PERFORATED STITCHING METHOD AND APPARATUS

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates to a method, apparatus, and computer-readable medium for stitching. The present disclosure relates more particularly to a method, apparatus, and computer-readable medium for stitching perforated material and creating perforated material.

Description of Related Art

Sewing and quilting machines a devices used to stitch fabric together with precision and speed. These machines typically consist of a needle, thread, bobbin, and moto, which work together to create various stitches. In a sewing machine, the fabric is fed through the machine by a set of feed dogs, while the needle moves up and down, interlocking thread from the spool with thread from the bobbin to create a stitch.

Quilting machines are designed with larger workspaces than sewing machines to accommodate the layers of fabric, batting, and backing found in most quilts. Both types of machines can produce a range of stitches, from simple straight lines to decorative designs. Many modern models are computerized, allowing for automated patterns, stitch selection, and precise control over tension and stitch length. Sewing and quilting machines come in various sizes, from compact models to large professional-grade machines for experienced quilters.

BRIEF SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present disclosure to provide a method, apparatus, and computer-readable medium for quilting.

A first exemplary embodiment of the present disclosure provides a method for stitching. The method includes creating, by a perforation machine, a plurality of perforations in a work piece, creating, by the perforation machine, a plurality of target perforations in the work piece, and identifying, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head. The method further includes determining, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations, moving the work piece based on the determined location of the sewing head with respect to the plurality of perforations, and stitching, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

A second exemplary embodiment of the present disclosure provides for an apparatus for stitching. The apparatus includes a sewing head including a reciprocating needle, a camera affixed to the sewing head, a motor operable to move the sewing head with respect to a work piece, a memory including computer program instructions, and a processor, wherein the sewing head including the reciprocating needle, the memory, and the processor are configured to cause the apparatus to identify, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head. The apparatus is further caused to determine, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations, move the work piece based on the determined location of the sewing head with respect to the plurality of perforations, and stitch, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

A third exemplary embodiment of the present disclosure provides for a method of stitching. The method includes identifying, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head. The method further includes determining, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations, moving the sewing head based on the determined location of the sewing head with respect to the plurality of perforations, and stitching, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

A fourth exemplary embodiment of the present disclosure provides a non-transitory computer-readable medium tangibly comprising computer program instructions which when executed on a processor of an apparatus causes the apparatus to at least create, by a perforation machine, a plurality of perforations in a work piece, create, by the perforation machine, a plurality of target perforations in the work piece, identify, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head, determine, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations, move the work piece based on the determined location of the sewing head with respect to the plurality of perforations, and stitch, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

A fifth exemplary embodiment of the present disclosure provides a non-transitory computer-readable medium tangibly comprising computer program instructions which when executed on a processor of an apparatus causes the apparatus to at least identify, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head, determine, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations, move the work piece based on the determined location of the sewing head with respect to the plurality of perforations, and stitch, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

The following will describe embodiments of the present disclosure, but it should be appreciated that the present disclosure is not limited to the described embodiments and various modifications of the invention are possible without departing from the basic principle. The scope of the present disclosure is therefore to be determined solely by the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a top view of a work piece suitable for use in practicing exemplary embodiments of this disclosure.

FIG. 2 is a perspective view of a perforating device suitable for use in practicing exemplary embodiments of this disclosure.

FIG. 3 is a perspective view of a device suitable for use in practicing exemplary embodiments of this disclosure.

FIG. 4 is a top view of a work piece suitable for use in practicing exemplary embodiments of this disclosure.

FIG. 5 is a perspective view of a sewing head suitable for use in practicing exemplary embodiments of this disclosure.

FIG. 6 is a logic flow diagram in accordance with a method, apparatus, and computer-readable medium for performing exemplary embodiments of this disclosure.

