200C can emit light in a lighted or blinking manner. The disconnection LED200A emits light when a disconnection occurs. The jumper LED200B emits light when a jumper occurs. The take-up LED200C emits light when a take-up failure occurs. The poor sewing of broken thread, skipping stitch and winding thread.

The projection 210 is provided near the needle bar 11 and below the thread guide portion 21. The protrusion 210 protrudes forward from the lower end portion of the head 5, and then bends downward and extends. The projection 210 has a needle bar LED210A at the lower portion. The needle bar LED210A can illuminate in a lighted or blinking manner. The needle bar LED210A lights up when a poor thread take-up occurs, and lights off after stopping the sewing operation. The needle bar LED210A may blink the number of times of occurrence of poor take-up when a poor take-up occurs.

As shown in fig. 4, the panel portion 220 includes a second display portion 221, a second input portion 222, and a speaker 223 (see fig. 5). The second display unit 221 is an LCD, and can display numbers, characters, and the like. The second input unit 222 is provided on the left and below the second display unit 221. The operator operates the second input unit 222 while looking at the second display unit 221 to input various instructions. Hereinafter, the first input unit 24 (see fig. 2) and the second input unit 222 are collectively referred to as an input unit.

The second display unit 221 includes a first screen 221A, a second screen 221B, a third screen 221C, and a fourth screen 221D in this order from the right. The first frame 221A mainly displays the number of times of occurrence of disconnection. The second screen 221B mainly displays the number of times of stitch skipping. The third frame 221C mainly displays the number of times of poor wire rewinding. The fourth screen 221D mainly displays a detection level described later. The second display unit 221 can also display the needle fall frequency of the needle 10 during a period from when the sewing machine 1 starts the sewing operation to when each sewing failure occurs.

The first display part 25, the second display part 221, the head amplifier 200 and the protrusion part 210 all give information when a sewing failure occurs. Hereinafter, the first display unit 25, the second display unit 221, the head amplifier 200, and the protrusion 210 are collectively referred to as a notification unit.

Referring to fig. 5, an electrical structure of the sewing machine 1 is explained. The control device 30 of the sewing machine 1 has a CPU 91. The CPU91 controls the operation of the sewing machine 1. The CPU91 is connected to a ROM92, a RAM93, a storage device 94, and an I/O interface (hereinafter referred to as I/O) 45. The ROM92 stores programs and the like for executing various processes such as a sewing process (see fig. 6) described later. The RAM93 temporarily stores various values. The storage device 94 is a non-volatile storage device.

The I/O45 is connected to the drive circuits 81 to 83. The drive circuit 81 is connected to the main motor 27. The drive circuit 82 is connected to the cloth feed motor 123. The drive circuit 83 is connected to the clamp motor 16. The main motor 27, the cloth feeding motor 123, and the thread take-up motor 16 include an encoder 27A, an encoder 123A, and an encoder 16A, respectively. The encoder 27A detects the rotational position of the output shaft of the main motor 27. The detection result of the encoder 27A indicates the rotational angle phase of the upper shaft 15, i.e., the upper shaft angle. The encoder 123A detects the rotational position of the output shaft of the cloth feeding motor 123. The encoder 16A detects the rotational position of the output shaft of the clamp motor 16. The CPU91 acquires the detection results of the encoders 27A, 123A, and 16A, and sends control signals to the drive circuits 81 to 83. Therefore, the CPU91 controls the driving of the main motor 27, the cloth feeding motor 123, and the thread take-up motor 16. Hereinafter, the main motor 27, the cloth feeding motor 123, and the thread take-up motor 16 will be collectively referred to as a drive motor.

