SEWING MACHINE

Abstract

A sewing machine includes a needle, a holding frame having a stitchable area within which the needle is operable to perform stitching, storing means for storing sewing data on various embroidery patterns, indicating means for indicating, within the stitchable area, positions on the workpiece that is held by the holding frame, stitching region setting means for setting a stitching region in accordance with the positions indicated by the indicating means, embroidery pattern creating means for creating, in accordance with a position and a size of the stitching region, and based on the sewing data, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region, and control means for controlling the needle and the holding frame to form the embroidery pattern on the workpiece within the stitching region in accordance with the embroidery pattern data.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority from Japanese Patent Application No. 2007-052383 filed on Mar. 2, 2007, the entire content of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a sewing machine operable to form an embroidery pattern on a cloth held by a frame-shaped member.

DESCRIPTION OF THE RELATED ART

A related art embroidery machine is operable to form an embroidery pattern onto a cloth while the embroidery pattern can be processed, e.g., an enlargement or a reduction, on a display screen such as a CRT (see, e.g., JP 2695445B2).

However, a size of an embroidery pattern displayed on a display screen like the related art embroidery machine is usually different from a size of an actual embroidery pattern to be formed. Thus, there has been a disadvantage that, in some cases, an embroidery pattern having a different size from an expected size is formed onto the cloth.

Moreover, there are some more disadvantages when forming an embroidery pattern so as to be adjacent to another embroidery pattern that is previously formed on a cloth. For example, if a processed embroidery pattern misarranged in a case where the embroidery pattern to be formed is smaller than expected, a gap is generated between the two embroidery patterns so that an arrangement balance of the whole embroidery is deteriorated. Therefore, an operator needs to rearrange a layout so that a working efficiency is reduced. This is the same for a case where the processed embroidery pattern is larger than expected, because the embroidery patterns overlap with each other.

In view of the above disadvantages, in another related art embroidery machine, a region in which a pattern is already formed and a region in which a pattern is going to be formed are displayed on the same display screen so as to allow a visual observation of relative positions, and an alarm is activated in the event that both of the regions overlap with each other (see, e.g., JP 6-047179A). However, according to this embroidery machine, an operator still needs to rearrange a layout after the alarm. Therefore, a working efficiency is reduced.

Further, even if a sewing program is created to form an embroidery pattern at an appropriate position on a cloth, on which an embroidery is previously formed, with a suitable size, the cloth having the embroidery formed thereon needs to be accurately attached to a certain portion of an embroidery machine (e.g., an embroidery frame), or otherwise the embroidery pattern is formed at a shifted position

SUMMARY OF THE INVENTION

One or more exemplary embodiments of the invention provide a sewing machine operable to form an embroidery pattern having a size that is suitable for a desired stitching region.

According to one or more exemplary embodiments of the invention, a sewing machine includes a needle movable in a vertical direction, a holding frame operable to hold a workpiece and movable in a horizontal direction, the holding frame having a stitchable area within which the needle is operable to perform stitching, storing means for storing sewing data on various embroidery patterns, indicating means for indicating, within the stitchable area, a plurality of positions on the workpiece that is held by the holding frame, stitching region setting means for setting a stitching region in accordance with the plurality of positions indicated by the indicating means, embroidery pattern creating means for creating, in accordance with a position and a size of the stitching region set by the stitching region setting means, and based on the sewing data stored in the storing means, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region, and control means for controlling, in accordance with the embroidery pattern data created by the embroidery pattern creating means, the needle and the holding frame to form the embroidery pattern on the workpiece within the stitching region.

According to one or more exemplary embodiments of the invention, a sewing machine includes a needle movable in a vertical direction, a holding frame operable to hold a workpiece and movable in a horizontal direction, the holding frame having a stitchable area within which the needle is operable to perform stitching, storing means for storing sewing data on various embroidery patterns, stitching region setting means for moving the workpiece to designate a plurality of positions on the workpiece, which are moved to a point right below the needle, and for setting a stitching region in accordance with the plurality of positions designated, embroidery pattern creating means for creating, in accordance with a position and a size of the stitching region set by the stitching region setting means, and based on the sewing data stored in the storing means, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region, control means for controlling, in accordance with the embroidery pattern data created by the embroidery pattern creating means, the needle and the holding frame to form the embroidery pattern on the workpiece within the stitching region.

According to one or more exemplary embodiments of the invention, a sewing machine includes a needle, a sewing machine motor operable to move the needle in the vertical direction, a holding frame operable to hold a workpiece, the holding frame having a stitchable area within which the needle is operable to perform stitching, a sewing machine frame having a bed portion on which the holding frame is disposed, a pulse motor coupled to the holding frame to move the holding frame in a horizontal direction, a memory in which sewing data on various embroidery patterns are stored, an indicator operable to visually indicate, on the workpiece, a point right below the needle, a movement instructing portion operable to instruct the pulse motor to move the cloth holding frame upon manually operating the movement instructing portion, the movement instructing portion being disposed on the sewing machine frame, a designating portion operable to designate positions of the cloth holding frame corresponding to at least two points on the workpiece indicated by the indicator upon manually operating the designating portion, the designating portion being disposed on the sewing machine frame, a control portion operable to calculate and set a stitching region in accordance with the positions designated by the designating portion, and to create, in accordance with a position of the stitching region within the stitchable area and a size of the stitching region, and based on the sewing data stored in the memory, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region, and control means for controlling, in accordance with the embroidery pattern data, the sewing machine motor and the pulse motor to form the embroidery pattern on the workpiece within the stitching region.