FIG. 7 is a logic flow diagram in accordance with a method, apparatus, and computer-readable medium for performing exemplary embodiments of this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

It is often desirable for functional or esthetic reasons for a work piece to include perforations and stitching that is evenly spaced around, through, and/or adjacent to some or all of the perforations. For example, perforations are commonly used on materials that cover car seats in order to provide ventilation or air flow to the user of the seat. Ventilated seats are typically more expensive to manufacture, which makes them less accessible for lower priced automobiles. Ventilated seats require careful engineering to ensure that the perforations in the seat material allow for air to circulate through the seat while maintaining comfort and durability for the user. As car technologies continue to advance, it's important that ventilated seats become more affordable and accessible to the broader market. For example, the integration of smart features such as climate control in car seats may require the use ventilated seats. However, it is typically labor intensive to engineer material that is perforated because the stitching needs to be spaced evenly from the perforations such that the stitching is not closer to one set of adjacent perforations than another set of adjacent perforations. The spacing between the stitching and the perforations on a work piece (e.g., cloth, leather, vinyl, polyester, leather upholstery, faux leather, nylon, suede, leatherette, etc.) is desirable because the perforations often are created in a particular pattern or design. A perforated patten in a work piece can make the work piece appear to be of higher quality or premium to a user. Additionally, perforations provide small holes in the work piece that allow for air to flow more easily through the work piece, which can allow for the work piece to dissipate heat when in close proximity to a user. Stitching that does not align with the perforations or is not evenly spaced from the perforations visually disrupts the esthetically pleasing nature of the look of the perforations. The most common solution to avoid stitching that intersects the perforations or is not evenly spaced from the perforations is for the stitching to be done by hand. It is difficult to use a sewing machine or quilting machine to automatically stitch a work piece that has perforations and for the perforations to remain evenly spaced from the stitching because a work piece will stretch when it is stitched. The stretching of a work piece causes the relative location of the perforations to move from the original location relative to the sewing head when the stitching began. Accordingly, stitching by hand or attempting to stitch automatically can be both costly and time consuming.

Embodiments of the present disclosure provide a method, apparatus, and computer-readable medium that allows a work piece 100 to be perforated with a plurality of perforations 102 and then stitched automatically with a sewing head 110 such that the stitches 104 are evenly spaced from the plurality of perforations 102 or such that the stitching pattern aligns with the pattern of the perforations 102. For example, the perforations 102 may appear to be in a diamond shaped pattern (shown in FIG. 4), a zig-zag pattern (shown in FIG. 1), or a hexagon pattern (shown in FIG. 3). Embodiments provide that the stitching 104 can be in a similar pattern around the perforations 102. As shown in FIG. 4, the perforations 102 are located to form a diamond shape and the stitching 104 occurs between the perforated diamond pattern in a similar diamond shape. In FIG. 3, the perforations 102 are located to form a hexagon shape and the stitching 104 occurs around the perforated octagon pattern in a similar hexagon shape.

Embodiments of the present disclosure provide a sewing machine 116 (shown in FIG. 5) that includes a sewing head 110 that is moveable along a frame 118 with respect to a work piece 100. The work piece 100 is maintained in a stationary location while the sewing head 110 is operable to be moved by a motor 120 with respect to the work piece 100. In one embodiment, the work piece 100 is maintained in a stationary location while a perforation machine 108 is operable to be moved by a motor with respect to the work piece 100. In another embodiment, the perforation machine 108 is maintained in a stationary location while the work piece retention unit 114 is operable to be moved by a motor wither respect to the perforation machine 108. The perforation machine 108 includes a processor and a memory that is operable to maintain computer program instructions that when executed by the processor cause the perforation machine 108 to punch perforations 102 (i.e., holes) in the work piece 100 in accordance to the pattern that is in the computer program instructions.

FIG. 1 illustrates a top view of an exemplary work piece 100 that has perforations 102 that have been punched by the perforation machine 108. The perforation machine 108 is also operable to created target perforations 106 that located adjacent to the perforations 102 around which the stitching 104 will occur. The target perforations 106 are located along the edges of the perforated area on the work piece 100 and include five perforations 102 that arranged in a cross configuration.