The I/O45 is connected to the drive circuits 84 to 88, the first input unit 24, the second input unit 222, the pedal 38, and the magnetic sensor 105. The drive circuit 84 is connected to the tangent electromagnetic element 17A. The driving circuit 85 is connected to the first display unit 25. The driver circuit 86 is connected to the head amplifier 200. The drive circuit 87 is connected to the needle bar LED 210A. The drive circuit 88 is connected to the second display unit 221 and the speaker 223. The CPU91 sends control signals to the drive circuits 84 to 88 to control the tangent solenoid 17A, the first display unit 25, the head amplifier 200, the needle bar LED210A, the second display unit 221, and the speaker 223. The first input unit 24 and the second input unit 222 output the input result of the operator to the CPU 91. The pedal 38 outputs the operation direction and the operation amount of the pedal 38 by the operator to the CPU 91. The magnetic sensor 105 outputs an output voltage indicating the face line tension to the CPU 91.

The storage device 94 stores detection criteria for various defects such as thread breakage, stitch skipping, and thread take-up defects in sewing defects described later. The detection reference is a value for the following purposes: the CPU91 determines whether or not a thread breakage, a stitch skipping, or a thread take-up failure has occurred by comparing the detection reference with the upper thread tension detected by the magnetic sensor 105. There is a stepped detection level in the detection reference. The higher the detection level is, the more easily the CPU91 determines that a sewing failure has occurred. The detection level of broken wires is called a broken wire detection level, the detection level of jumpers is called a jumpers detection level, and the detection level of poor wire take-up is called a wire take-up detection level.

The sewing failure of the sewing machine 1 will be described. The sewing failure indicates that a normal stitch is not formed in the sewing operation. The sewing failure comprises poor winding, broken thread and stitch skipping. The poor take-up is poor balance between the upper thread 6 and the lower thread which form a stitch on the cloth when the upper thread 6 is lifted by the take-up lever 23. For example, when the face thread 6 is too strongly interwoven with the ground thread, the cloth near the stitch shrinks. The thread breakage is a defect that the upper thread 6 is broken during sewing and a stitch is not formed on the fabric. The skip stitch is a failure in catching the needle thread 6 by the shuttle in sewing and is a failure in forming a normal stitch on the cloth. The sewing machine 1 sets detection references corresponding to a broken thread, a skip stitch, and a defective take-up respectively.

With reference to fig. 2 and 3, an outline of the operation of the sewing machine 1 will be described. The operator places the cloth on the needle plate 7. The upper shaft 15 moves the needle bar 11 and the thread take-up lever 23 up and down by driving of the driving motor, and the shuttle rotates. When the needle 10 is inserted into the fabric and then ascends after descending to the bottom dead center, the shuttle catches the endless upper thread 6 held by the eye of the needle 10 with the tip of the shuttle and weaves the upper thread 6 with the lower thread. The needle 10 is withdrawn upward from the fabric. At this time, the feed dog 13 is driven by the feed motor 123 and the main motor 27 to project upward from the feed dog hole 14 and swing rearward. Therefore, the cloth moves rearward. The thread take-up lever 23 lifts the upper thread 6 interlaced with the lower thread by the shuttle, thereby forming a stitch on the fabric. The cloth is sewn by repeating the above operations by the upper shaft 15, the needle 10, the shuttle, the thread take-up lever 23, and the cloth feeding mechanism.

The sewing process will be described with reference to fig. 6 to 12. When the operator turns on the power of the sewing machine 1, the CPU91 reads out the program from the ROM92 and starts the sewing process. The CPU91 sets each flag stored in the storage device 94 to 0. Hereinafter, the case where each flag is set to 0 is referred to as an off flag, and the case where each flag is set to 1 is referred to as an on flag.

As shown in fig. 6, the CPU91 executes initialization processing (S1). At this time, the CPU91 sets the variable N stored in the RAM93 to 0. The variable N is a counter for counting the number of needle drops of the needle 10.

