Abstract: A stitching apparatus with thread tension control is provided. Tension in a thread is monitored during stitching apparatus operations, and remedial action is taken in response to the detection of an anomaly in the thread tension profile. The remedial action can include altering a feed rate of the thread in order to adjust the thread tension, and/or repeating a previous operation. Anomaly detection can be performed with respect to stitching or sewing operations, and also with respect to trim operations performed in connection with moving between elements and/or thread color changes.

Abstract: A stitching apparatus with thread tension control is provided. Tension in a thread is monitored during stitching apparatus operations, and remedial action is taken in response to the detection of an anomaly in the thread tension profile. The remedial action can include altering a feed rate of the thread in order to adjust the thread tension, and/or repeating a previous operation. Anomaly detection can be performed with respect to stitching or sewing operations, and also with respect to trim operations performed in connection with moving between elements and/or thread color changes.

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.

Abstract: A stitching apparatus is disclosed which has at least one active thread feeder and is operable to adjust stitching operation based on the condition of a thread being stitched. The active thread feeder is operable to feed thread from a spool to a needle assembly, where the thread is stitched into fabric. The stitching apparatus includes at least one thread sensor. The thread sensor outputs information related to thread tension, which is received at a control which includes a first controller, and the first controller is used for controlling the thread. The control can calculate a thread feed length, and activate the active thread feeder to feed the appropriate amount of thread to the needle assembly. The control can use information from the thread sensor to adjust thread tension by adjusting the active thread feeder. The control can also detect a break in the thread, or a break in an underthread which is located in a lower arm assembly and is used to lock stitches.

Abstract: A stitching apparatus is disclosed which has at least one active thread feeder and is operable to adjust stitching operation based on the condition of a thread being stitched. The active thread feeder is operable to feed thread from a spool to a needle assembly, where the thread is stitched into fabric. The stitching apparatus includes at least one thread sensor. The thread sensor outputs information related to thread tension, which is received at a control which includes a first controller, and the first controller is used for controlling the thread. The control can calculate a thread feed length, and activate the active thread feeder to feed the appropriate amount of thread to the needle assembly. The control can use information from the thread sensor to adjust thread tension by adjusting the active thread feeder. The control can also detect a break in the thread, or a break in an underthread which is located in a lower arm assembly and is used to lock stitches.

Abstract: A presser foot assembly is disclosed which is operable to adjust the pressure applied to a fabric by a presser foot in a stitching machine. The presser foot assembly includes an adjustment element, a linkage and a presser foot. A connecting end of the presser foot is connected to the linkage. The adjustment element is operable to be adjusted while the stitching machine is operating, and adjusts the linkage such that the travel distance of a foot end of the presser foot changes. The adjustment element can include an adjustment eccentric, which adjusts the location of a cam. The linkage can include a cam follower, the height of a second end of which is changed when the cam is adjusted. The connecting end of the presser foot engages with the second end of the cam follower, and thus the height of the foot end is adjusted, allowing for more or less pressure to be applied to the fabric.

Abstract: A method and apparatus are disclosed for indicating stitching position in a stitching machine. The apparatus includes a laser assembly which emits laser light. The laser assembly is mounted to an upper arm assembly of the stitching machine, and is operable to indicate a location of at least a portion of a pattern to be stitched using the stitching machine. The laser assembly is mounted such that the laser light is unobstructed prior to hitting fabric which is to be stitched. The stitching machine may include a user interface which can be used to activate the laser assembly. The stitching machine may also trace an outline of a pattern to be stitched while the laser assembly is activated in order to verify that the pattern does not overlap a hoop which holds the fabric.

Abstract: A method and apparatus are disclosed which provide a plurality of stitching machines which may be synchronized without mechanical coupling of the stitching machines. Each of the plurality of stitching machines are connected to a control, which coordinates operations of the stitching machines, including the download of patterns to be stitched by the stitching machines. A master stitching machine is selected by either the control, or the stitching machines. Each of the stitching machines, during stitching operations transmits a heartbeat signal to the master stitching machine. The heartbeat signal can include information related to stitching operations, which the master can use to determine that each stitching machine is operating properly. Several clusters of stitching machines may also be present, with each cluster having a master stitching machine.

Abstract: Automatic testing and diagnosing a computerized stitching machine of a stitching system is provided. The system includes one or more programs that test operation of stitching machine components and generate specific error or status messages related to such components. Control panel software can be invoked to allow viewing of detailed status information for various components and the operation of specific components individually. Networking software can be enabled to allow this information to be viewed using a screen display and controlled from a location remote from the site of the stitching machine.

Abstract: A tensioning assembly for applying tension to portions of a cap is provided. The tensioning assembly increases the tension applied to cylindrical sections of the cap that are located between the cap visor and the back of the cap. The tensioning assembly includes a tensioning disk that is moveable inwardly and outwardly, as well as being rotatable, when an embroidery pattern is being stitched on the cap. The tensioning assembly is connected to a drive apparatus and its position relative thereto can be adjusted, depending upon the size of the cap. A cable adjustment assembly is also preferably included for maintaining desired tension of a cable that is coupled to a drive beam used in providing linear motion that is translated to rotational movement of the cap being embroidered. A holder assembly is connected to the drive apparatus for maintaining desired positioning of the drive beam particularly when the drive apparatus is detached from the computerized embroidery machine.

