Microdynamics, Inc.

Stephen S Treadwell

Charles R Martell

Elmer N Leslie

Donald D Isett

Don D Isett

An adaptive semi-automatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40a) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edge by the sensors (40a). The system includes controls (98) coupled to microprocessor controller (51) for dynamically adjusting the sensitivity of the sensors (40a) for variances in the materials being sewn.

Method and apparatus for automatically adjusting the sensitivity of edge

An adaptive semi-automatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edge of the sensors (40). The speed of the sewing machine at the time the material edge is detected is monitored and compared to a reference speed. The number of final stitches is then dynamically adjusted to compensate for the speed variance from the reference speed.

Method and apparatus for varying the length or stitches sewn by a sewing

An adaptive semi-automatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed direct drive motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edge by the sensors (40). The amount of stitch completion at the time of detection of the material edge is monitored and a stitch length variance mechanism (17) is actuated at a selected angle of motor rotation taking into account the time delay of the stitch length variance mechanism and the feed characteristics of sewing machine (12) to precisely control the length of the last stitch sewn to improve the accuracy of the seam end point.

Method and apparatus for accurately controlling the seam margins

A semi-automatic split needle bar sewing machine (10) includes a sewing machine (12) which is driven by a motor (26) that drives a left needle (22) and a right needle (23). A presser foot (24) is operated by presser lift actuator (30). The needles (22) and (23) can activate in unison or independently by use of fall out actuators (41) and (43), respectively. A control chassis (50) includes a microprocessor controller (51) that is programmable through an input panel (44). An edge detector (40) detects the edge of the material to provide feedback for the microprocessor controller (51). The microprocessor controller (51) is operable to sew a decorative pattern with mitered corners by sensing the pivot point of the mitered corner and automatically disengaging one of the needles (22) or (23). The microprocessor controller (51) then continues single needle sewing around the apex of the mitered corner by counting a predetermined number of stitches and varying the length of the stitches such that the needle is in the correct position when the single needle sewing again arrives at the pivot point on the other side of the mitered corner. In this manner, it is not necessary for the operator to manually adjust the length of the stitches around the apex of the mitered corner.

Method and apparatus for sewing mitered corners on a split needle bar

The present invention includes a sewing machine (12) with a variable top feed mechanism (25) that feeds the top layer of material for a sleeve at a variable rate to change the fullness thereof. The machine (12) is driven by a motor (42) which is controlled by a controller (51). A program is taught to the controller (51) for storage therein. The controller (51) then controls both the motor (42) and a controller (45) for the top feed mechanism to regulate the number of stitches and the relative rates of speed for the top and bottom materials fed by the machine. The program initially is taught to the machine and can be utilized for any type of material or size by inputting the correct sizes and types of material on a control panel (44). The machine (12) therefore semi-automatically sews sleeves onto armholes with the correct fullness sewn therein.

Automatic sewing machine and method for jacket sleeve attachment

An adaptive semiautomatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. The system (10) has manual, teach and auto modes of operation. In the teach mode, control parameters for each seam are stored as the operator sews the initial piece. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edges by the sensors (40). In dependence upon the amount of the stitch which has been sewn upon edge detection, the reverse lever (17) is moved against stop member (13) in order to reduce the length of the last stitch sewn in order to improve the accuracy of the seam end point.

Control system for providing stitch length control of a sewing machine

An adaptive semiautomatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. The system (10) has manual, teach and auto modes of operation. In the teach mode, control parameters for each seam are stored as the operator sews the initial piece. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edges by the sensors (40). In one embodiment, a window is set up around the stitch count at which terminal countdown initiates to avoid spurious signals. In another embodiment, momentary toggles of the sensors (40) are ignored so that an even wider range of sizes can be sewn with the same taught program.

Control system for sewing machine

A semiautomatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn, material edge sensors (40) mounted in spaced relationship in front of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable preprogrammed number of final stitches responsive to material edges detected by the sensors (40) only when the stitch count falls within a predetermined window of values so that inaccuracies from stitch counting are limited to a small portion of the overall seam length. If the sensors (40) do not detect a material edge within the window of stitch values, the sewing system (10) reverts to pure stitch counting to determine seam length.

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Richardson, TX, United States of America

Stephen S Treadwell