According to one or more exemplary embodiments of the invention, a sewing machine includes a needle, a sewing machine motor operable to move the needle in the vertical direction, a holding frame operable to hold a workpiece, the holding frame having a stitchable area within which the needle is operable to perform stitching, a sewing machine frame having a bed portion on which the holding frame is disposed, a pulse motor coupled to the holding frame to move the holding frame in a horizontal direction, a memory in which sewing data on various embroidery patterns are stored, a movement instructing portion operable to instruct the pulse motor to move a portion of the workpiece, which is held the cloth holding frame, to a point right below the needle upon operating the movement instructing portion, the movement instructing portion being disposed on the sewing machine frame, a designating portion operable to designate positions of at least two portions of the workpiece, which are moved to the point right below the needle by the movement instructing portion, upon operating the designating portion, the designating portion being disposed on the sewing machine frame, a control portion operable to calculate and set a stitching region in accordance with the positions designated by the designating portion, and to create, in accordance with a position of the stitching region within the stitchable area and a size of the stitching region, and based on the sewing data stored in the memory, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region, and control means for controlling, in accordance with the embroidery pattern data, the sewing machine motor and the pulse motor to form the embroidery pattern on the workpiece within the stitching region.

Other aspects and advantages of the invention will be apparent from the following description, the drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a sewing machine according to an exemplary embodiment of the invention;

FIG. 2 is a block diagram showing a configuration of the sewing machine;

FIG. 3 is a plan view showing an example of an operation panel of the sewing machine;

FIG. 4 is a plan view showing an example of the operation panel on which an embroidery data screen is displayed;

FIG. 5 is a flowchart for setting a stitching region and to form an embroidery pattern;

FIG. 6 is an explanatory view showing the operation panel on which a selected embroidery pattern is displayed in a display region;

FIG. 7A is an explanatory view showing a light spot indicating a start point of the stitching region on a cloth held in a holding frame;

FIG. 7B is an explanatory view showing the operation panel on which a first point corresponding to the light spot indicating the start point is displayed;

FIG. 8A is an explanatory view showing a light spot indicating an end point of the stitching region on the cloth held in the holding frame;

FIG. 8B is an explanatory view showing the operation panel on which a second point corresponding to the light spot indicating the end point is displayed,

FIG. 9 is an explanatory view related to embroidery pattern data created with an increase in a size of an embroidery pattern;

FIG. 10 is an explanatory view related to embroidery pattern data created with a reduction in the size of the embroidery pattern; and

FIG. 11 is an explanatory view showing the operation panel on which a stitching region and an embroidery pattern with an adjusted size are displayed on the display region.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments of the invention will be explained with reference to the drawings. The following exemplary embodiments do not limit the scope of the invention.

An embroidery machine M (hereinafter, “a sewing machine M”) according to an exemplary embodiment includes a holding frame 11 (an embroidery frame) operable to hold a cloth to be sewn (a workpiece W), and a needle 8 which is movable in a vertical direction. The sewing machine M forms an embroidery pattern, in accordance with a sewing data, on the cloth held by the holding frame 11 by vertically moving the needle 8 while moving the holding frame 11 in a horizontal direction.

In the following description, a Z-axis direction (or an up-and-down direction) is a direction in which the needle 8 carries out the vertical movement, an X-axis direction (or a right-and-left direction) is a direction orthogonal to the Z-axis direction, and a Y-axis direction (or a front-and-rear direction) is a direction orthogonal to the Z-axis direction and the X-axis direction.

As shown in FIGS. 1 and 2, the sewing machine M further includes a sewing machine body 1, a frame moving mechanism 13, and an operation panel 20. The frame moving mechanism 13 and the operation panel 20 are provided on the sewing machine body 1.

As shown in FIG. 1, the sewing machine body 1 includes a sewing machine frame 2 having an exterior of a U shape when seen from a side. The sewing machine frame 2 includes an arm portion 2a extending in the X-axis direction on an upper side, a bed portion 2b extending in the X-axis direction on a lower side, and a vertical drum portion 2c coupling the arm portion 2a and the bed portion 2b.

The sewing machine M further includes a driving mechanism inside the sewing machine frame 2. The driving mechanism has an upper shaft (not shown) and a lower shaft (not shown) which are rotatable and extending in the X-axis direction. The upper shaft is disposed in the arm portion 2a and the lower shaft is disposed in the bed portion 2b.

The upper shaft is coupled to a sewing machine motor 5 (see FIG. 2), and a rotating force is applied from the sewing machine motor 5. The lower shaft is coupled to the upper shaft via a power transmitting mechanism (not shown). When the upper shaft is rotated, a power of the upper shaft is transmitted to the lower shaft so that the lower shaft is rotated.