Abstract: A sewing machine is provided for splicing together two different threads. The machine includes a thread tree with a number of thread spools with each thread thereof being inserted through flexible plastic tubing. A movable carriage assembly locates the new thread to be spliced relative to a splicing device passageway that receives the new thread to be spliced along with the old thread. The splicing device includes a front air inlet for drawing the new thread into the passageway of the splicing device and a rear air inlet for creating air turbulence during the splicing operation. Also used in moving the new thread through the passageway is an insertion drive roller connected to a pivotal rocker. A thread clamp cover connected to the rocker cooperates with the trimmer blades to trim the old thread. A thread clamp and a thread clamp magnet cooperate to hold the old thread in a desired position during the insertion of the new thread into the splicing device.

Abstract: A chenille type embroidery machine (10) has an apparatus for rotational steering and height adjustment of a needle (22). An actuator (24) locks or unlocks a locking clip (92) to allow the needle (22) to rotate with a needle height adjuster assembly (46) or to be moved vertically up or down. The needle assembly (46) comprises the needle (22), a needle bar 23, a bar clamp (70), a height adjuster locking block (84), an internal needle height adjuster (88), the locking clip (92) and springs (108a-d). When the actuator (24) is in its "unactuated" condition, the height adjuster locking block (84) is locked to the internal needle height adjuster (88) by the locking clip (92) for rotation therewith. In the unactuated condition, the needle (22) is rotationally steered with the assembly (46). In the "actuated" condition, the actuator (24) extends a shaft (126) to move the locking clip ( 92) and disengage the locking block (84) from the internal adjuster (88).

Abstract: A laser engraving apparatus is provided. The apparatus includes a laser device for outputting a laser beam. A workpiece to be engraved is positioned on a support member. To direct the laser beam to a predetermined position relative to the workpiece, the apparatus includes a beam delivery system. The beam delivery system includes a number of mirrors and a carriage assembly. The carriage assembly includes an X-carriage and a Y-carriage. These two carriages are moved to cause movement of two of the mirrors whereby the laser beam can be controllably and simultaneously positioned in both X and Y directions to engrave the workpiece. The components and location of the X and Y carriages relative to the workpiece and laser device, as well as to each other, result in a portable unit. The laser engraving apparatus is also modular in that it is able to communicate with a separate, independent controller for use in operating the apparatus to engrave any one of a number of selected, creative patterns.

Abstract: The present invention provides a laser engraver for engraving a pattern on a workpiece. The pattern is established on the workpiece by using a X-Y assembly to move a laser beam in two dimensions relative to the workpiece. The X-Y assembly employs a X proportional-integral-differential (PID) controller and a Y PID to generate control signals for moving the X-Y assembly. The PIDs generate the control signal based upon the current positon of the laser beam and a target position for the laser beam. The current position is provided by encoders operatively attached to motors that, in turn, move mirrors that direct the laser beam to the workpiece. The depth of cut is, preferably, controlled by using the integral of the difference between the position of the laser beam as it is moved by the X-Y assembly and a reference position. Alternatively, proportional control based upon the absolute difference between the position of the laser as it is moved by the X-Y assembly and the reference position can be utilized.

Abstract: A modular system for use with X-Y peripherals is provided. The system includes a master controller operatively connected to one or more slave X-Y peripherals in a network. Different types of slave X-Y peripherals are accommodated by the system, e.g. sewing machines and engravers. Each slave X-Y peripheral has a unique address for independent communication with the master controller. The master controller tracks the functional relationship existing between it and each slave X-Y peripheral using state architecture. Servo control of a tool or head in an X-Y peripheral is also disclosed. The tool is movable in a Z dimension relative to a workpiece residing in an X-Y plane. Method and apparatus are also provided for positioning a carriage of an X-Y peripheral at a home or reference position in one or more dimensions.

Abstract: A method and apparatus are provided for operator-controlled stitching of letters on materials wherein the letters have common stitch parameters. The operator selects desired stitch parameters, such as letter height, letter width, and stitch density, and stores the parameters in memory. In using the stored stitch parameters, the operator recalls them using a keyboard and also selects letters which are to be stitched using the stored and recalled stitch parameters. The apparatus is able to apply or use the recalled stitch parameters in connection with the selected letters to stitch the letters. In addition, the operator is able to define a number of different stitch patterns having selected and stored letters which can later be recalled for stitching thereof.

Abstract: An improvement in a digitizer for use in computer drafting has been provided wherein a multiple wire connector located in both the X beam and Y beam is held in a taut and concealed condition within the respective beams for any position of the digitizer. An adjustable attachment is provided between the extrusions for the X and Y beam and the respective X and Y guide bars so that the guide bar can be aligned in a straight condition regardless of any warping of the beams during extrusion. A mechanical brake is also provided for fixing the position of the digitizer during use.