The CPU91 determines whether or not the non-notification setting signal is received (S2). When there is a sewing failure which is not required to be notified when the sewing failure is detected, among the sewing failures such as a broken thread, a skip stitch, and a take-up failure, an operator operates the input section. At this time, the CPU91 receives the non-notification setting signal. When the CPU91 determines that the non-notification setting signal has not been received from the input unit (S2: no), the CPU91 shifts the process to S9 (see fig. 7).

When the CPU91 determines that the non-notification setting signal is received from the input unit (S2: yes), the CPU91 determines whether or not the disconnection non-notification signal is received (S3). When the operator operates the input unit to set the disconnection-related information as the non-notification, the CPU91 receives the disconnection-related information signal. When the CPU91 determines that the disconnection notification signal has not been received from the input section (S3: no), the CPU91 shifts the process to S5. When the CPU91 determines that the disconnection notification signal has been received from the input unit (yes in S3), the CPU91 turns on the disconnection notification flag (S4) and the process proceeds to S5.

The CPU91 determines whether the skip pin non-notification signal is received (S5). When the operator operates the input unit without notification when the skip is not required, the CPU91 receives a skip notification signal. When the CPU91 determines that the skip pin non-notification signal has not been received from the input section (S5: no), the CPU91 shifts the process to S7. When the CPU91 determines that the skip pin non-notification signal is received from the input unit (S5: yes), the CPU91 turns on the skip pin non-notification flag (S6), and the process proceeds to S7.

The CPU91 determines whether a poor wire take-up non-notification signal is received (S7). When the operator operates the input unit to set the wire-rewinding failure not to be notified, the CPU91 receives a wire-rewinding failure not-notification signal. When the CPU91 determines that the wire-rewinding failure notification signal has not been received from the input unit (S7: no), the CPU91 transfers the process to S9. When the CPU91 determines that the wire takeup failure non-notification signal is received from the input unit (S7: yes), the CPU91 turns on the wire takeup failure non-notification flag (S8), and the process proceeds to S9.

As shown in fig. 7, the CPU91 determines whether a defective quantity initialization signal has been received (S9). During the sewing operation of the sewing machine 1, the CPU91 counts the number of sewing failures, which is the number of occurrences of each sewing failure. The CPU91 counts the sewing failure quantity of broken thread by using a variable J, counts the sewing failure quantity of skip stitch by using a variable K, and counts the sewing failure quantity of take-up failure by using a variable L. When the operator performs an operation of setting the sewing defect number (values of the variable J, the variable K, and the variable L) to 0 using the input unit, the CPU91 receives the defect number initialization signal. When the CPU91 determines that the defect number initialization signal has not been received from the input section (S9: no), the CPU91 shifts the process to S11. When the CPU91 determines that the defect number initialization signal has been received from the input unit (S9: yes), the CPU91 sets the number of sewing defects stored in the storage device 94 to 0(S10), and the process proceeds to S11.

The CPU91 determines whether a detection level signal is received (S11). When the operator performs an operation of changing the detection level using the input unit, the CPU91 receives a detection level signal. When the CPU91 determines that the detection level signal has not been received from the input section (S11: no), the CPU91 shifts the process to S20 (see fig. 8).

When the CPU91 determines that the detection level signal is received from the input unit (S11: yes), the CPU91 determines whether or not the disconnection level signal is received (S12). When the operator performs an operation of changing the disconnection detection level using the input unit, the CPU91 receives a disconnection detection level signal. When the CPU91 determines that the disconnection level signal has not been received from the input section (S12: no), the CPU91 shifts the process to S14. When the CPU91 determines that the disconnection detection level signal has been received from the input unit (S12: yes), the CPU91 sets the disconnection detection level in accordance with the result of the operation of the input unit by the operator (S13). At this time, the CPU91 displays the disconnection detection level on the fourth screen 221D. The CPU91 shifts the process to S14.

