Computerized stitching including embroidering

• US 6,983,192 B2
• Filed: 05/03/2004
• Issued: 01/03/2006
• Est. Priority Date: 01/31/2002
• Status: Active Grant

• Current Assignee: Melbo International B.V.
• Original Assignee: Melco Industries Incorporated (Oerlikon USA, Inc. (Florida))
• Inventors: Kern, Peter, Ton, Robert Bruce, Grayson, Donald, Block, Jeffrey T.
• Primary Examiner(s): Nerbun, Peter
• Assistant Examiner(s): KAUFFMAN, BRIAN K
• Application Number:
  US10/838,664
• Publication Number:
  US 20040210336A1
• Time in Patent Office: 610 Days
• Field of Search: 700/130, 700/136, 700/138, 112/470.01, 112/155, 112/102.5
• US Class Current: 700/138
• CPC Class Codes: B65H 2553/26 Piezoelectric sensors
• CPC Class Codes: B65H 2701/31 Textiles threads or artificial strands of filaments
• CPC Class Codes: B65H 59/40 Applications of tension indicators
• CPC Class Codes: D05B 19/12 characterised by control of operation of machine
• CPC Class Codes: D05B 29/02 Presser-control devices
• CPC Class Codes: D05B 45/00 Applications of measuring devices for determining the length of threads used in sewing machines measuring devices in embroidery machines D05C, in general G01B
• CPC Class Codes: D05B 47/04 Automatically-controlled tensioning devices
• CPC Class Codes: D05B 47/06 Applications of tensometers application of tension indicators in handling thin or filamentary material B65H59/40; for embroidery machines D05C11/08; tensometers in general G01L
• CPC Class Codes: D05B 51/00 Applications of needle-thread guards; Thread-break detectors for embroidery machines D05C11/00
• CPC Class Codes: D05C 11/08 Thread-tensioning arrangements inside the shuttle D05C11/18

Abstract

A plurality of stitching machines and a control system used in stitching patterns into a plurality of items is capable of flexible control. The plurality of stitching machines may include one or more clusters of stitching machines, with each cluster able to stitch patterns into items independently of other clusters. Stitching machines within the plurality of stitching machines, or within the clusters of stitching machines, may be set to stitch patterns into items using one of a synchronized mode and an unsynchronized mode. When in the synchronized mode, the stitching machines perform stitching substantially synchronously with other stitching machines, and when in the unsynchronized mode the stitching machines perform stitching independently of the status of other stitching machines.

Claims

1. A method for stitching using a plurality of stitching machines, comprising:

establishing a network that includes a plurality of stitching machines including at least first and second stitching machines that can communicate with a control system that includes at least a first controller, said control system for use in providing a selected one of a synchronized mode and an unsynchronized mode;

selecting a first pattern to stitch using said plurality of stitching machines;

selecting a one of said synchronized mode and said unsynchronized mode; and

stitching at least the first pattern by said plurality of stitching machines, wherein when said synchronized mode is selected each of the stitching machines stitches the first pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines stitches the first pattern independently of other of said plurality of stitching machines.

2. The method for stitching using a plurality of stitching machines, as claimed in claim 1, wherein said establishing a network step comprises:

configuring said network, by said control system, to include at least a first cluster of stitching machines within said plurality of stitching machines, said first cluster including at least said first stitching machine; and

setting said first cluster to operate in one of said synchronized mode and unsynchronized mode, and

wherein said stitching step includes stitching at least the first pattern by said first cluster.

3. The method for stitching using a plurality of stitching machines, as claimed in claim 1, further comprising:

detecting an error in said first stitching machine when said unsynchronized mode is selected;

stopping stitching by said first stitching machine; and

continuing stitching said first pattern by other of said plurality of stitching machines.

4. The method for stitching using a plurality of stitching machines, as claimed in claim 1, further comprising:

placing said first stitching machine into an idle mode;

selecting a second pattern to stitch using said plurality of stitching machines; and

stitching at least said second pattern by other of said plurality of stitching machines while said first stitching machine remains idle.

