SEQUIN FEEDER APPARATUS AND SEWING MACHINE CAPABLE OF SEWING SEQUINS
Sequin feeder apparatus includes at least two sequin feed units each including a sequin feed mechanism for feeding a continuous sequin strip toward a predetermined cutting position and a sequin-cutting cutter section located in the predetermined cutting position. One of the sequin feed units is selected and positioned in a predetermined sewing operation position, and driving force of a feeding drive mechanism is transmitted to the sequin feed mechanism to feed out a sequin. Respective cutting positions of the cutter sections of the feed units are adjustable independently of each other.
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The present invention relates generally to sequin feeder apparatus for use in sewing machines which sew a sequin onto a sewing workpiece while severing the sequin from a ribbon or strip of continuously-connected sequins. More particularly, the present invention relates to a sequin feeder apparatus which is capable of changing the sequin to be sewn from one type to another in the middle of sewing, as well as a sewing machine suited to sew sequins of different pitches in combination.
Example of the conventional sequin feeder apparatus is known from German Utility Model Registration No. G9209764.2, U.S. Pat. No. 5,755,168 or German Patent No. DE19538084 (corresponding to U.S. Pat. No. 5,755,168 above). Such a known sequin feeder apparatus includes a feed mechanism, which causes a strip of a multiplicity of continuously-connected sequins (or spangles) (hereinafter referred to as “continuous sequin strip”) to be let out or paid out from a reel, having the continuous sequin strip wound thereon, onto a support plate and then, through predetermined forward and rearward (i.e., advancing and retracting) movement of a feed lever, feeds the continuous sequin strip at a predetermined pitch corresponding to the size of each sequin of the strip. One sequin is sewn at a time onto a sewing workpiece while being severed or cut off from the continuous sequin strip having been fed in interlocked relation to a sewing operation by a needle bar of the sewing machine.
Further, Japanese Patent Application Laid-open Publication No. 2004-167097 discloses an embroidery sewing machine including a sequin feeder apparatus attached to a sewing head so that sequins can be sewn onto a sewing workpiece, such as an embroidering fabric.
Furthermore, Korean Patent Application Laid-open Publication No. 10-2006-68405 and Korean Patent Publication No. 10-614630 (corresponding to the No. 10-2006-68405 laid-open publication) disclose an apparatus capable of changing or switching the sequin to be sewn to from one type to another in the middle of sewing. The disclosed apparatus includes two sequin reels each having wound thereon a different strip of continuously-connected sequins of a predetermined shape and color, and feeding rods for individually feeding out the respective continuous sequin strips, paid out from the reels, to a needle entry point. By selecting the feeding-out operation by any one of the feeding rods on the basis of a control signal, the disclosed apparatus can successively perform sequin sewing while switching between the continuous sequin strips to be fed toward the needle entry point. However, the disclosed apparatus is provided with only one, common cutter section for cutting a sequin off from any one of the sequin strips; namely, a sequin of one of the continuous sequin strips, which has been fed out by the corresponding feeding rod, is cut off by the common cutter section. Therefore, although sequins can be made different in size between two continuous sequin strips to be set on the reels, the sequin sizes can no longer be changed freely once continuous sequin strips having sequins of predetermined sizes are set. Because, the common cutter section, shared between the two continuous sequin strips, comprises a movable cutter blade having a predetermined stepped structure and a fixed cutter blade (or die) having a similar predetermined stepped structure, and the stepped structures of these movable and fixed cutter blades have to be mechanically fixed. Namely, if the apparatus is constructed so that continuous sequin strips of different sequin sizes are set on the two reels, the mechanically-fixed structures of the common cutter section can not deal with the different sequin sizes.
SUMMARY OF THE INVENTIONIn view of the foregoing, it is an object of the present invention to provide an improved sequin feeder apparatus which includes a plurality of sequin feed units such that the sequin to be sewn can be changed from one type to another in the middle of sewing and which allows a sequin feed amount of each of the sequin feed units to be changed as desired. It is another object of the present invention to provide an improved sewing machine which is suited to sew sequins of desired different feed pitches in combination using such an improved sequin feeder apparatus.
According to one aspect of the present invention, there is provided a sequin feeder apparatus, which comprises: at least two sequin feed units each including a sequin feed mechanism for feeding a continuous sequin strip toward a predetermined cutting position and a sequin-cutting cutter section located in the predetermined cutting position; a sequin selection mechanism for selecting one of the at least two sequin feed units and positioning the selected one sequin feed unit in a predetermined sewing operation position; and a drive mechanism for engaging with the sequin feed mechanism of the one sequin feed unit, positioned in the predetermined sewing operation position, and thereby driving, in response to a sewing operation, the engaged sequin feed mechanism to feed the continuous sequin strip toward the predetermined cutting position. Here, the predetermined cutting position in each of the sequin feed units is adjustable independently of the predetermined cutting position in the other sequin feed unit, and the cutter section is driven, in response to the sewing operation, to cut a sequin off from the continuous sequin strip having been fed to the predetermined cutting position.
According to another aspect of the present invention, there is provided a sewing machine where the aforementioned sequin feeder apparatus of the present invention is provided in association with a sewing head.
Each of the sequin feed units includes its own sequin feed mechanism and sequin-cutting cutter section, and the predetermined cutting position in each of the sequin feed units is adjustable independently of the predetermined cutting position in the other sequin feed unit. Thus, in each of the sequin feed units, the cutting position, where the cutter section cuts a sequin off from the sequin strip, can be adjusted as desired independently of the cutting position in the other sequin feed unit; thus, the sequin feed units can respectively handle sequins of desired feed sizes. Because the present invention thus arranged allows a sequin feed amount of the continuous sequin strip in each of the feed units to be changed as desired independently of the sequin feed amount in the other feed unit, the sewing machine, to which is applied the sequin feeder apparatus of the present invention, can perform sequin sewing while combining sequins of desired different feed pitches.