The CPU91 determines whether a skip level signal is received (S14). When the operator performs an operation of changing the stitch detection level using the input unit, the CPU91 receives a stitch detection level signal. When the CPU91 determines that the jumper level signal has not been received from the input section (S14: no), the CPU91 shifts the process to S16. When the CPU91 determines that the skip-stitch level signal is received from the input unit (S14: yes), the CPU91 sets a skip-stitch detection level according to the result of the operation of the input unit by the operator (S15). At this time, the CPU91 causes the fourth screen 221D to display the skip stitch detection level. The CPU91 shifts the process to S16.

The CPU91 determines whether a wire takeup level signal is received (S16). When the operator performs an operation of changing the wire rewinding failure detection level using the input unit, the CPU91 receives a wire rewinding level signal. When the CPU91 determines that the wire takeup level signal has not been received from the input section (S16: no), the CPU91 shifts the process to S20 (see fig. 8). When the CPU91 determines that the wire takeup level signal is received from the input unit (S16: yes), the CPU91 sets a wire takeup detection level according to the result of the operation of the input unit by the operator (S17). At this time, the CPU91 causes the fourth screen 221D to display the line-up detection level. The CPU91 shifts the process to S20.

As shown in fig. 8, the CPU91 determines whether to start the sewing operation of the sewing machine 1 based on the detection result of the pedal 38 (S20). When the operator does not step on the pedal 38, the pedal 38 outputs an off signal to the CPU 91. When the CPU91 receives the close signal from the pedal 38, the CPU91 determines that the sewing operation is not started and the CPU91 stands by (S20: no).

When the operator steps on the pedal 38 after the cloth is placed on the needle plate 7, the pedal 38 outputs an on signal to the CPU 91. When the CPU91 receives the ON signal from the pedal 38, the CPU91 determines that the sewing operation is started (S20: YES). The CPU91 starts the process of updating the variable N based on the detection result of the encoder 27A (S22). The CPU91 determines the upper axial angle based on the detection result of the encoder 27A, and adds 1 to the variable N every time the needle 11 moves up and down based on the upper axial angle. The CPU91 continues this process during the sewing operation. The CPU91 starts driving the drive motor (S25) and starts the sewing operation.

The CPU91 executes tension acquisition processing (S31). The CPU91 acquires the face line tension based on the detection result of the magnetic sensor 105. The CPU91 determines whether or not a sewing failure has occurred based on the acquired needle thread tension (S32). When the CPU91 determines that a sewing failure has not occurred (S32: no), the CPU91 shifts the process to S34.

When the CPU91 determines that a sewing failure has occurred (S32: yes), the CPU91 stores category information indicating the type of the sewing failure that has occurred in the RAM 93. The CPU91 executes the sewing failure processing (S33). As shown in fig. 9, the CPU91 obtains the value of the variable N when a sewing failure occurs (S101). The value of the variable N is the number of times the needle bar 11 moves up and down in the period from the start of sewing to the occurrence of a sewing failure. The CPU91 determines the sewing failure based on the type information stored in the RAM93 (S102).

The CPU91 executes the disconnection-time processing (S103). As shown in fig. 10, the CPU91 determines whether or not a thread breakage has occurred based on the sewing failure determined in S102 (see fig. 9) (S200). When the CPU91 determines that thread breakage has not occurred (S200: no), the CPU91 ends the thread breakage processing and returns to the sewing failure processing (see fig. 9).

When the CPU91 determines that a disconnection has occurred (yes in S200), the CPU91 determines whether the disconnection non-notification flag is on (S201). When the CPU91 determines that the thread breakage non-notification flag is on (S201: yes), the CPU91 ends the thread breakage processing and returns to the sewing failure processing.

When the CPU91 determines that the disconnection notification flag is off (S201: no), the CPU91 stops driving of the drive motor (S202). The sewing machine 1 stops the sewing operation. The CPU91 notifies the occurrence of a disconnection via the notification section (S203). The CPU91 causes the first display unit 25 to display a message, turns on the disconnection LED200A, and causes the speaker 223 to emit a buzzer sound. The CPU91 causes the second display unit 221 to display the N value acquired in S101 (S204). The CPU91 adds 1 to the value of the variable J stored in the storage device 94 (S205). The CPU91 causes the first screen 221A to display the value of the variable J (S206).

