Advancements in Single Needle Lockstitch Sewing …Brother).pdf · Single Needle Lockstitch Sewing Machines Key Design ... It provides the end user with the ability to more easily

© 2011 Brother Industries, Ltd. All Rights Reserved. 1

CONFIDENTIAL

SPESA Conference, Sept. 17, 2015

Advancements in Manufacturing Technology

Advancements in Single Needle Lockstitch Sewing Machines

and Electronic Programmable Sewing Machine

Technology

Rick Frye Director of Sales & Engineering, IPD Div.

Brother International Corp.

© 2011 Brother Industries, Ltd. All Rights Reserved. 2 CONFIDENTIAL

Single Needle Lockstitch Sewing Machines

Key Design Elements Still in Use Today

- Open arm bed design - Rotary hand wheel- Vertical motion driven needle- Thread take-up assembly- Check Spring device- Upper adjustable thread tension- Presser foot mechanism- Stitch length regulator- Lower material feed mechanism- Rotary shuttle hook mechanism



Brief History of “Key” Technology Advancements

1960

1970

1980

1990

2000

2010

2015

Needle PositioningAuto Thread Trimming

Motor Control& Functions

Direct Drive Tech.& Lubrication ?



What if we had an Electronic Feeding System ?

S-7300ASingle Needle Direct Drive Lock Stitch with “Electronic Feeding System”



World’s First!With PM feed, feed mechanism has been computerized.

Pulse motor provides accurate Movement and positioning, for many advantages

World’s First!Single Needle Lockstitch Sewing Machine with “Pulse Motor” feed mechanism.



What are the Key Benefits of Electronic Feeding System Technology ?

Feed Motion Profile: The feed motion movement profile can be changed to accommodate the feeding of a variety of material types and conditions.

Multiple Stitch Lengths:Multiple stitch lengths can be programmed within a single seam to address seam quality or simply for decorative stitching.

Reduction in Needle Breakage:Control of the position of the feed mechanism reduces any opportunity for needle breakage during directional change when back tacking.



The feed dog motion “profile’ can be easily selected electronically to accommodate a variety of material types and conditions.



Multiple stitch lengths can be programmed within a single seam to address seam quality or simply for decorative stitching



Control of the position of the feed mechanism reduces any opportunity for needle breakage during directional change (reverse) at high speeds.

Needle

Presser foot

During the Sewing Reverse switching SW ON

Needle breakage occursThe signal

instantaneously sent out with the needle above the presser foot or even below the presser foot.

Switch ON



Precise position of the feed mechanism at thread trimming combined with the Dual moving knife thread trimming system design allows for better thread tail length control.



SummaryThere are a number of advantages to having a single needle lockstitch sewing machine with direct coupled “pulse motor control” of the feed mechanism. This technology provides a more flexible and versatile machine for use in todays sewn products industry.

It provides the end user with the ability to more easily adapt the use of the machine to a variety of fabrics, sewing conditions, and product construction.


Switching Gears


Elec. Programmable Sewing Machine Technology

Advancements in Electronic Programmable Sewing Machine Technology.



What products & industries are programmable machines most commonly used for ?

-Shoes, Footwear, leather handbags, luggage, fashion leather goods

-Automotive airbags, automotive seat belts, aircraft seat belts

-Safety harness, fall protection, cargo nets, cargo straps / slings

-Military apparel, vests, chin straps, ammo packs, mollies,

-Ball caps, athletic apparel, jeans,

-Used in the manufacturing of a wide array of industries, products, and applications

Commonly Sewn Products



Electronic Programmable Sewing Machines have become more advanced in the last 10 years due to advancements in motion control technology and control processing speeds.

Their use has become more popular as they become more versatile and affordable due to their ability to be programmed and tooled for sewing a variety of products and stitch patterns.

Many aftermarket systems and devices are designed around the use of the electronic programmable sewing.



Closed Loop Servo control

With “Closed Loop” servo control, high-precision pattern sewing is possible and feed drifting does not occur in high speed or heavy material sewing.

･Minimum Resolution 0.05mmMovement is resolved at 0.05mm per pulse making slanted stitch lines and curves more accurately sewn.

ControlBoxMotor

Encoder Command (output signal to drive motor)

Feed Back (to check how much motor has driven)

Servo Control

Feed drifting(Position slippage)

☓



Virtually all sewing patterns for electronic programmable sewing machines are created using some form of a teach pendant device or off line using a PC equipped with pattern programming software.



What if,………. an electronic programmable sewing machine could some how “create its own sewing

program” based on the object being sewn ?



It is Possible !



A system has been developed which is integrated with a programmable Sewing machine that employs an industrial PC with software, custom camera, and lighting, to “automatically” create a stitch pattern around the perimeter of a regular or irregular shaped object (patch, label, applique, etc.) within the sewing area of the machine.

PC Display with product image

Vision Camera and Lighting

Applique / Patch / Label



With this system, the camera takes a photo of the object and processes the image using preset stitch specifications to create a stitch pattern based upon the perimeter of the object.

Selectable Preset Stitch Parameters include:-Stitch Type: straight or zig zag

-Stitch Length: (for zig zag you select pitch width and length)

-Line Offset: ( + / - )

-Over sew stitches

-Starting Quadrant



A new program is created for each item placed in the sewing area no matter its position or orientation.

The time to process and create a new program is less than (3) seconds !



Video demo of process



Sewn Example



Here is another example of sewing a pattern requiring the “outside” and “inside” border to be sewn.



Sewn Example



Here is example of sewing a consecutive pattern with no changes to settings.



Sewn Example



When creating the Pattern, the article to be sewn must lay flat

PATCH

BACKGROUND FABRICANGLE OF CAMERA VIEW



VGSM Requirements

PERIMTER/BORDER: Outer perimeter (border) of patch color must be consistent around the entire perimeter. This also includes any inner openings.

COLOR CONTRAST: Background fabric color and border color must have a recognizable contrast difference in color in order to be used

SURFACE: Background fabric cannot be shiny or have reflective or a “sheen” surface. (some limitation may also apply to the patch / applique

FLATNESS: Patch / applique must lay flat. Any variance to the height at the perimeter can distort the image making the sewing pattern irregular

LIGHTING: Changes in ambient lighting can affect the settings and how the system operates. Ambient lighting should remain consistent for best results.



Thank you

Documents

Advancements in Single Needle Lockstitch Sewing …Brother).pdf · Single Needle Lockstitch Sewing Machines Key Design ... It provides the end user with the ability to more easily