5. A method for stitching using a plurality of stitching machines, comprising:

establishing a network that includes a plurality of stitching machines including at least first and second stitching machines that can communicate with a control system that includes at least a first controller, said control system for use in providing a selected one of a synchronized mode and an unsynchronized mode;

selecting a first pattern to stitch using said plurality of stitching machines;

stitching at least the first pattern by said plurality of stitching machines, wherein when said synchronized mode is selected each of the stitching machines stitches the first pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines stitches the first pattern independently of other of said plurality of stitching machines;

wherein said establishing a network step comprises;

configuring said network, by said control system, to include at least a first cluster of stitching machines within said plurality of stitching machines, said first cluster including at least said first stitching machine;

setting said first cluster to operate in one of said synchronized mode and unsynchronized mode; and

wherein said stitching step includes stitching at least the first pattern by said first cluster;

wherein said configuring step further includes configuring said network to include a second cluster of stitching machines, each of said first and second clusters having at least one stitching machine, and

wherein said setting step includes setting said first cluster to operate in one of said synchronized mode and unsynchronized mode and setting said second cluster to operate in one of said synchronized mode and unsynchronized mode.

6. The method for stitching using a plurality of stitching machines, as claimed in claim 5, wherein said selecting step includes:

selecting said first pattern to stitch using said first cluster and selecting a second pattern to stitch using said second cluster.

7. The method for stitching using a plurality of stitching machines, as claimed in claim 6, comprising:

re-configuring said network, by said control system, to include at least a third cluster of stitching machines within said plurality of stitching machines, said third cluster including at least said first stitching machine;

setting said third cluster to operate in one of said synchronized mode and unsynchronized mode;

selecting a third pattern to stitch using said third cluster; and

stitching at least the third pattern by said third cluster, wherein when said synchronized mode is selected each of the stitching machines in said third cluster stitches the third pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines in said third cluster stitches the third pattern independently of other of said plurality of stitching machines in said third cluster.

8. A method for stitching using a plurality of stitching machines, comprising:

establishing a network that includes a plurality of stitching machines including at least first and second stitching machines that can communicate with a control system that includes at least a first controller, said control system for use in providing a selected one of a synchronized mode and an unsynchronized mode;

selecting a first pattern to stitch using said plurality of stitching machines;

stitching at least the first pattern by said plurality of stitching machines, wherein when said synchronized mode is selected each of the stitching machines stitches the first pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines stitches the first pattern independently of other of said plurality of stiching machines;

detecting an error in said first stitching machine when said synchronized mode is selected;

stopping stitching by said plurality of stitching machines;

backing said first stitching machine at least to a point in said stitching pattern where said error occurred;

stitching using said first stitching machine to a stitch count of other of said plurality of stitching machines after correction of said error; and

continuing stitching said first pattern by said plurality of stitching machines.

9. A method for stitching using a plurality of stitching machines, comprising;

establishing a network that includes a plurality of stitching machines including at least first and second stitching machines that can communicate with a control system that includes at least a first controller, said control system for use in providing a selected one of a synchronized mode and an unsynchronized mode;

selecting a first pattern to stitch using said plurality of stitching machines;

stitching at least the first pattern by said plurality of stitching machines, wherein when said synchronized mode is selected each of the stitching machines stitches the first pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines stitches the first pattern independently of other of said plurality of stitching machines;

choosing the first pattern from a plurality of available patterns;

selecting a hoop size for use in stitching the first pattern, wherein when said synchronized mode is selected each of said stitching machines is set to have the same hoop size, and when said unsynchronized mode is selected each of said stitching machines can be set to different hoop sizes; and

adjusting at least a first stitching setting, wherein when said synchronized mode is selected each of said stitching machines is set to have the same first stitching setting, and when said unsynchronized mode is selected each of said stitching machines can be set to different first stitching settings.

10. The method for stitching using a plurality of stitching machines, as claimed in claim 9, wherein said first stitching setting includes one of stitching speed, color sequence, and material thickness.

11. A method for stitching using a plurality of stitching machines, comprising:

establishing a network that includes a plurality of stitching machines including at least first and second stitching machines that can communicate with a control system that includes at least a first controller, said control system for use in providing a selected one of a synchronized mode and an unsynchronized mode;

selecting a first pattern to stitch using said plurality of stitching machines;

stitching at least the first pattern by said plurality of stitching machines, wherein when said synchronized mode is selected each of the stitching machines stitches the first pattern substantially synchronously and when said unsynchronized mode is selected each of the stitching machines stitches the first pattern independently of other of said plurality of stitching machines; and

wherein said stitching at least the first pattern step includes;

detecting a command at said first stitching machine when said unsynchronized mode is selected;

determining if said command is a flex-mode sync command; and

performing said command on said first stitching machine when said command is not a flex-mode sync command, and synchronously performing said command on all of said plurality of stitching machines when said command is a flex-mode sync command.