A needle bar 8a is coupled to a front end of the upper shaft, and is supported on the sewing machine arm 2a. The needle bar 8a is movable in the Z-axis direction by the rotation of the upper shaft. The needle 8 is exchangeably provided on a lower end of the needle bar 8a. The sewing machine arm 2a is provided with a presser 12 which moves in the vertical direction interlockingly with the needle bar 8a to press the cloth around the needle 8 in order to prevent the cloth from being lifted up by the vertical motion of the needle 8.

The sewing machine M further includes a shuttle (not shown) disposed on a front end of the lower shaft. When the lower shaft is rotated together with the upper shaft, stitches are formed by a cooperation of the needle 8 and the shuttle.

Since coupling structures of the sewing machine motor 5, the upper shaft, the needle bar 8a, the needle 8, the lower shaft and the shuttle are similar to those in the related art structures, detailed explanations thereof will be omitted.

As shown in FIG. 1, the sewing machine M further includes a projector 30 (indicating means, an indicator) operable to indicate an optional position on the cloth held by the holding frame 11. The projector 30 is attached to the sewing machine arm 2a.

The projector 30 includes a light emitting portion such as an LED or a laser diode from which a light is irradiated toward the cloth to indicate the position on the cloth with a light spot. More specifically, the projector 30 is configured to indicate, with the light spot, the position on the cloth toward which the needle 8 is pointing downward, i.e., a position where the needle 8 pierces the cloth if the needle 8 is moved down (a stitch point right below the needle 8).

As shown in FIG. 1, the frame moving mechanism 13 is disposed on the bed portion 2b. The frame moving mechanism 13 includes a carriage 13a and an attaching member 13b to which the holding frame 11 attached so as to be movable in the horizontal direction above the bed portion 2b.

The holding frame 11 is attached to the frame moving mechanism 13 via the attaching member 13b. In addition to the carriage 13a, an X-axis motor 14 and a Y-axis motor 15 (see FIG. 2), which are pulse motors, disposed in the bed portion 2b are coupled to the attaching member 13b.

The holding frame 11 is operable to hold the cloth (the workpiece W) and is moved by the X-axis motor 14 and the Y-axis motor 15. Accordingly, the cloth held together with the holding frame 11 is moved in the front- and rear direction and in the right-and-left direction (i.e., in the X-axis direction and in the Y-axis direction), whereby the cloth is positioned with respect to the needle 8. The movement of the holding frame 11 is interlocked with the operations of the needle 8 and the shuttle so that a stitching work based on certain sewing data is carried out on the cloth and a seam is thus formed. More specifically, an embroidery with a desirable stitching pattern is formed on the cloth held inside the holding frame 11, i.e., within a stitchable area of the holding frame 11.

In other words, the sewing machine M includes the holding frame 11 having the stitchable area, which is the inner side area thereof, and a an embroidery pattern corresponding to sewing data is formed within a desirable region on the cloth held on the inner side of the holding frame 11.

The sewing machine M further includes a key matrix 16 having a start/stop switch 16a, a reverse stitching switch 16b, a thread cutting switch 16c and a speed regulating volume 16d as shown in FIGS. 1 and 2.

The key matrix 16 has the function of an operation key for driving the sewing machine M to vertically move the needle bar 8a (the needle 8) and to operate the holding fame 11. More specifically, a signal output based on the operation of the key matrix 16 is output as a signal for operating various keys to a control portion 100, and the control portion 100 is operable to drive the sewing machine motor 5, thereby operating the sewing machine M in response to the operating signal.

The sewing machine M further includes an operation panel 20 for an operator to carry out various setting operations for the sewing machine M or an operation for inputting various data as shown in FIGS. 1 and 2. The operation panel 20 and the sewing machine M (the control portion 100) are coupled to each other through a line.

As shown in FIG. 2, the operation panel 20 includes a liquid crystal display 22 (display means) and a touch panel 21 disposed on a display screen of the liquid crystal display 22 (on a front side of the display screen) to serve as a transparent touch switch, and is disposed on a front surface of the frame of the sewing machine M. By touching operation keys displayed on the liquid crystal display 22, the touch panel 21 can detect a position indicated by the touch, and can input various data or an operating indication corresponding to the position thus detected. The position on the touch panel 21 may be detected through an electromagnetic induction, a magnetic strain, or a pressure sensing. The operation key displayed on the operation panel 20 (the display means) is indicated through the touch to input an operation so that the display on the liquid crystal display 22 of the operation panel 20 is switched variously and various operation screens and display screens, and various operation keys and set data are displayed. A signal input by touching and indicating the operation panel 20 is output to the control portion 100. Thus, the operation panel 20 has the function of an input portion and a display portion of the sewing machine M.

The liquid crystal display 22 has a display region 22a (see FIG. 3) for displaying, e.g., an embroidery pattern to be formed on a cloth. The display region 22a has a range corresponding to the stitchable area of the holding frame 11.

As shown in FIGS. 3 and 4, for example, an operation key group displayed on the operation panel 20 has a enter key 21a for deciding data input or selected in the operation panel 20 and carrying out setting related to the data, a cancel key 21b for cancelling the set data, a pattern selecting key 21c for displaying an embroidery data screen 210 (see FIG. 4) to select data on a desirable embroidery pattern from sewing data related to a plurality of embroidery patterns stored in storing means (an ROM 102), and a stitching region setting portion 21d for carrying out a regulation to move a position indicated by a light irradiated from the projector 30 and changed into a light spot over the cloth held in the holding frame 11, thereby setting a desirable stitching region.