It should be appreciated that embodiments of target perforations 106 include an X configuration, star configuration, diamond configuration, square or rectangular configuration, a letter of the alphabet (A, B, C, D, etc.), a number, roman numeral, symbol, logo, trademark, or any other small distinct design that can be located adjacent to the plurality of perforations 102 that will be stitched and that do not take up significant space on the work piece 100. Target perforations 106 include a collection of no more than 4-6 perforations 102. In one embodiment the target perforations 106 include 1-2 perforations 102. In another embodiment, the target perforations 106 include more than six (6) perforations 102. Embodiments of the target perforations 106 can generally located adjacent to the edge of the perforations 102 on which stitching will begin and adjacent to the opposite edge of the perforations 102 on which the stitching will end. In another embodiment, the target perforations 106 will be located along only the edge of the perforations 102 on which the stitching will begin.

FIG. 2 illustrates a work piece 100 and a perforation machine 108. The perforation machine 108 is operable to punch perforations 102 in the moveable work piece 100. The head 109 of the perforation machine 108 will remain stationary with respect to the work piece 100 while the work piece 100 moves. The perforation machine 108 will punch perforations 102 in the work piece 100 according to a predetermined pattern that is in the memory of the perforation machine 108. It should be appreciated that embodiments include the perforation machine 108 being operable to move and punch perforations 102 with respect to a stationary work piece 100.

Once the perforation machine 108 punches the plurality of perforations 102 in the work piece 100, the sewing head 110 (shown in FIGS. 3 and 5) which includes a reciprocating needle 122 (shown in FIG. 5) is operable to stitch stitches 104 in a work piece 100 that is moveable with respect to the stationary sewing head 110. It should be appreciated that embodiments include the sewing head 110 being operable to move with respect to the work piece 100 to stitch the work piece 100 around certain perforations 102.

In practice, the sewing head 110 will include a camera 112 or a camera 112 will be affixed to the sewing head 110. The camera 112 will take a photo of the target perforation 106 that is located along and spaced apart from the plurality of perforations 102. The processor 128 will then determine where the work piece 100 should move to such that the sewing head 110 can begin stitching 104 based on the location of the target perforation 106. In other words, the target perforation 106 is spaced from the location that stitching 102 will begin at a distance known to the processor. The memory 130 of the sewing head 110 will maintain computer program instructions 132 that include stitching instructions of where the reciprocating needle 122 should be dropped to create a stitch 104. The processor 128 will determine where to move the work piece 100 with respect to the sewing head 110 based on the photo of the target perforation 106 and where the computer program instructions 132 indicate that the plurality of perforations 102 are located (and thus where the stitches 104 should begin such that the stitches 104 are evenly spaced or evenly surround the perforations 102). In another embodiment, the processor 128 will determine where to move the work piece 100 based on the photo of the target perforation 106 and where the computer program instructions 132 indicate stitching 104 should begin because the computer program instructions indicate the location of stitches 104 with relation to the target perforations 106. The sewing head 110 will then stitch across the work piece 100 (e.g., from left to right, right to left, top to bottom, bottom to top, etc.) until the sewing head 110 reaches the edge of the area of the work piece 100 that it is programmed to stitch. The sewing head 110 with the camera 112 will then take a photo of the target perforation 106 that is located along the side on which it stopped stitching and will perform the process again by taking a photo of the target perforation 106 and then moving the sewing head 110 based on the photo so that it can begin stitching again. In another embodiment, the sewing head 110 may return to the same side or portion of the work piece 100 in which it began stitching and will take a photo of a different target perforation 106 to determine the location to begin stitching again based on the location of the target perforation 106 from the photo.