The following will describe embodiments of the present invention, but it should be appreciated that the present invention is not limited to the described embodiments and various modifications of the invention are possible without departing from the basic principles. The scope of the present invention is therefore to be determined solely by the appended claims.
First, a description will be given about a first embodiment of the sequin feeder apparatus 1.
Each of the sequin feeder apparatus 1 generally comprises: two sequin feed units 20 and 21; a sequin selection mechanism (composed of components 44-50, 60-67 and the like that will be later described with reference to
Further, each of the sequin feed units 20 and 21 includes the sequin feed mechanism 19 for feeding a continuous sequin strip 13 toward a predetermined cutting position, and a sequin-cutting cutter section (composed of components 36 and 23b that will be later described with reference to
These two reels 14 are coaxially mounted side by side, or juxtaposed, on a same mounting shaft provided on the fixed base 3. Further, pairs of first, second and third rollers 15, 16 and 17 for guiding portions of the continuous sequin strips 13 paid out from the reels 14 are supported on the fixed base 3, and fourth rollers 18 are supported on the mounting base 4; each of the pairs of the rollers 15, 16, 17 and 18 is also composed of two rollers coaxially mounted side by side. Further, two tension rollers 10 are provided between the first rollers 15 and the second rollers 16, and these tension rollers 10 are supported on tension bases 72 and 73 rotatably mounted on the shafts of the first and second rollers 15 and 16, respectively. Torsion springs (not shown) are mounted on the shafts of the first and second rollers 15 and 16, so that the tension base 72 is normally urged in a clockwise direction of
Portion of the continuous sequin strip 14 paid out from each of the reels 14 is directed to and supported on the first roller 15, tension roller 10, second roller 16, third roller 17 and fourth roller 18 in the mentioned order as shown in
Although the two sequin feed units 20 and 21 provided in opposed relation to each other are constructed of same mechanical components (i.e., mechanically constructed in the same manner), the feed units 20 and 21 are arranged and shaped in symmetrical relation to each other. Thus, details of the mechanical components of only one of the sequin feed units 20 will be described representatively with reference to
First, details of the sequin feed mechanism 19 will be described. Link arm 25 is fixed to the shaft 24 supported on the supporting plate 22, and a link pin having a slanted distal end surface is fixed to a free end portion of the link arm 25. Feed lever 29, having an engaging portion 29a at its distal end, is pivotably supported, via a shaft 30, on a free end portion of the pivot arm or lever 27. Torsion spring (not shown) for normally urging the feed lever 29 in the clockwise direction is fitted on the shaft 30, by which the distal end portion of the feed lever 29 is normally urged toward the support plate 23. With the feed lever 29 urged in the clockwise direction, the pivot lever 27 is normally urged in a direction where it abuts against a stopper 31. The stopper 31 is in the form of a threaded rod screwed to a bracket 32 secured to the supporting plate 22, and the stopper 31 is locked by screwing up of a nut. The pivot lever 27 abuts against the rear end of the stopper 31. The lock lever 33 is provided over the feed lever 29. The lock lever 33 has an engaging claw (or engaging projection) 33a at its one end and a stopper portion 33b at its other end. Intermediate portion of the lock lever 33 is pivotably supported, via a pin 35, on a support block 34 that is in turn fixed to the supporting plate 22. The engaging claw 33a of the lock lever 33 is inserted through a through-hole 29b formed in the feed lever 29. Torsion spring (not shown) is provided on the pin 35 fixed to the support block 34, and the lock lever 33 is normally biased, by that torsion spring, in the counterclockwise direction. With the lock lever 33 normally biased in the counterclockwise direction like this, the lock lever 33 in its free state abuts against a stopper portion 34a of the support block 34, and thus, the lock lever 33 is held in a posture or position where the end of the engaging claw 33a projects into the slit 23a of the support plate 23. The engaging claw 33a of the lock lever 33 held in this posture engages the sewing hole Sa of one of the sequins S of the continuous sequin strip 13 led onto the support plate 23 to thereby immovably lock the continuous sequin strip 13 during sequin sewing (cutting).
The following lines describe details of the cutter section comprising the fixed cutter blade 23b and movable cutter blade 36. Such movable cutter blade 36 is pivotably supported via a pin 37 on a distal end portion of the support plate 23 and is normally held, via a torsion spring 38, in a retracted or evacuated posture or position where it is spaced upward from the fixed cutter blade 23b. The movable cutter blade 36 is depressed by a needle clamp 40, provided at the lower end of a needle bar 39, as the needle bar 39 descends. Such depression by the needle clamp 40 causes the movable cutter blade 36 to pivot downward against the resilient biasing force of the torsion spring 38, so that the movable cutter blade 36 cuts the continuous sequin strip 13 across a connecting portion Sb (see
Next, with reference to
The following lines describe the sequin selection mechanism (44-50, 60-67 and the like). As illustrated in
As clear from
On the other hand, when the left slide member 46 is in a slide position where it abuts against the left limiting member 66 via a shock-absorbing member 67, it means that the second sequin feed unit 21 has been selected and positioned in the sewing operation position, as shown in
Note that the sliding movement for selecting the sequin feed unit 20 or 21 in order to change the sequin to be sewn to from one type to another in the middle of a series of sequin pattern sewing operations is performed by the sequin selection mechanism (44-50, 60-67 and the like) while the needle bar 39 is in a raised or upper position. In this way, it is possible to eliminate a need for temporarily stopping the vertical movement of the needle bar 39 (i.e., effecting so-called “jumping” of the needle bar 39) in order to switch between the sequin types, so that the sewing efficiency can be enhanced.