The CPU91 acquires the value of the variable N when the drive of the drive motor is stopped by S202 (S207). In some cases, when the sewing speed is high, the value of the variable N at the time of occurrence of a thread breakage is different from the value of the variable N at the time of stop of driving of the drive motor. The CPU91 calculates the amount of movement and the direction of movement of the cloth material during the period from when the yarn breakage occurs to when the drive motor stops, based on the difference between the value of the variable N when the drive of the drive motor stops and the value of the variable N when the yarn breakage occurs (S208). The CPU91 drives the drive motor in the reverse direction of the direction of driving during the sewing operation based on the calculated amount of movement and the movement direction (S209). The CPU91 stops driving the drive motor (S210) and turns on a stop flag (S211). The CPU91 ends the thread breakage processing and returns to the sewing failure processing.

As shown in fig. 9, after the disconnection time processing (S103), the CPU91 executes the stitch skipping time processing (S104). As shown in fig. 11, the CPU91 determines whether or not a stitch skipping has occurred based on the sewing failure determined in S102 (S300). When the CPU91 determines that stitch skipping has not occurred (S300: no), the CPU91 ends the stitch skipping processing and returns to the sewing failure processing.

When the CPU91 determines that a skip stitch has occurred (yes in S300), the CPU91 determines whether the skip stitch non-notification flag is on (S301). When the CPU91 judges that the skip stitch non-notification flag is ON (S301: YES), the CPU91 ends the skip stitch processing and returns to the sewing failure processing.

When the CPU91 determines that the skip-stitch non-notification flag is off (S301: no), the CPU91 notifies the occurrence of a skip-stitch via the notification unit (S302). The CPU91 causes the first display unit 25 to display a message, turns on the jumper LED200B, and causes the speaker 223 to sound a buzzer. The CPU91 causes the second display unit 221 to display the N value acquired in S101 (S303). The CPU91 adds 1 to the value of the variable K stored in the storage device 94 (S304). The CPU91 causes the second screen 221B to display the value of the variable K (S305).

The CPU91 determines whether the value of the variable K reaches the skip point upper limit value (S306). The skip-stitch upper limit value is stored in the storage device 94 in advance. When the CPU91 determines that the value of the variable K has not reached the stitch upper limit value (S306: no), the CPU91 ends the stitch skipping processing and returns to the sewing failure processing. When the CPU91 determines that the value of the variable K has reached the skip point upper limit value (yes in S306), the CPU91 controls the thread cutting solenoid 17A to execute thread cutting (S307). The CPU91 stops driving of the drive motor (S308). The CPU91 acquires the value of the variable N when the drive of the drive motor is stopped by S308 (S309). The CPU91 calculates the amount and direction of movement of the cloth during the period from the occurrence of the skip stitch to the stop of the drive motor (S310). The CPU91 calculates the movement amount and the movement direction based on the difference between the value of the variable N when the driving of the drive motor is stopped and the value of the variable N when the stitch occurs. The CPU91 drives the drive motor in the reverse direction of the direction of driving during the sewing operation based on the calculated amount of movement and the movement direction (S311). The CPU91 stops driving the drive motor (S312) and turns on the stop flag (S313). The CPU91 ends the stitch skipping processing and returns to the sewing failure processing.

As shown in fig. 9, after the stitch skipping processing (S104), the CPU91 executes the wire rewinding failure processing (S105). As shown in fig. 12, the CPU91 determines whether a poor thread take-up occurs based on the sewing failure determined in S102 (S400). When the CPU91 determines that the poor thread take-up has not occurred (S400: no), the CPU91 ends the poor thread take-up processing and returns to the poor sewing processing.