When the sewing head 110 creates stitches 104 in a given area of work piece 100, the length and width of the work piece 100 stretches, shrinks, moves or shifts because the stitches 104 have created areas of the work piece 100 that are tighter than other areas of the work piece 100. In other words, portions of a work piece 100 may shrink, stretch and/or bulge and therefore move when the work piece 100 is stitched relative to the location prior to the stitching. This means that the location of particular perforations 102 move from their original location with respect to other perforations 102 when the work piece 100 is stitched. The more stitching 104 that occurs in a given work piece 100, the more that the work piece 100 shrinks, stretches and/or bulges and the perforations 102 move from their original location. The computer program instructions account for the movement of the work piece 100 as the sewing head 110 stitches, e.g., a given row of a work piece 100, by locating a target perforation 106 and will determine the location of where stitching 104 should begin such that the stitching 104 is evenly spaced from and aligns with the perforations 102.

The target perforations 106 are located at “known” locations with respect to where stitching 104 at a given edge of the plurality of perforations 102 should begin. In other words, the relative location of the target perforations 106 with respect to nearest or adjacent perforations 102 is a fixed amount or distance that is programmed or predetermined into the computer program instructions 132. In another embodiment, the relative location of the target perforations 106 with respect to nearest or adjacent perforations 102 is determined prior to the stitching being performed by the user inputting the location of the target perforations 106 into the computer program instructions 132 or camera 112 taking images of the target perforations 106 and the adjacent perforations 102 and the processor 128 determining the distance between the target perforations 106 and the adjacent perforations 102 based on the image. In one embodiment the process would include identifying, by the camera 112, one of the plurality of target perforations 106 in the work piece 100. The process further includes determining, by the processor 128, a location of the sewing head 110 with respect to the plurality of perforations 102 located adjacent to the one of the plurality of target perforations 106, moving the sewing head 110 based on the determined location of the sewing head 110 with respect to the plurality of perforations 102, and stitching, by the sewing head 110, stitches 104 adjacent to a set of the plurality of perforations 102 in the work piece 100, the set of the plurality of perforations 102 being located adjacent to the one of the plurality of target perforations 106.

Since the target perforations 106 are part of the work piece 100, as the work piece 100 is stitched, the target perforations 106 will move in a similar manner to that of other unstitched perforations. Accordingly, determining the location and movement of the target perforations 106 will indicate how other perforations 102 that do not have stitching 104 around them or near them will have moved. The processor will then cause the motor to move the work piece 100 with respect to the sewing head 110 to accommodate for the movement of the perforations 102 and work piece 100 and will then have the sewing head 110 stitch adjacent to a given set of the perforations 102.

The sewing head 110 is attached is a main frame 118 that is coupled to support frame 119. Main frame 118 includes a combination of legs, struts, and support bars to maintain a position of support frame and sewing machine 116 above a floor or opposing surface. Support frame 119 provides a workpiece retention area that retains the work piece 100 or a portion of work piece 100 relative to main frame 118 and relative to sewing machine 116.

Sewing head 110 includes a portion above the plane of the work piece retention area and a second portion below the plane of the workpiece retention area, thereby providing for passage of a portion of reciprocating needle 122 through work piece 100 and selectively engaging the passage of a length of thread through work piece 100. Exemplary embodiments of sewing head 110 are configured to operably move and stitch through the plane of the workpiece retention area through the use of a plurality of wheels, gears, rails slides 124, or combinations thereof.

A controller is operably connected to the sewing head 110. The controller can include a processor, a display and input, such as a touch screen, keyboard, keypad, and/or mouse 126. The controller can be physically connected to the main frame 119 or the sewing machine 116. Alternatively, the controller can be a stand-alone device, which communicates with the sewing machine 116 through a wired or wireless connection.

A motor is operably connected to and communicates with the controller. The motor controls the up and down speed of reciprocating needle 122 and movement of sewing head 110 relative to workpiece retention area. In some embodiments, the motor includes one or more motors each operable to move a different element or multiple elements of sewing machine 116. For instance, motor may include one motor operable to control the reciprocating needle 122 and a second motor operable to control an X and Y axis movement of the workpiece retention unit. In another embodiment, the motor includes one motor operable to control reciprocating needle 122, a second motor operable to control an X-axis movement of the work piece 100, and a third motor operable to control an Y-axis movement of the work piece.