The following lines describe the feeding drive mechanism (51-59 etc.). Referring to
The driven lever 53 has its free end portion connected to a free end portion of a driving lever 56 via a connecting link 55, and the driving lever 56 is fixed to the shaft of a motor 57 secured to the left side surface of the mounting base 4. Torsion spring 58 is provided on the pivot shaft 52, which normally urges the driven lever 53 and transmission lever 54 in the clockwise direction of
Next, sequin feeding operation by the sequin feed mechanism 19 will be described. First, in response to counterclockwise rotational driving (i.e., forward driving operation) of the motor 57, the driving lever 56 is caused to pivot through a predetermined angle in the counterclockwise direction so that a connection between the lower end of the connecting link 55 and the free end of the driven lever 53 is caused to pivot downward through a predetermined angle in the counterclockwise direction. Thus, the pivot shaft 52 is caused to pivot through a predetermined angle in the counterclockwise direction, so that the engagement portion 54a at the lower end of the transmission lever 54 is driven rearwardly (rightward or counterclockwise in
One stroke length of the feed lever 29 in the forward or rearward movement generally corresponds to a one-pitch feed amount of the continuous sequin strip 13. As detailed in the above-discussed No. 2004-167097 laid-open publication, the sequin feeding operation is carried out upon completion of sewing of the leading sequin S (and cutting of the continuous sequin strip across the connecting portion Sb immediately following the leading sequin S) shown in
The sequin feeding operation in the instant embodiment, which is generally the same as disclosed in the above-discussed No. 2004-167097 laid-open publication, will be described briefly below. As the feed lever 29 is moved forward (leftward in
As the feed lever 29 is moved rearward (rightward in
Next, an adjustment mechanism (68, 69) for variably adjusting the cutting position (position relative to a sewing needle 77) in each of the sequin feed units 20 and 21.
However, as the supporting plate 22 is adjusted in position as noted above, the link pin 26 of the link arm 25 is also displaced in the front-rear direction so that positional relationship between the link pin 26 and the engagement portion 54a of the transmission lever 54 in the returned position would go wrong. But, if the link arm 25 is placed in a freely movable state by loosening in advance a screw 81 (see
Through the positional adjustment of the supporting plate 22, the sequin feed unit 21 is adjusted in position in the front-rear direction. Because the sewing needle 77 attached to the needle bar 39 of the machine head is relatively fixed in position (horizontal position), the aforementioned front-rear positional adjustment of the sequin feed unit 21 can adjust the position of the cutter section (36 and 23b) relative to the sewing needle 77, i.e. cutting position (or horizontal distance between the axis of the vertical movement of the sewing needle 77 and the fixed cutter blade 23b). The cutting position is adjusted in accordance with the size of each sequin (i.e., distance from the sewing hole Sa to the connecting portion Sb of the sequin as shown in
The instant embodiment is not limited to the aforementioned “following” adjustment; for example, the cutting position of the sequin feed unit 21 may be adjusted by measuring a distance from the center of the sewing needle 77 to the fixed cutter blade 23b on the basis of data indicative of the distance from the sewing hole Sa to the fixed cutter blade 23b and adjusting the measured distance to equal the distance indicated by the data. Alternatively, such adjustment based on the measured distance data and copying adjustment may be used in combination. Further, a suitable scale may be provided in relation to the adjustment screw 69 so that correspondency between the current setting of the adjustment screw 69 and the cutting position (or distance from the center of the sewing needle 77 to the fixed cutter blade 23b) can be grasped on the basis of the scale. The adjustment mechanism is not limited to one using the adjustment screw 69 as set forth above and may be one using another linear displacement mechanism. In an alternative, the adjustment screw 69 may be omitted, in which case the supporting plate 22 may be adjusted in its front-rear position by the human operator holding and moving the supporting plate 22 with his or her hand with the supporting-plate adjusting screw 68 loosened in advance. In another alternative, the cutting position may be variably adjusted by automatically linearly displacing the corresponding sequin feed unit 20 or 21 using a drive means, such as a linear motor.
The mechanism for adjusting the cutting position of the other sequin feed unit 20 is constructed in the same manner as the aforementioned cutting-position adjusting mechanism of the sequin feed unit 21. However, it should be noted that, in the instant embodiment of the present invention, the cutting position, i.e. position of the cutter section (36 and 23b) relative to the sewing needle 77, of each of the sequin feed units 20 and 21 can be adjusted independently of the cutting position of the other sequin feed unit. Namely, whereas each of the sequin feed units 20 and 21 is slidable in the left-right horizontal direction integrally with the fixed bracket 44 in response to the movement of the above-mentioned slide plate 45, the cutting positions of the sequin feed units 20 and 21 can be adjusted independently of each other because the feed units 20 and 21 are independently adjustable in position in the front-rear direction relative to the fixed bracket 44. Thus, if the respective cutting positions of the sequin fced units 20 and 21 are adjusted in accordance with the sequin sizes (i.e., distances from the sewing hole Sa to the connecting portion Sb) of continuous sequin strips set on the units 20 and 21, and if the sequin sizes are different from each other, the position, in the front-rear direction, of the support plate 23, i.e. the position of the cutter section (36 and 23b), will differ between the units 20 and 21.