12. A stitching apparatus, comprising:

a plurality of stitching machines including at least a first stitching machine and a second stitching machine; and

a control communicating with said plurality of stitching machines, said control including at least a first controller, and in which said control configures said plurality of stitching machines to operate in a selected one of a synchronized mode and an unsynchronized mode in response to receiving a selection from a user of one of said synchronized mode and said unsynchronized mode;

wherein said plurality of stitching machines and said control define a network in which at least a first pattern is stitched substantially synchronously by each of said plurality of stitching machines when said control provides said plurality of stitching machines in said synchronized mode, and in which at least a first pattern is stitched by said first stitching machine independently of other of said plurality of stitching machines when said control provides said plurality of stitching machines in said unsynchronized mode.

13. The stitching apparatus, as claimed in claim 12, wherein said control is operable to configure said plurality of stitching machines to operate as at least a first cluster and a second cluster, said first cluster containing at least one stitching machine and said second cluster containing at least one stitching machine, and

wherein said control configures each of said first cluster and second cluster to operate in a selected one of said synchronized mode and unsynchronized mode when said cluster contains more than one stitching machine.

14. The stitching apparatus, as claimed in claim 13, wherein the at least one stitching machine of said first cluster is operable to stitch at least a second pattern and the at least one stitching machine of said second cluster is operable to stitch at least a third pattern.

15. The stitching apparatus, as claimed in claim 12, wherein said control is further operable to determine a maximum number of clusters enabled for said stitching apparatus.

16. The stitching apparatus, as claimed in claim 12, wherein a second stitching machine is in an idle mode, and wherein at least said first pattern is stitched by other of said plurality of stitching machines while said second stitching machine remains idle.

17. A stitching apparatus, comprising:

a plurality of stitching machines including at least a first stitching machine and a second stitching machine; and

a control communicating with said plurality of stitching machines, said control including at least a first controller, and in which said control configures said plurality of stitching machines to operate in a selected one of a synchronized mode and an unsynchronized mode;

wherein said plurality of stitching machines and said control define a network in which at least a first pattern is stitched substantially sychronously by each of said plurality of stitching machines when said control provides said plurality of stitching machines in said sychronized mode, and in which at least a first pattern is stitched by said first stitching machine independently of other of said plurality of stitching machines when said control provides said plurality of stitching machines in said unsynchronized mode;

wherein said control is further operable to determine a maximum number of clusters enabled for said stitching apparatus; and

wherein said control includes at least one dongle used in the determination of said maximum number of clusters enabled for said stitching apparatus.

18. The stitching apparatus, as claimed in claim 17, wherein said maximum number of clusters enabled for said stitching apparatus is equal to the number of dongles in said control.

19. A stitching apparatus, comprising:

a plurality of stitching machines including at least a first stitching machine and a second stitching machine; and

a control communicating with said plurality of stitching machines, said control including at least a first controller, and in which said control configures said plurality of stitching machines to operate in a selected one of a synchronized mode and an unsynchronized mode;

wherein said plurality of stitching machines and said control define a network in which at least a first pattern is stitched substantially synchronously by each of said plurality of stitching machines when said control provides said plurality of stitching machines in said synchronized mode, and in which at least a first pattern is stitched by said first stitching machine independently of other of said plurality of stitching machines when said control provides said plurality of stitching machines in said unsynchronized mode; and

wherein said control is further operable to;

determine the first pattern to be stitched by said plurality of stitching machines;

determine a hoop size for use in stitching the first pattern, wherein when said synchronized mode is selected each of said stitching machines is set to have the same hoop size, and when said unsynchronized mode is selected each of said stitching machines may be set to have different hoop sizes; and

determine at least a first stitching setting for stitching the first pattern, wherein when said synchronized mode is selected each of said stitching machines is set to have the same first stitching setting, and when said unsynchronized mode is selected each of said stitching machines may be set to have different first stitching settings.

20. The stitching apparatus, as claimed in claim 19, wherein said first stitching setting includes one of stitching speed, color sequence, and material thickness.