When the CPU91 determines that a wire rewinding failure has occurred (yes in S400), the CPU91 determines whether the wire rewinding failure non-notification flag is on (S401). When the CPU91 determines that the poor thread take-up notification flag is on (S401: yes), the CPU91 ends the poor thread take-up processing and returns to the poor thread take-up processing (see fig. 9).

When the CPU91 determines that the wire-rewinding failure notification flag is off (S401: no), the CPU91 adds 1 to the value of the variable L stored in the storage device 94 (S402). The CPU91 notifies the occurrence of a wire-rewinding failure by the notification portion (S403). The CPU91 causes the first display unit 25 to display a message, causes the take-up LED200C to blink, lights the needle bar LED210A, and causes the speaker 223 to sound a buzzer. The number of blinks of the take-up LED200C is the same as the value of the variable L. The CPU91 causes the second display unit 221 to display the value of the variable N acquired in S101 (S404). The CPU91 causes the third screen 221C to display the value of the variable L (S405). The CPU91 ends the processing for poor thread take-up and returns to the processing for poor sewing. Even if poor wire winding occurs, the driving motor does not stop driving. In this case, the operator can continue the sewing or interrupt the sewing after confirming the poor take-up by the notification part.

As shown in fig. 9, after the thread take-up failure processing (S105), the CPU91 ends the sewing failure processing and returns to the sewing processing (see fig. 8). As shown in fig. 8, after the sewing failure time processing (S33), the CPU91 shifts the processing to S34.

The CPU91 determines whether the stop flag is on (S34). When the CPU91 determines that the stop flag is on (S34: yes), the CPU91 shifts the process to S59. When the CPU91 determines that the stop flag is off (S34: no), the CPU91 determines whether or not to end the sewing operation based on the detection result of the pedal 38 (S35). The pedal 38 continues to output an on signal while the operator continues to depress the pedal 38. When the CPU91 receives the ON signal from the pedal 38, the CPU91 determines not to end the sewing operation (S35: NO). The CPU91 shifts the process to S31 and executes the tension acquisition process (S31).

When the operator releases the pedal 38, the pedal 38 outputs a close signal to the CPU 91. When the CPU91 receives the off signal from the pedal 38, the CPU91 controls the thread cutting solenoid 17A to perform thread cutting (S57). The CPU91 stops driving of the drive motor (S58). The CPU91 stops the update process of the variable N started through S22 (S59).

The CPU91 determines whether or not the power of the sewing machine 1 is turned off (S63). When the CPU91 determines that the operator has not performed an operation to turn off the power of the sewing machine 1 (S63: no), the CPU91 shifts the process to S1 (see fig. 6). While the CPU91 is waiting (NO in S20), the operator places the unsewn cloth on the needle plate 7 instead of the sewn cloth and steps on the pedal 38 (YES in S20). When the CPU91 determines that the operator has performed an operation to turn off the power of the sewing machine 1 (S63: yes), the CPU91 stores the values of the variable J, the variable K, and the variable L in the storage device 94(S71), and ends the sewing process.

As described above, the CPU91 acquires the needle thread tension based on the detection result of the magnetic sensor 105 (S31). When the CPU91 judges that a sewing failure has occurred based on the acquired needle thread tension (S32: yes), the CPU91 determines the occurred sewing failure (S102). When the sewing failure is judged to include any one of the thread breakage, the stitch skipping and the thread take-up failure, the CPU91 notifies it individually in a notification manner corresponding to each failure (S103 to S105). The sewing machine 1 notifies the types of the sewing failures individually. Therefore, the sewing machine 1 can notify the user of the sewing failure by distinguishing the type of the sewing failure.

The CPU91 counts the needle drop count of the needle 10 (S22). When a sewing failure occurs, the CPU91 obtains the number of needle drops during a period from the start of sewing to the occurrence of the sewing failure (S101). The CPU91 causes the second display unit 221 to display the needle fall count acquired in S101 (S204, S303, S404). Therefore, the operator can easily grasp the sewing failure occurrence position.