The following lines describe variable setting of the sequin feed amount (feed pitch) of the sequin feed mechanism 19 in each of the sequin feed units 20 and 21. When a reel 14 holding a continuous sequin strip 13 requiring sequin feed pitch adjustment has been newly set on any one of the sequin feed units 20 and 21, the sequin feed amount (feed pitch) of the sequin feed mechanism 19 in the unit 20 or 21 is first adjusted in the following manner. First, the screw 28 (see
Then, the locked condition of the support block 34 of the lock lever 33 is canceled, and the lock lever 33 is adjusted with the pivot arm or lever 27, feed lever 29 and continuous sequin strip 13, lying on the support plate 23, held in the “feed-out completed position”. Then, with the stopper portion 33b at the upper end of the lock lever 33 abutted against the stopper portion 34a of the support block 34, the lock lever 33 is adjusted in position by manually adjusting the position, in the front-rear position, of the support block 34 so that the engaging claw 33a of the lock lever 33 engages with the sewing hole of a predetermined sequin of the continuous sequin strip 13 lying on the support plate 23; the predetermined sequin is several sequins after (e.g., second sequins from) the sequin S1 engaged by the engaging portion 29a of the feed lever 29. The support block 34 is locked with the lock lever 33 adjusted in position in the aforementioned manner.
In variably setting the sequin feed amount (feed pitch) of the sequin feed mechanism, the “feed-out completed position”, i.e. start position (=end position) of the reciprocative stroke for effecting one-pitch sequin feeding, is set/adjusted through mechanical positional adjustment of the pivot lever 27, feed lever 29 and lock lever 33. Then, the end position (=start position) of the reciprocative stroke for effecting one-pitch sequin feeding is set/adjusted by setting data indicative of a rotational range of the motor 57, which effects one-pitch sequin feeding driving, to a value corresponding to a one-pitch feed amount of the feed lever 29. Such data indicative of a rotational range of the motor 57 may be set by human operator's manual setting operation on an operation panel 90 (
Basically, the feeding may be performed using, as one feed pitch, the size (i.e., diameter) of a sequin to be fed out; in practice, however, a value slightly greater than the sequin size (i.e., diameter) is set as a one-pitch feed amount of the feed lever 29, in order to allow feed-out of the sequin strip 13 to be effected with an increased reliability. For example, in the case of a sequin having a 6 mm diameter, the one-pitch feed amount is set at about 7 mm, or in the case of a sequin having a 4 mm diameter, the one-pitch feed amount is set at about 5 mm. Namely, by setting the one-pitch feed amount of the feed lever 29 to a value slightly greater than the sequin size (i.e., diameter), the engaging portion 29a of the feed lever 29 is positioned a little ahead (leftward in
The following paragraphs describe an example of the sequin sewing operation using the aforementioned sequin feeder apparatus 1. In the case where sequin sewing is to be performed using the machine head H having the sequin feeder apparatus 1 set thereon, two different types of sequins can be sewn as desired by using the two sequin feed units 20 and 21 during sewing of an embroidery pattern while switching between the units 20 and 21. According to the present invention, as set forth above, each of the sequin feed units 20 and 21 is capable of setting/changing its sequin feed pitch as desired, and thus, the “two different types of sequins” may differ in any of not only shape and color but also size (diameter). Further, even the same sequin feeder apparatus 1 can sew sequins of any desired size (diameter), i.e. any desired feed pitch, in accordance with a desired sequin sewing design. Note that sewing control to be described below is implemented by a not-shown control device (e.g., computer) executing a sewing control program, containing a sequence of operations to be explained below, on the basis of desired sequin-design sewing pattern data related to two-sequin-combined embroidery. Although a flow chart of the sewing-controlling operational sequence is not shown here, such a flow chart may be readily realized on the basis of the following description of the sewing-controlling operational sequence.
First, two reels 14 holding, i.e. having wound thereon, continuous sequin strips 13 differing in sequin shape, color and/or size are prepared in accordance with a two-type-sequin-combined embroidering design and then set on the base 3 side by side in correspondence with the two sequin feed units 20 and 21 Portions of the sequin strips 13 are paid out from the two reels 14, then directed to and supported on the first rollers 15, tension rollers 10, second rollers 16, third rollers 17 and fourth rollers 18 in the mentioned order and then guided to the feed units 20 and 21. The portion of the continuous sequin strip 13 paid out from the right reel 14 in
After completion of predetermined adjustment and setting, the operation of the sewing machine is started, upon which sequin embroidery sewing is carried out under the control of the control device and on the basis of desired sequin-pattern sewing pattern data using a combination of at least two types of sequins. For example, the desired sequin sewing pattern data are embroidery sewing data of a format programmed to realize a desired sewing pattern and include data for driving the embroidery frame along the X and Y axes in accordance with the desired sewing pattern. The sewing pattern data also include data for selecting sequins to be used for sewing in correspondence with an initial stitch and groups of desired one or a plurality of stitches. First, which one of the sequin feed units 20 and 21 should be used is instructed on the basis of the data for selecting a sequin in correspondence with the initial stitch. If use of the first sequin feed unit 20 has been instructed, the motor 63 is driven to position the first sequin feed unit 20 in the sewing operation position as shown in
Once a stitch at which a sequin change or switch from one type to another is to be effected arrives as the sequin sewing progresses, use of the second sequin feed unit 21, for example, is instructed on the basis of the embroidery sewing data. Then, while the needle bar 39 is in its raised position, the motor 63 is driven to position the second sequin feed unit 21 in the sewing operation position as illustrated in
In the aforementioned manner, the first embodiment of the invention can change the sequin to be sewn from one type to another without stopping the rotation of the sewing machine and without jumping the needle bar 39. Of course, the manner of the sequin change control in the instant embodiment is not limited to the aforementioned, and the needle bar 39 may be jumped throughout the sequin-changing slide operation.