The stitching region setting portion 21d includes an arrow keys 211 (a movement instructing portion) for moving the X-axis motor 14 or the Y-axis motor 15 corresponding to one pulse every touch operation in order to move the holding frame 11 holding the cloth therein, and a point enter key 212 (a designating portion) for determining, as a stitching region locating point by a manual operation, a cloth holding frame moving position corresponding to a stitch point to be a light spot position indicated by the light irradiated from the projector 30. The stitching region setting portion 21d functions as a part of stitching region setting means.

The liquid crystal display 22 of the operation panel 20 serves to display the operation key group, to display, on the display region 22a, a point corresponding to a position (a light spot) in which the projector 30 indicates the cloth and to display, on the display region 22a, a stitching region corresponding to a range in which a desirable embroidery pattern is sewn onto the cloth and an embroidery pattern to be formed in the stitching region.

The display region 22a of the liquid crystal display 22 corresponds to the stitchable area on the inside of the holding frame 11, and an embroidery pattern related to a stitching region displayed on the display region 22a is formed through sewing in a position to which the stitching region in the cloth held on the inside of the holding frame 11 (the stitchable area) corresponds.

As shown in FIG. 2, moreover, the sewing machine M has the control portion 100 connected to the sewing machine motor 5, the X-axis motor 14, the Y-axis motor 15, the key matrix 16, the operation panel 20 and the projector 30.

The control portion 100 includes a CPU 101 for executing various processings and controls in accordance with a certain control program for the sewing machine motor 5, the X-axis motor 14, the Y-axis motor 15, the operation panel 20, the projector 30 and other actuators (not shown), the ROM 102 (storing means, a memory) which stores programs for executing various processings and controls and data required for the various processings and controls, an RAM 103 which stores various data and serves as a work area for various processings, an EEPROM 104 for storing newly created sewing data, an interface (not shown) for connecting the CPU 101 to various apparatuses, and a pulse motor driver (not shown) for each motor.

The CPU 101 intensively controls an operation processing of each portion in the sewing machine M in accordance with the various control programs and sewing data for the embroidery machine which are stored in the ROM 102 or the various data stored in the EEPROM 104 in response to an operation signal input from the key matrix 16, various setting signals or various data which are input from the operation panel 20, stores a result of the processing in the work area in the RAM 103, and furthermore, stores, in the EEPROM 104, the various data input by the operation of the operation panel 20 or the result of the processing stored in the RAM 103 if necessary.

The CPU 101 functions as control means for controlling the driving operation of each portion constituting the sewing machine M.

The ROM 102 stores control programs and control data of the sewing machine M, and data and display screen information which are related to various sewing operations.

For example, the ROM 102 to be the storing means prestores a plurality of sewing data (embroidery data) on various embroidery patterns (seam shapes) for operating the needle bar 8a (the needle 8) and the holding frame 11 in order to form various seams on the cloth. For the sewing data, coordinates of a shape point indicative of a seam shape (shape point data) and coordinates of a stitch point which are obtained by a calculation based on the shape point (stitch point data) are stored as coordinate data on a stitch point related to a position of the needle 8 with respect to the holding frame 11 (a coordinate point). Moreover, moving amount data related to a moving amount in a relative movement of the holding frame 11 with respect to the needle 8 are stored in order to dispose the needle 8 in the position of the coordinate data.

The RAM 103 is provided with various work memories and counters, and is used as a work area during a processing of input data or a sewing operation.

The EEPROM 104 stores various data, for example, new sewing data created based on the sewing data stored in the ROM 102 and new sewing data set through the operation panel 20 by the operator.

The sewing data to be stored in the EEPROM 104 are related to an embroidery pattern disposed in a stitching region displayed on the display region 22a, for example, and include embroidery pattern data corresponding to an embroidery pattern created by the control portion 100 (embroidery pattern creating means) for a stitching region set by the control portion 100 (stitching region setting means).

In other words, the embroidery pattern data correspond to an embroidery pattern obtained by enlarging or reducing an embroidery pattern corresponding to the sewing data stored in the ROM 102 corresponding to a stitching region set to the display region 22a of the operation panel 20.

The control portion 100 processes a driving signal input from an X-axis origin sensor (not shown) provided in the X-axis motor 14, a Y-axis origin sensor (not shown) provided in the Y-axis motor 15 or the key matrix 16, various set data input from the operation panel 20 and various data stored in the ROM 102 and the EEPROM 104 in accordance with various control programs for the embroidery machine which are stored in the ROM 102, and executes a control of each motor, the operation panel 20 or the other actuators.

The control portion 100 executes a processing of control means for reading the sewing data stored in the ROM 102 or the EEPROM 104 to start the driving operation of the sewing machine motor 5 and to drive the X-axis motor 14 and the Y-axis motor 15 in order to obtain a stitch point indicated by the sewing data, thereby positioning the holding frame 11 at the needle 8 (the needle bar 8a) when the CPU 101 executes a certain control program in the execution of a sewing work. In other words, the control portion 100 executes a sewing control for continuously carrying out a processing of controlling an operation of each portion in the sewing machine till the completion of the sewing work in order to sequentially position the holding frame 11 into a plurality of stitch points, thereby locating the needle 8 based on the coordinate data on the seam shape set as the sewing data synchronously with a rotation of the sewing machine motor 5, and thus forming the embroidery pattern on the cloth.