The CPU91 acquires the needle drop frequency during the period from the start of sewing to the occurrence of a sewing failure (S101). The CPU91 acquires the needle fall frequency during the period from the start of sewing to the stop of driving of the drive motor (S207, S309). The CPU91 calculates the amount and direction of movement of the cloth during the period from the occurrence of the sewing failure to the stop of the drive motor, based on the number of times acquired in S101 and the numbers acquired in S207 and S309 (S208 and S310). The CPU91 drives the drive motor in the reverse direction of the direction of driving during the sewing operation based on the calculated amount of movement and the calculated direction of movement (S209, S311). Therefore, the sewing machine 1 can move the cloth in the reverse direction of the sewing direction by the cloth feeding mechanism and move the cloth back to the sewing failure position. Therefore, the operator can easily restart the sewing from the sewing failure occurrence place.

The second display unit 221 includes a first screen 221A, a second screen 221B, and a third screen 221C. The first frame 221A displays the number of times of occurrence of disconnection. The second screen 221B displays the number of times of stitch skipping. The third frame 221C displays the number of times of poor wire rewinding. The sewing machine 1 can notify the user of the type of defective sewing by using only the second display unit 221. Therefore, the operator can easily grasp the type of the sewing failure.

When a poor wire take-up occurs, the CPU91 counts the number of times of the poor wire take-up occurrence (S402). At this time, the CPU91 blinks the take-up LED200C the number of times counted (S403). The operator can easily grasp the number of times of poor take-up. Therefore, the operator can conveniently grasp the abnormality of the sewing machine 1 according to the occurrence frequency of poor take-up.

The needle stem LED210A is disposed near the needle stem 11. The needle bar LED210A is located in a position convenient for an operator to view. Therefore, the operator can easily grasp the occurrence of the wire rewinding failure. The operator can conveniently grasp the abnormity of the sewing machine 1 by identifying the occurrence of poor take-up.

When the disconnection occurs, the CPU91 stops driving the drive motor (S202). Therefore, the operator can deal with the disconnection as early as possible.

The CPU91 determines whether or not the disconnection non-notification signal, the skip needle non-notification signal, and the wire-rewinding failure non-notification signal have been received (S3, S5, and S7). Upon receiving the disconnection non-notification signal, the CPU91 turns on a disconnection non-notification flag (S4). Upon receiving the jumper non-notification signal, the CPU91 turns on the jumper non-notification flag (S6). When the wire rewinding failure notification signal is received, the CPU91 turns on the wire rewinding failure notification flag (S8). When the CPU91 determines that the disconnection notification flag is on (S201: yes), the CPU91 does not notify when a disconnection occurs. When the CPU91 determines that the skip-stitch non-notification flag is on (S301: yes), the CPU91 does not notify when a skip stitch occurs. When the CPU91 determines that the wire rewinding failure notification flag is on (S401: yes), the CPU91 does not notify when a wire rewinding failure occurs. The operator does not need to be aware of a sewing defect that is of less importance to the operator. Therefore, the sewing machine 1 can suppress the operator from feeling annoyed.

The sewing machine 1 can set detection references corresponding to a broken thread, a skip stitch, and a defective take-up respectively. There is a stepped detection level in the detection reference. The higher the detection level is, the more easily the CPU91 determines that sewing failure has occurred. The detection level of the broken line is the detection level of the broken line. And the detection grade of the skipping pins is the skipping pin detection grade. And the detection grade of poor take-up is a take-up detection grade. The CPU91 determines whether or not the disconnection level signal, the jumper level signal, and the line-up level signal have been received (S12, S14, and S16). Upon receiving the disconnection level signal, the CPU91 sets a disconnection detection level (S13). Upon receiving the jumper pin level signal, the CPU91 sets a jumper pin detection level (S15). Upon receiving the wire takeup level signal, the CPU91 sets a wire takeup detection level (S17). The operator does not need to be aware of a sewing defect that is of less importance to the operator. Therefore, the sewing machine 1 can suppress the operator from feeling annoyed.