Note that the present invention is not limited to the case where the embroidery sewing data include sequin-selecting (changing) data only in correspondence with a stitch at which a sequin change is to be effected as noted above; the embroidery sewing data may include sequin-selecting (changing) data per stitch.
In an alternative, the sequin-changing slide control may be automatically performed on the basis of a predetermined sequin changing pattern or may be manually performed as necessary in response to operation, by the human operator, of the operation panel 90, instead of being performed on the basis of embroidery sewing data as set forth above. For example, the “predetermined sequin changing pattern” may be one in accordance with which a predetermined number n of sequins of the first sequin feed unit 20 are sewn in succession and then a predetermined number m of sequins of the second sequin feed unit 21 are sewn in succession; thus, the sequin to be sewn can be changed from one type to another through repletion of the pattern. In such a case, it is preferable that the “n” and “m” values may be manually set/changed as desired by the human operator operating the operation panel 90. In still another alternative, a plurality of different sequin changing patterns may be prepared in advance so that the human operator can select, as necessary, any desired one of the sequin changing patterns by operating the operation panel 90.
In the above-described embodiment, the two sequin feed units 20 and 21 symmetrically arranged and substantially identically constructed are provided in opposed relation to each other. Alternatively, such identically-constructed sequin feed units 20 and 21 may be provided side by side in a same orientation. In such a case, the shape of the link arm 25, fixing the link pin 26, is modified so that the link arm 25 can move without interfering with the transmission lever 54 during the sliding movement of the feed units 20 and 21. In the case where the link arm 25 is modified in shape and construction as noted above, three or more sequin feed units, rather than the two sequin feed units 20 and 21, can be provided side by side in such a manner that any desired one of the feed units can be selected through the sliding movement. Thus, switching can be made among three or more types of sequins
The first embodiment has been described above as constructed to adjust the cutting position of each of the sequin feed units 20 and 21 through positional adjustment of the supporting plate 22 (i.e., the whole of the sequin feed unit in question). Alternatively, the support plate 23 may be made adjustable in position relative to the supporting plate 22 so that desired adjustment of the cutting position can be performed through positional adjustment of the support plate 23 alone. In such a case, the mechanism for linearly displacing the support plate 23 may employ a rotation-to-linear-displacement conversion mechanism, such as the above-mentioned adjustment screw 69, linear motor, or the like.
Second EmbodimentWith reference to
Each of the right and left levers 106 and 107 functions as a displacement member displaceable between first and second positions. The “first position” is where the displacement member (lever 106 or 107) is held in abutting contact with the corresponding continuous sequin strip 13, while the “second position” is where the displacement member (lever 106 or 107) is located past the first position, without abutting against the corresponding continuous sequin strip 13, due to a stoppage (i.e., runout) of the supply of the continuous sequin strip 13.
Magnetic sensor 109 is provided on the upper surface of the second base plate 104 and on pivoting trajectories of the detecting portions 106b and 107b, and a permanent magnet 110 is provided on the lower surface of the first base plate 102b. When none of the detecting portions 106b and 107b is located between the magnetic sensor 109 and the permanent sensor 110 as shown in
The detection device 101 in the second embodiment operates as follows at the time of sequin sewing. First, as in the first embodiment, two reels 14 holding, or having wound thereon, continuous sequin strips 13 differing in shape and/or size, are set side by side on the fixed base 4. Portions of the continuous sequin strips 13, paid out from the reels 14, are passed to and engaged with the individual rollers and detection device 101 and then directed to the corresponding sequin feed units 20 and 21. In the detection device 101, the continuous sequin strips 13 are set on the guiding portions 103a, 104a and 103b, 104b, respectively. When a continuous sequin strip 13 is set relative to the right side of the detection device 101, for example, the following operation takes place. As long as no continuous sequin strip 13 is set on the right side of the detection device 101, the right lever 106 is held in the second position where the knob 108 is oriented vertically downward as shown in
When sequin sewing is started after the continuous sequin strips 13 have been properly set in place in the aforementioned manner, the two levers 106 and 107 are held in the first position as shown in
In the aforementioned detection device 101, the magnetic sensor 109 is kept in the ON state while the lever 106 or 107 is held in the second position. Thus, when sequin sewing is to be performed with a continuous sequin strip 13 set only on one of the two sequin feed units (i.e., with no sequin color change to be effect), there is no need to make an arrangement for preventing a state of the other sequin feed unit, where no continuous sequin strip 13 is set, from being detected, e.g. by evacuating the lever 106 or 107 of the other sequin feed unit. Because the lever 106 or 107 of the other sequin feed unit, where no continuous sequin strip 13 is set, is held in such a manner that the corresponding knob 108 is oriented vertically downward by its own weight alone, the lever 106 or 107 of the other sequin feed unit might undesirably pivot if the embroidery sewing machine vibrates greatly, which tends to result in a false detection. To avoid such an inconvenience, holding members, such as leaf springs, may be provided to restrict movement the levers 106 and 107 such that, when any one of the levers 106 or 107 is in the second position (where the knob 108 is oriented vertically downward), the lever 106 or 107 can be reliably prevented from undesirably pivoting due to vibration. Alternatively biasing members, such as torsion springs, for normally urging the levers 106 and 107 to the second position (i.e., position where the knob 108 is oriented vertically downward), in which case it is preferable to provide stoppers for holding the thus-urged levers 106 and 107 in the second position.