Moreover, the control portion 100 functions as the stitching region setting means for setting a stitching region in which a desirable embroidery pattern is formed corresponding to the position of the cloth which is indicated by the projector 30.

More specifically, the control portion 100, as the stitching region setting means, executes a control for determining, as stitching region locating points, two points corresponding to light spots on the cloth indicated by a light irradiated from the projector 30, thereby setting a rectangular range in which a virtual line connecting the two points is a diagonal line as a stitching region in which a desirable embroidery pattern is formed.

In other words, the operator can indicate, with a light spot on the cloth, a desirable position on the cloth held in the holding frame 11 by touching the arrow keys 211 of the stitching region setting portion 21d in the operation panel 20 and moving the holding frame 11 holding the cloth therein to move the light spot relatively. Therefore, upon touching the determination key 212 to determine a position on the cloth at which the light spot of the light irradiated from the projector 30 as a stitching region locating point, it is possible to acquire the coordinates of two points indicated by the light spot respectively, thereby setting a stitching region.

The control portion 100 also functions as the embroidery pattern creating means for creating embroidery pattern data in such a manner that an embroidery pattern based on the sewing data stored in the ROM 102 has such a size as to be held in the stitching region corresponding to a position or a size of the stitching region set by the control portion 100 as the stitching region setting means.

More specifically, the control portion 100, as the embroidery pattern creating means, executes a control for acquiring a dimension of a rectangle to be the set stitching region through a calculation based on coordinates of the point obtained as the stitching region locating point to be the position in which the light spot of the light irradiated by the projector 30 indicates the cloth or a moving amount of the holding frame 11, enlarging and reducing the embroidery pattern in such a manner that the embroidery pattern is held in the stitching region, and creating embroidery pattern data obtained by regulating coordinate data on the stitch point in the sewing data on the embroidery pattern corresponding to the enlargement or the reduction.

The control portion 100, as the embroidery pattern creating means, creates the embroidery pattern data so as to have such a size that ends of the embroidery pattern in a longitudinal direction thereof contact the stitching region without changing an aspect ratio of the embroidery pattern.

The control portion 100 also functions as sewing control means for controlling the operation of each portion in the sewing machine based on the embroidery pattern data created by the control portion 100 as the embroidery pattern creating means, thereby executing a sewing work for an embroidery pattern having a size changed depending on a set stitching region in a position to which the stitching region on the cloth held in the holding frame 11 corresponds.

Next, a processing operation to be executed when setting a stitching region within a desirable range on the cloth held in the holding frame 11 and forming, on the cloth, an embroidery pattern having a size depending on the stitching region in the sewing machine M according to the exemplary embodiment will be described with reference to a flowchart shown in FIG. 5.

First of all, a cloth is set into the holding frame 11 of the sewing machine M. The holding frame 11 stands by at an origin position. In the exemplary embodiment, it is assumed that two embroideries are formed on the cloth set onto the holding frame 11.

When the control portion 100 detects that the operator touches the pattern selecting key 21c of the operation panel 20 (see FIG. 3), an embroidery data screen 210 for selecting data on a desirable embroidery pattern from the sewing data on a plurality of embroidery patterns stored in the ROM 102 is displayed on the display screen of the operation panel 20 as shown in FIG. 4. Embroidery data selection keys 210a related to embroidery patterns of six shapes including a star, a circle, a square, a triangle, a crescent and an ellipse respectively are displayed on the embroidery data screen 210. When a pattern switching key 210c of the embroidery data screen 210 is touched, the embroidery data selection keys 210a corresponding to embroidery patterns other than the six types is displayed.

When one of the embroidery data selection keys 210a of the embroidery data screen 210 (e.g., the embroidery data selection key 210a corresponding to an ellipse) is touched by the operator to select a desirable embroidery pattern, and a pattern enter key 210b is touched to decide the selection, the control portion 100 displays a shape of the selected embroidery pattern (the ellipse shape) on the display region 22a in the operation panel 20 as shown in FIG. 6 (Step S101).

When the control portion 100 detects that the operator touches the arrow keys 211 of the stitching region setting portion 21d in the operation panel 20 in order to set a stitching region to be a range in which the selected sewing pattern is to be sewn (Step S102), subsequently, the projector 30 is turned on and the X-axis motor 14 and the Y-axis motor 15 are driven corresponding to the operation from the arrow keys 211 so that the holding frame 11 is moved to change the relative positions of the light spot of the light irradiated from the projector 30 with the cloth held in the holding frame 11 (Step S103). As described above, the projector 30 which is turned on irradiates the light toward a position on the cloth corresponding to the stitch point of the needle 8, and the operator manipulates the arrow keys 211 in such a manner that the desirable position of the cloth is moved to the irradiating point of the projector 30.

When the point enter key 212 of the stitching region setting portion 21d is touched (Step S104: Yes), the control portion 100 registers a point indicated with the light spot by the projector 30 at that time as a stitching region locating point (Step S105).

On the other hand, when the point enter key 212 is not touched (Step S104; No), the processing returns to Step S102.