FIG. 6 presents a logic flow diagram for performing aspects of the present disclosure. Block 600 states (a) creating, by a perforation machine, a plurality of perforations in a work piece; (b) creating, by the perforation machine, a plurality of target perforations in the work piece; (c) identifying, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head; (d) determining, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations; (e) moving the work piece based on the determined location of the sewing head with respect to the plurality of perforations; and (f) stitching, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations.

Some of the non-limiting implementations detailed above are also summarized in FIG. 6 following block 600. Block 602 indicates wherein the plurality of perforations are based on a predetermined pattern stored in the memory. Block 604 states wherein the plurality of target perforations are located spaced apart from the plurality of perforations. Block 606 relates to wherein the plurality of target perforations are located on the work piece such that they are spaced from outside edge of the plurality of perforations. Block 608 states wherein the sewing head with the camera is operable to move with respect to the work piece. Next block 610 states wherein the processor is operably connected to a memory storing data having (i) location information of the plurality of perforations and (ii) location information of stitches to be added adjacent to the plurality of perforations. Block 612 recites wherein the stitches are located adjacent to only the set of plurality of perforations. Block 614 indicates identifying, by the camera, a second one of the plurality of target perforations in the work piece after completing stitching adjacent to the set of the plurality of perforations in the work piece, determining, by the processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the second one of the plurality of target perforations; moving a location of the work piece to stitch a second set of the plurality of perforations based on the determined location of the sewing head with respect to the plurality of perforations located adjacent to the second one of the plurality of target perforations; and stitching, by the sewing head, stitches adjacent to the second set of the plurality of perforations in the work piece, the second set of the plurality of perforations being located adjacent to the second one of the plurality of target perforations.

Reference is now made to FIG. 7 which illustrates another logic flow diagram for performing aspects of this disclosure. Block 700 states identify, by a camera, one of the plurality of target perforations in the work piece, wherein the camera is affixed to a sewing head; determine, by a processor, a location of the sewing head with respect to the plurality of perforations located adjacent to the one of the plurality of target perforations; move the work piece based on the determined location of the sewing head with respect to the plurality of perforations; and stitch, by the sewing head, stitches adjacent to a set of the plurality of perforations in the work piece, the set of the plurality of perforations being located adjacent to the one of the plurality of target perforations. Block 702 indicates wherein the plurality of perforations are based on a predetermined pattern stored in the memory. Block 704 recites wherein the plurality of target perforations are located spaced apart from the plurality of perforations. Block 706 states wherein the plurality of target perforations are located on the work piece such that they are spaced from outside edge of the plurality of perforations. Block 708 states wherein the sewing head with the camera is operable to move with respect to the work piece. Block 710 states wherein the processor is operably connected to a memory storing data having (i) location information of the plurality of perforations and (ii) location information of stitches to be added adjacent to the plurality of perforations. Block 712 states wherein the stitches are located adjacent to only the set of plurality of perforations.

The logic diagrams of FIGS. 6 and 7 may be considered to illustrate the operation of a method, a result of execution of computer program instructions stored in a computer-readable medium. The logic flow diagram of FIGS. 6 and 7 may also be considered a specific manner in which components of the device are configured to cause that device to operate, whether such a device is a sewing machine, quilting machine, perforation machine or some other device, or one or more components thereof. The various blocks shown in FIGS. 6 and 7 may also be considered as a plurality of coupled logic circuit elements constructed to carry out the associated function(s), or specific result of strings of computer program instructions or code stored in a memory.

Various embodiments of the computer-readable medium include any data storage technology type which is suitable to the local technical environment, including but not limited to semiconductor based memory devices, magnetic memory devices and systems, optical memory devices and systems, fixed memory, removable memory, disc memory, flash memory, dynamic random-access memory (DRAM), static random-access memory (SRAM), electronically erasable programmable read-only memory (EEPROM) and the like. Various embodiments of the processor include but are not limited to general purpose computers, special purpose computers, microprocessors, digital signal processors and multi-core processors.

The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.