Note that, in the above-described second embodiment, the detection device 101 only detects that any one of the two continuous sequin strips 13 has run out and does not specifically detect which one of the two continuous sequin strips 13 has run out. This is because the second embodiment can achieve necessary and sufficient functions by automatic deactivation of the sewing machine or information to the human operator based on the mere detection that any one of the two continuous sequin strips 13 has run out. However, the present invention is not so limited, and two detection devices of the aforementioned construction may be provided, in correspondence with two continuous sequin strips 13 to be set, so as to specifically detect which one of the two continuous sequin strips 13 has run out.
Note that the detection device 101 for detecting that a continuous sequin strip 13 has run out is also applicable to sequin feeder apparatus of the conventionally-known type where only one continuous sequin strip is set and fed, instead of being limited to the sequin feeder apparatus 1 of the type where two or more continuous sequin strips 13 are set side by side to permit sequin selection or change as desired. In such a case, the construction of the detection device 101 shown in
Further, the detection device 101 may comprise any suitable detection means, such as an optical sensor or mechanical sensor, rather than a magnetic sensor.
Other Improvements or ModificationsAccording to the present invention, spring members for holding the two reels 14 sideways against excessive rotation are provided at positions where the reels 14 are set side by side. Thus, some force would act on the two juxtaposed reels 14 such that the reels 14 tend to rotate together; consequently, as one of the reels 14, which is currently involved in sequin sewing, rotates, the other reel 14, which is not currently involved in the sequin sewing, may undesirably rotate together with the one reel 14 and slacken to have adverse influences on the sequin sewing. To avoid such adverse influences, it is desirable to take some measure to prevent the two reels 14 from rotating together. As an example of such a measure, a key groove may be formed in the mounting shaft supporting the reels 14, and a washer having a key formed, on its inner periphery, for fitting engagement with the key groove may be provided between the two reels 14. Alternatively, a part of the mounting shaft may be formed into a substantial D sectional shape, and a washer having a hole corresponding in sectional shape to that part may be provided between the two reels 14. In this way, the two reels 14 can be reliably prevented from rotating together, and, besides, the holding force applied sideways effectively acts on both of the reels 14.
Further, the mounting base 4 may be constructed so that it can also be stopped and held in an intermediate position between the lowered position and the evacuated position. For example, when the sequin sewing operation is to be switched to the embroidery operation by the sequin needle bar, it has been conventional to hold the mounting base in the lowered position in order to reduce the necessary working time; however, according to the modification of the present invention, the mounting base 4 is raised from the lowered position to the intermediate position without the sewing machine being deactivated. With such a modification, it is possible to avoid the inconveniences that the movable cutter blade 36 is easily damaged by being unnecessarily hit by the needle clamp 40. Furthermore, the modification can reduce the time required for ascending and descending of the mounting base 4, and, because the sewing machine is not deactivated, it can effectively reduce the loss of the operating time as compared to the case where the switching from the sequin sewing operation to the embroidery operation is effected with by the base 4 held in the lower position. Alternatively, the needle bar may be held in the jumping state, in which case too the loss of the operating time can be considerably reduced. Note that the “intermediate position” of the mounting base 4 may be any suitable position where the movable cutter blade 36 is not hit by the needle bar 40. Also note that, in the case where the mounting base 4 is constructed to be able to be stopped and held in the intermediate position as noted above, the mounting base 4 may be evacuated from the intermediate position to the evacuated position upon deactivation of the sewing machine. Further, the human operator may set individually whether the mounting base 4 should be held in the lowered position or should be raised to the intermediate position or to evacuated position in various predetermined states, such as when the thread is to be cut and when a thread breakage has been detected.
In the case where the sequin feeder apparatus 1 is attached to the left side of the needle bar case 2 as shown in
Furthermore, for each of the sequin feeder apparatus 1, there may be provided a feeding switch operable to instruct an operation for feeding a continuous sequin strip 13, a switching switch operable to instruct that the sequin feed unit to be used for feeding the continuous sequin strip 13 be changed or switched over to the left or right sequin feed unit 20 or 21, an ascending/descending switch operable to instruct that the sequin feeder apparatus 1 be caused to ascend or descend, and other switches, so that any desired operation can be instructed by the human operator manually operating a corresponding one of the switches.
During operation of the sewing machine, embroidery sewing data corresponding to several stitches may be pre-read so that sequin changing (switching) can be effected at a stitch preceding the sewing of the several stitches. More specifically, once a particular stitch at which a sequin change is to be effected is identified through pre-reading of the embroidery sewing data, a determination is made as to whether or not the sequin change is possible at a stitch preceding the particular stitch. If the preceding stitch is a stitch at which a sequin is not to be fed out, then it is determined that the sequin change is possible at the preceding stitch. If, on the other hand, the preceding stitch is a stitch at which a sequin is to be fed out, then it is determined that the sequin change is impossible at the preceding stitch, and jump stitch data is inserted for jumping the needle bar between needle stitches so that a sequin change can be effected during the jumping of the needle bar.
Such a sequin change will be described in more detail below in relation to a case where sequin patterns shown in
The following lines describe a sequence of operations performed by the control device (e.g., computer) for sewing the sequin pattern shown in
The following lines describe a sequence of operations performed by the control device (e.g., computer) for sewing the sequin pattern shown in
Note that, even where a stitch at which no sequin is to be fed is present before a stitch at which a sequin is to be sewn as in the sequin pattern of
The following lines describe an example manner in which a sequin pattern is created using the basic principles of the present invention. Sequin pattern, comprising a heretofore-unachievable, novel pattern structure, can be created by using the sequin feeder apparatus 1 of the present invention to sew two sequins C and D of different types to a workpiece in an overlapped relation to each other as shown in
The following lines describe constructions of the sequin feed units 123 and 124 and mounting sections thereof. For mounting of the sequin feed units 123 and 124, the sequin selection mechanism 122 includes base members 125 on its left and right sides. Each of the sequin feed units 123 and 124 includes a mounting bracket 126 having a mounting groove 126a and hole 126b. Each of the sequin feed units 123 and 124 can be detachably fixed to the corresponding bracket 125 by means of two stepped screws 132, and the height of the groove 126a and diameter of the hole 126b of the mounting bracket 126 are appropriately chosen such that shaft portions 132a of the stepped screws 132 can be fitted in the groove 126a and hole 126b with no wobbling or backlash. In this way, the mounting brackets 126 can always be positioned in same positions relative to the corresponding base members 125.