Next, the control portion 100 decides whether two stitching region locating points are registered or not (Step S106).

When the two stitching region locating points are registered (Step S106; Yes), the processing proceeds to Step S107.

On the other hand, the two stitching region locating points are not registered (Step S106; No), the processing returns to Step S102.

Specific description will be given to Steps S102 to S106.

For example, as shown in FIGS. 7A and 7B, when the embroidery pattern of the ellipse shape is selected in a state in which the cloth having two embroideries N formed thereon is set onto the holding frame 11 of the sewing machine M, the embroidery pattern of the ellipse shape is displayed on the display region 22a of the operation panel 20. In this state, the operator touches the arrow keys 211 of the stitching region setting portion 21d to move the position of the cloth with respect to a light spot S irradiated from the projector 30, thereby causing a desirable cloth position which does not overlap with the existing embroideries N to be coincident with the light spot S.

At this time, a point P corresponding to the position of the light spot S, that is, a needle position is also moved over the screen in the display region 22a with the movement of the holding frame 11.

When the point enter key 212 of the stitching region setting portion 21d is touched, a point indicated with the light spot S by the projector 30 at that time is registered as a stitching region locating point to be a start point of a stitching region A and the point P displayed on the display region 22a is fixed as a first point P1 onto the screen.

In the same manner, subsequently, the operator touches the arrow keys 211 to move the cloth position with respect to the light spot S so as to cause another desirable cloth position which does not overlap with the existing embroidery N to be coincident with the light spot S, and furthermore, touches the point enter key 212 so that a point indicated with the light spot S is registered as a stitching region locating point to be an end point of the stitching region A and the point P displayed on the display region 22a is fixed as a second point P2 onto the screen as shown in FIGS. 8A and 8B.

A rectangular range in which a virtual line connecting two points of the first point P1 and the second point P2 is a diagonal line serves as the stitching region A. Therefore, it is preferable to ascertain whether the existing embroidery N enters the range, thereby registering the stitching region locating point.

At Step S107, the rectangular range in which the virtual line connecting two points of the stitching region locating points is the diagonal line is set as the stitching region A based on coordinates of the two points (P1, P2) registered as the stitching region locating points, driving amounts of the X-axis motor 14 and the Y-axis motor 15 which move the holding frame 11 when each stitching region locating point is registered, and a moving amount of the holding frame 11 (Step S107).

Then, the control portion 100 calculates a length ΔX of the stitching region A in the right-and-left direction and a length ΔY the stitching region A in the front-and-rear direction, respectively.

In Step S107, the control portion 100 calculates a distance from the origin position of the holding frame 11 to a center of the stitching region A in order to decide where to start the stitching. A distance RX from the origin position of the holding frame 11 to the center of the stitching region A in the right-and-left direction is calculated as RX=LX+ΔX/2 wherein LX is a distance from the origin position to the first point P1 in the right-and-left direction, while a distance RY from the origin position to the center of the stitching region A in the front-and-rear direction is calculated as RY=LY+ΔY/2 wherein LY is a distance from the origin position to the first point P1 in the front-and-rear direction.

Subsequently, sewing data on the selected embroidery pattern (the embroidery pattern of the ellipse shape) are read from the ROM 102 and a maximum dimension in the right-and-left direction (i.e., in the X-axis direction) and a maximum dimension in the front-and-rear direction (i.e., in the Y-axis direction) of the embroidery pattern are acquired based on the sewing data (Step S108). The respective maximum dimensions Mx, MY of the embroidery pattern are stored in the ROM 102 corresponding to the sewing data on the embroidery pattern every embroidery pattern.

ΔX/MX and ΔY/MY are calculated to compare a size (ΔX, ΔY) of the set stitching region A with a size (MX, MY) of the selected embroidery pattern (Step S109).

If a decision of ΔX/MX=1 and ΔY/MY=1 is made (Step S110; Yes), the processing proceeds to Step S112.

If a decision of ΔX/MX>1 and ΔY/MY>1 is made (Step S111; Yes), moreover, the processing proceeds to Step S113.

If a decision of ΔX/MX<1 or ΔY/MY<1 is made (Step S111; No), furthermore, the processing proceeds to Step S114.

In Step S112, the control portion 100 does not change the size of the embroidery pattern but creates embroidery pattern data obtained by coordinating and changing the sewing data in such a manner that the embroidery pattern is disposed in the center of the stitching region A (Step S112) and stores the embroidery pattern data in the EEPROM 104 (Step S115).

In Step S113, the control portion 100 creates the embroidery pattern data obtained by coordinating and changing the sewing data on the embroidery pattern in order to increase the size of the embroidery pattern (Step S113) and stores the embroidery pattern data in the EEPROM 104 (Step S115).

In other words, if ΔX/MX>1 and ΔY/MY>1 are set, the size of the stitching region A is larger than that of the embroidery pattern. Therefore, the enlarged embroidery pattern is disposed in the center of the stitching region A and the size of the embroidery pattern is increased to be held in the stitching region A.

More specifically, the size of the embroidery pattern is increased in a magnification of a smaller one of the values of ΔX/MX and ΔY/MY which are calculated in Step S109. For example, if ΔX/MX=1.2 and ΔY/MY=1.1 are set (see FIG. 9), there is carried out a processing of multiplying the size of the embroidery pattern by 1.1 in the X-axis and Y-axis directions and the enlarged embroidery pattern is disposed in the center of the stitching region A, and embroidery pattern data are created to be held in the stitching region A.