The CPU91 executing S31 exemplifies the first acquisition unit of the present invention. The CPU91 executing S32 is an example of the detection unit of the present invention. The CPU91 executing S33 is an example of the first control unit of the present invention. The CPU91 executing S22 exemplifies the first counter unit of the present invention. The CPU91 when executing S202 and S308 is an example of the stop unit of the present invention. The CPU91 when executing S208 and S310 is an example of the determination unit of the present invention. The CPU91 executing S209 and S311 is an example of the second control unit of the present invention. The first display unit 25 and the second display unit 221 are examples of the display unit of the present invention. The needle bar LED210A, the thread breakage LED200A, the jumper pin LED200B, and the thread take-up LED200C are examples of the light emitting unit of the present invention. The CPU91 when executing S402 is an example of the second counter unit of the present invention. The CPU91 when executing S202 is an example of the third control unit of the present invention. The CPU91 executing S3, S5, and S7 is an example of the first setting unit of the present invention. The CPU91 executing S12, S14, and S16 is an example of the second setting unit of the present invention.

The present invention is not limited to the above-described embodiments. The panel unit 220 may be detachably provided on the table 9. Since the panel unit 220 can be provided at any position of the table 9 or other position easily visible to the operator, the operator can easily grasp the occurrence of defective sewing. The panel portion 220 may be provided to the sewing apparatus 100. The first display unit 25 and the second display unit 221 may not be provided.

In the initialization process, the value of N may not be initialized, but the CPU91 may initialize the value of N in accordance with the result of the operation on the input unit by operating the input unit when the operator wants to initialize the value of N.

The skip-stitch upper limit value may not be set in advance. When the operator wants to change the skip-stitch upper limit value, the operator may operate the input unit, and the CPU91 may set the skip-stitch upper limit value according to the operation result on the input unit. The jumper pin upper limit value may not be set. In this case, the CPU91 may stop the driving of the drive motor in response to the occurrence of a stitch skipping, and stop the sewing operation.

The processing in S208 to S210 and the processing in S310 to S312 may be omitted. In this case, the sewing machine 1 may not move the cloth to the place where the sewing failure occurs. The CPU91 may display the needle drop count in the period from the start of sewing to the stop of driving of the drive motor on the second display unit 221.

The disconnection detection level and the skip stitch detection level may not be set. In this case, a detection criterion for determining the occurrence of the sewing failure by the CPU91 may be set in advance. The detection level displayed on the fourth screen 221D may be only the line rewinding detection level.

Alternatively, the head amplifier 200 may inform each sewing failure by using only one LED. In this case, the LED of the head amplifier 200 is preferably a full-color LED so that the types of defective sewing can be distinguished. Alternatively, the needle bar LED210A may notify of a sewing failure other than a poor thread take-up. In this case, the needle bar LED210A is preferably a full-color LED so that the type of defective sewing can be distinguished. When the LED of the notification portion is a full-color LED, the light emission color may be changed depending on the type of the sewing failure, the number of times of the sewing failure.

Instead of using the CPU91, a microcomputer, an ASIC, or the like may be used as the processor. A plurality of processors may perform distributed processing for sewing processing or the like.

The processing and detection criteria for sewing may be downloaded from a server (not shown) connected to a network (that is, received as a transmission signal) and stored in a storage device. In this case, the processing such as sewing processing and the detection reference may be stored in a non-temporary storage medium such as a storage device included in the server.

The cloth feeding mechanism may be a mechanism that feeds the cloth in the horizontal direction by moving a holder that holds the cloth in the left-right direction and the front-back direction.