Each of the mounting brackets 126 is fixed to a corresponding supporting plate 127 by means of two fastening screws 128. The mounting bracket 126 includes a mounting section for each of the fastening screws 128, which has a stepped shape having a through-hole for passage therethrough a threaded portion of the fastening screw 128 and an increased-diameter portion for fitting engagement therein of a head portion of the fastening screw 128. The through-hole and increased-diameter portion of the mounting section together constitute an elongated hole extending in the front-rear direction of the sequin feeder apparatus. Further, each of the mounting brackets 126 has a guide hole 126c extending in the front-rear direction of the sequin feeder apparatus so that one of guide pins 129 fixed to the supporting plate 127 can be slidably fitted therein. In each of the mounting brackets 126, an adjustment screw 130 is supported by a support section 126d, bent at a right angle from the body of the bracket 126, in such a manner that the screw 130 is rotatable about its axis but immovable in the axial direction thereof, and the adjustment screw 130 has a distal end portion screwed into a threaded hole of a support member 131 that is in turn fixed to the supporting plate 127. Thus, in response to rotation of the adjustment screw 130, the support member 131 having the threaded hole and the supporting plate 127 are linearly displaced without the adjustment screw 130 being linearly displaced. Thus, as the adjustment screw 126 is rotated clockwise or counterclockwise, the supporting plate 127 is linearly displaced in the forward or rearward direction so that its position in the front-rear direction can be adjusted. The other structural elements of the sequin feeder apparatus 120 than the above-described will not be described here because they are similar in function to those of the sequin feeder apparatus 1 according to the first embodiment of the invention although slightly different from the latter in terms of shapes and positions of some of the component parts.
When some adjustment has to be made for at least one of the sequin feed unit 123 and 124 in the sequin feeder apparatus 120 in accordance with the size of sequins to be sewn, the sequin feed unit 123 or 124, requiring the adjustment, is detached from the body of the sequin feeder apparatus 120, and the sequin feed amount (i.e., positional adjustment of the pivot lever and lock lever) of the detached sequin feed unit 123 or 124 is adjusted. After that, the sequin feed unit 123 or 124 is re-attached to the body of the sequin feeder apparatus 120, and then the cutting position (position relative to a sewing needle 77) is adjusted by rotating the adjustment screw 130 clockwise or counterclockwise to move the supporting plate 127 in the front-rear direction. Then, the rotational range of the sequin-feeding drive motor is set, as necessary, to a value corresponding to a one-pitch sequin feed amount. Namely, the desired adjustment can be made with ease by detaching the sequin feed unit 123 or 124, requiring the adjustment, from the body of the sequin feeder apparatus 120 as noted above.
Further, because each of the mounting brackets 126 can always be positioned in the same position relative to the corresponding base members 125, the cutting position in the sequin feed unit 123 or 124 will not vary even though the feed unit 123 or 124 is detached and attached after the supporting plate 127 is positioned in position according to the sequin size. Therefore, if some scale means indicative of adjusted positions of the supporting plate 127 corresponding to various sequin sizes is provided, and if arrangements are made for permitting the cutting position adjustment while the feed unit 123 or 124 is detached from the body of the sequin feeder apparatus 120, the desired adjustment can be made with ease. Further, such arrangements permit novel usage of the sequin feeder apparatus, in accordance with which sequin feed units adjusted according to various sequin sizes are prepared in advance and switching is made to one of such prepared sequin feed units, which corresponds to the size of a sequin to be used, without making various adjustments in accordance with the size of the sequin to be used.
Note that, whereas the structure for sliding the sequin selection mechanism in each of the above-described embodiments has been described above as comprising the two rods and member slidably supported on the rods, the present invention is not limited to such a structure and any other desired sliding structure comprising a linear rail may be employed.
This application is based on, and claims priority to, JP PA 2006-280396 filed on 13 Oct. 2006. The disclosure of the priority application, in its entirety, including the drawings, claims, and the specification thereof, is incorporated herein by reference.
Claims
1. A sequin feeder apparatus comprising:
- at least two sequin feed units each including a sequin feed mechanism for feeding a continuous sequin strip toward a predetermined cutting position and a sequin-cutting cutter section located in the predetermined cutting position;
- a sequin selection mechanism for selecting one of said at least two sequin feed units and positioning the selected one sequin feed unit in a predetermined sewing operation position; and
- a drive mechanism for engaging with said sequin feed mechanism of said one sequin feed unit, positioned in the predetermined sewing operation position, and thereby driving, in response to a sewing operation, the engaged sequin feed mechanism to feed the continuous sequin strip toward the predetermined cutting position,
- wherein the predetermined cutting position in each of said sequin feed units is adjustable independently of the predetermined cutting position in other of said sequin feed units, and
- said cutter section is driven, in response to the sewing operation, to cut a sequin off from the continuous sequin strip having been fed to the predetermined cutting position.
2. A sequin feeder apparatus as claimed in claim 1 wherein each of said sequin feed units includes an adjustment mechanism for adjusting a position, relative to a position of a sewing needle, of said cutter section of the sequin feed unit independently of the other of said sequin feed units.