If the size of the embroidery pattern is multiplied by 1.2 in the X-axis and Y-axis directions, there is a drawback that the embroidery gets out of the stitching region A in the Y-axis direction.

In Step S114, the control portion 100 creates the embroidery pattern data obtained by coordinating and changing the sewing data on an embroidery pattern in order to reduce a size of the embroidery pattern (Step S114) and stores the embroidery pattern data in the EEPROM 104 (Step S115).

In other words, if ΔX/MX<1 or ΔY/MY<1 is set, the size of the stitching region A is smaller than that of the embroidery pattern. Therefore, the reduced embroidery pattern is disposed in the center of the stitching region A and the size of the embroidery pattern is reduced to be held in the stitching region A.

More specifically, the size of the embroidery pattern is increased in a magnification of a smaller one of the values of ΔX/MX and ΔY/MY which are calculated in Step S109. For example, if ΔX=X 0.8 and ΔY/MY=0.7 are set (see FIG. 10), there is carried out a processing of multiplying the size of the embroidery pattern by 0.7 in the X-axis and Y axis directions and the reduced embroidery pattern is disposed in the center of the stitching region A, and embroidery pattern data are created to be held in the stitching region A.

If the size of the embroidery pattern is multiplied by 0.8 in the X-axis and Y-axis directions, there is a drawback that a reduction ratio is insufficient and the embroidery gets out of the stitching region A in the Y-axis direction.

As shown in FIG. 11, subsequently, an embroidery shape related to the embroidery pattern data created corresponding to the position or size of the set stitching region A is converted into display data, and the display data are displayed on the display region 22a of the operation panel 20 (Step S116).

Upon pressing the sewing start switch 16a in the sewing machine M, the respective portions such as the sewing machine motor 5 and the X-axis and Y-axis motors 14 and 15 to be the pulse motors are operated. Consequently, stitches for the embroidery pattern depending on the created embroidery pattern-data are formed within a range corresponding to the stitching region A of the cloth held in the holding frame 11 (Step S117), and the sewing machine M ends the series of sewing processing.

In the sewing machine M according to the exemplary embodiment of the invention, thus, the projector 30 (the indicating means, the indicator) irradiates a light toward the cloth held in the holding frame 11 to indicate an optional position on the cloth through the light spot of the light irradiated from the projector 30. Consequently, it is possible to set a stitching region in which a desirable embroidery is to be formed.

Depending on the position or size of the set stitching region, the embroidery pattern data for sewing the embroidery pattern having such a size as to be held in the stitching region are created. Based on the embroidery pattern data, therefore, it is possible to easily form a sewing pattern having a desirable size in a stitching region to be a desirable range.

In other words, the sewing machine M can set a stitching region within a desirable range to keep away from an existing embroidery or emblem also in a cloth having the embroidery or emblem applied thereto. Based on the sewing data which are prestored in the ROM 102, moreover, it is possible to create embroidery pattern data on an embroidery pattern corresponding to the set stitching region. Consequently, it is possible to form an embroidery pattern at an optional place on the cloth with an optional size.

Accordingly, it is apparent that the sewing machine M can suitably form an embroidery pattern having a size regulated corresponding to a desirable stitching region.

Moreover, it is possible to display the point P corresponding to the position in which the projector 30 (the indicating means, the indicator) indicates the workpiece W on the display region 22a of the liquid crystal display 22 (the display means) and to display the set stitching region A and the embroidery pattern created corresponding to the stitching region A on the display region 22a of the liquid crystal display 22 (the display means). Therefore, the operator can confirm the position of the workpiece W at which the projector 30 (the indicating means, the indicator) indicates and the set stitching region A and embroidery pattern from the display of the liquid crystal display 22 (the display means).

Accordingly, the operator can set the stitching region A and create the embroidery pattern data more easily and efficiently.

While the description has been given by taking the projector 30 as an example of the indicating means (the indicator) in the exemplary embodiment, the invention is not restricted thereto but the needle 8 provided on the needle bar 8 may serve as the indicating means (the indicator) to indicate the cloth held in the holding frame 11 with a tip portion (a lower end) of the needle 8, thereby inputting a point and setting a stitching region, for instance. In such a case, it is possible to set the stitching region without requiring an additional component.

While description has been made in connection with exemplary embodiments of the present invention, those skilled in the art will understand that various changes and modification may be made therein without departing from the present invention. It is aimed, therefore, to cover in the appended claims all such changes and modifications falling within the true spirit and scope of the present invention.

Claims

1. A sewing machine comprising:

a needle movable in a vertical direction;

a holding frame operable to hold a workpiece and movable in a horizontal direction, the holding frame having a stitchable area within which the needle is operable to perform stitching;

storing means for storing sewing data on various embroidery patterns;

indicating means for indicating, within the stitchable area, a plurality of positions on the workpiece that is held by the holding frame;

stitching region setting means for setting a stitching region in accordance with the plurality of positions indicated by the indicating means;

embroidery pattern creating means for creating, in accordance with a position and a size of the stitching region set by the stitching region setting means, and based on the sewing data stored in the storing means, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region; and

control means for controlling, in accordance with the embroidery pattern data created by the embroidery pattern creating means, the needle and the holding frame to form the embroidery pattern on the workpiece within the stitching region.

2. The sewing machine according to claim 1, further comprising display means having a display region corresponding to the stitchable area of the cloth holding frame,

wherein the display means is operable to display, on the display region, at least one of a point corresponding to one of the positions on the workpiece indicated by the indicating means, the stitching region set by the stitching region setting means, and the embroidery pattern corresponding to the embroidery pattern data created by the embroidery pattern creating means.

3. The sewing machine according to claim 1, wherein the indicating means comprises a light source from which a light is irradiated toward a point right below the needle.

4. A sewing machine comprising:

a needle movable in a vertical direction;

a holding frame operable to hold a workpiece and movable in a horizontal direction, the holding frame having a stitchable area within which the needle is operable to perform stitching;

storing means for storing sewing data on various embroidery patterns;

stitching region setting means for moving the workpiece to designate a plurality of positions on the workpiece, which are moved to a point right below the needle, and for setting a stitching region in accordance with the plurality of positions designated;

embroidery pattern creating means for creating, in accordance with a position and a size of the stitching region set by the stitching region setting means, and based on the sewing data stored in the storing means, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region; and

control means for controlling, in accordance with the embroidery pattern data created by the embroidery pattern creating means, the needle and the holding frame to form the embroidery pattern on the workpiece within the stitching region.

5. The sewing machine according to claim 4, further comprising display means having a display region corresponding to the stitchable area of the cloth holding frame,

wherein the display means is operable to display, on the display region, at least one of a point corresponding to one of the positions designated by the stitching region setting means, the stitching region set by the stitching region setting means, and the embroidery pattern corresponding to the embroidery pattern data created by the embroidery pattern creating means.

6. A sewing machine comprising:

a needle;

a sewing machine motor operable to move the needle in the vertical direction;

a holding frame operable to hold a workpiece, the holding frame having a stitchable area within which the needle is operable to perform stitching;

a sewing machine frame having a bed portion on which the holding frame is disposed;

a pulse motor coupled to the holding frame to move the holding frame in a horizontal direction;

a memory in which sewing data on various embroidery patterns are stored;

an indicator operable to visually indicate, on the workpiece, a point right below the needle;

a movement instructing portion operable to instruct the pulse motor to move the cloth holding frame upon manually operating the movement instructing portion, the movement instructing portion being disposed on the sewing machine frame;

a designating portion operable to designate positions of the cloth holding frame corresponding to at least two points on the workpiece indicated by the indicator upon manually operating the designating portion, the designating portion being disposed on the sewing machine frame;

a control portion operable to calculate and set a stitching region in accordance with the positions designated by the designating portion, and to create, in accordance with a position of the stitching region within the stitchable area and a size of the stitching region, and based on the sewing data stored in the memory, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region; and

control means for controlling, in accordance with the embroidery pattern data, the sewing machine motor and the pulse motor to form the embroidery pattern on the workpiece within the stitching region.

7. The sewing machine according to claim 6, further comprising a display having a display region corresponding to the stitchable area of the cloth holding frame,

wherein the display is operable to display, on the display region, at least one of a point corresponding to one of the positions designated by the designating portion, the stitching region, and the embroidery pattern corresponding to the embroidery pattern data.

8. The sewing machine according to claim 6, wherein the indicator comprises a light source from which a light is irradiated toward the point right below the needle, and wherein the movement instructing portion relatively moves the cloth holding frame with respect to the point toward which the light is irradiated from the light source upon manually operating the movement instructing portion.

9. A sewing machine comprising:

a needle;

a sewing machine motor operable to move the needle in the vertical direction;

a holding frame operable to hold a workpiece, the holding frame having a stitchable area within which the needle is operable to perform stitching;

a sewing machine frame having a bed portion on which the holding frame is disposed;

a pulse motor coupled to the holding frame to move the holding frame in a horizontal direction;

a memory in which sewing data on various embroidery patterns are stored;

a movement instructing portion operable to instruct the pulse motor to move a portion of the workpiece, which is held the cloth holding frame, to a point right below the needle upon operating the movement instructing portion, the movement instructing portion being disposed on the sewing machine frame;

a designating portion operable to designate positions of at least two portions of the workpiece, which are moved to the point right below the needle by the movement instructing portion, upon operating the designating portion, the designating portion being disposed on the sewing machine frame;

a control portion operable to calculate and set a stitching region in accordance with the positions designated by the designating portion, and to create, in accordance with a position of the stitching region within the stitchable area and a size of the stitching region, and based on the sewing data stored in the memory, embroidery pattern data on an embroidery pattern having a size that is fittable within the stitching region; and

control means for controlling, in accordance with the embroidery pattern data, the sewing machine motor and the pulse motor to form the embroidery pattern on the workpiece within the stitching region.

10. The sewing machine according to claim 9, further comprising a display having a display region corresponding to the stitchable area of the cloth holding frame,

wherein the display is operable to display, on the display region, at least one of a point corresponding to one of the positions designated by the designating portion, the stitching region, and the embroidery pattern corresponding to the embroidery pattern data.