3. A sequin feeder apparatus as claimed in claim 2 wherein said adjustment mechanism of each of said sequin feed units adjusts the cutting position, where said cutter section cuts the sequin off from the sequin strip, by linearly displacing a whole of the sequin feed unit.
4. A sequin feeder apparatus as claimed in claim 2 wherein each of said sequin feed units includes a support plate for supporting thereon the continuous sequin strip to be fed toward the cutting position, and said cutter section of the sequin feed unit is provided at a distal end of said support plate, and
- said adjustment mechanism of each of said sequin feed units adjusts the cutting position, where said cutter section cuts the sequin off from the sequin strip, by linearly displacing said support plate of the sequin feed unit.
5. A sequin feeder apparatus as claimed in claim 3 wherein said adjustment mechanism of each of said sequin feed units includes a mechanism for linearly displacing the whole of said sequin feed unit.
6. A sequin feeder apparatus as claimed in claim 5 wherein said mechanism for linearly displacing the whole of the sequin feed unit includes a mechanism for converting rotation of an adjustment screw into linear displacement of the sequin feed unit.
7. A sequin feeder apparatus as claimed in claim 1 wherein said cutter section of each of said sequin feed units includes a fixed cutter blade and movable cutter blade that operate independently of the fixed cutter blade and movable cutter blade of the other sequin feed unit.
8. A sequin feeder apparatus as claimed in claim 1 wherein said sequin feed mechanism of each of said sequin feed units is capable of setting a sequin feed amount independently of the sequin feed mechanism of the other sequin feed unit.
9. A sequin feeder apparatus as claimed in claim 8 wherein said drive mechanism drives said sequin feed mechanism of the one sequin feed unit, currently positioned in the predetermined sewing operation position, with a drive amount corresponding to the sequin feed amount set by said sequin feed mechanism of the one sequin feed unit.
10. A sequin feeder apparatus as claimed in claim 1 wherein said at least two sequin feed units are disposed side by side in such a manner that said sequin feed units are slidable together, and
- said sequin selection mechanism positions one of said at least two sequin feed units in the predetermined sewing operation position by sliding said at least two sequin feed units together.
11. A sequin feeder apparatus as claimed in claim 1 wherein said drive mechanism includes:
- an engagement portion for engaging with said sequin feed mechanism of the one sequin feed unit positioned in the predetermined sewing operation position;
- a motor drivable in interlocked relation to the sewing operation; and
- a link mechanism for transmitting motion of said motor to said engagement portion, and
- wherein said sequin feed mechanism of the one sequin feed unit positioned in the predetermined sewing operation position is caused to operate, in response to the motion of said motor and via said link mechanism and said engagement portion, to thereby feed the continuous sequin strip toward the predetermined cutting position.
12. A sequin feeder apparatus as claimed in claim 1 wherein said cutter section of the one sequin feed unit positioned in the predetermined sewing operation position is driven, in response to movement of a needle bar during the sewing operation, to thereby cut a sequin off from the continuous sequin strip.
13. A sequin feeder apparatus as claimed in claim 1 which further comprises a detection device for detecting whether or not a supply of the continuous sequin strip from a sequin strip supply source to any of said sequin feed units has run out.
14. A sequin feeder apparatus as claimed in claim 1 wherein each of said sequin feed units is detachably attached to a base section of said sequin selection mechanism.
15. A sewing machine comprising the sequin feeder apparatus, recited in claim 1, in association with a sewing head.
16. A sewing machine as claimed in claim 15 wherein different continuous sequin strips of at least two types are supplied from the sequin strip supply sources to the at least two sequin feed units, and
- which further comprises a control device that, on the basis of sewing pattern data of a desired sequin pattern that uses at least two types of sequins in combination, controls the sequin selection mechanism to select any one of said at least two sequin feed units at a particular sewing position where the sequin to be used is to be changed from one type to another, said control device then performing control such that sequin sewing is performed using the selected sequin feed unit.
17. A sewing machine as claimed in claim 16 wherein the desired sequin pattern comprises a pattern to be made by alternately selecting and sewing the at least two types of sequins.
18. A sewing machine as claimed in claim 16 wherein the desired sequin pattern comprises a pattern to be made by alternately selecting and sewing the at least two types of sequins in overlapped relation to each other.
19. A sequin feeder apparatus comprising:
- a sequin feed unit including a sequin feed mechanism for feeding a continuous sequin strip toward a predetermined cutting position and a sequin-cutting cutter section located in the predetermined cutting position;
- a drive mechanism for driving, in response to a sewing operation, the sequin feed mechanism to feed the continuous sequin strip toward the predetermined cutting position, the cutter section being driven, in response to the sewing operation, to cut a sequin off from the continuous sequin strip having been fed to the predetermined cutting position;
- a displacement member provided between a sequin strip supply source and the sequin feed unit and displaceable between a first position and a second position, said first position being where said displacement member is held stationary in abutting contact with the continuous sequin strip supplied from the sequin strip supply source to the sequin feed unit, said second position being where, due to absence of the continuous sequin strip, said displacement member is located past said first position without abutting against the continuous sequin strip; and
- a detection device for detecting that said displacement member has shifted from said first position to said second position,
- wherein that a supply of the continuous sequin strip has run out is detected on the basis of an output of said detection device.
Type: Application
Filed: Oct 11, 2007
Publication Date: Apr 17, 2008
Applicant: TOKAI KOGYO MISHIN KABUSHIKI KAISHA (Kasugai-shi)
Inventor: Aisuke Murase (Kasugai-shi)
Application Number: 11/870,703
International Classification: D05B 3/12 (20060101);