Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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2AUTOMATIC QUILTING MACHINE FOR SPECIALIZED
3QUILTING OF PATTERN~ WHICH CAN BE CONTROLLED BY A
4REMOTE JOY STICK AND MONITORED ON A VIDEO SCREEN
6BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The field of the present invention relates to frame
quilting machines which are large table-like structures used
11 to sew patterns into large textile items; in particular
12 bedspreads and quilts. The field of the present invention
13 also relates to industrial sewing machine apparatus and
processes used to sew patterns and stitching into large
fabrics, which sewing operation is not easily performed on
16 conventional sewing machines
17
182. DESCRIPTION OF THE PRIOR ART
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21Industrial sewing machine operations are known in the
22 prior art. Patterns and stitching into fabrics is commonly
23 performed on industrial sewing machines. The operator hand
guides the fabric between the needle and the sewing machine
table and the pattern is sewn into the fabric. This process
is practical for small pieces of fabric and is commonly done
2267 on piéce goods such as garments. When handling larger pieces
of fabric such as a roll of fabric, a method known in the
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2 prior art is roll to roll sewing. The sewing machine head is
3 l~cated along an X-axis and the material is unwound from a
4 roll and caused to move transverse to the sewing machine head
such that the fabric moves along a Y-axis. The sewing machine
6 sews a stitch into the large fabric as the head moving along
7 the X-axis and the fabric moving along the Y-axis intersect
ô each other. The fabric is then wound onto a second receivin~
roll.
11 When sewing a very large piece of fabric such as a
bedspread or quilt, a frame quilting machine is used. The
123 frame quilting machine comprises a large frame, usually made
14 of metal, onto which the fabric to be sewn is spread.
Commonly, the pattern is sewn by a sewing machine guided by a
16 computer into which a predetermined pattern has been
17 programmed. The fabric remains stationary on the frame and
the sewing machine head moves along the fabric and stitches
18
29 in the predetermined pattern.
21 Sewing machines and various frame quilting apparatus and
22 processes have previously been patented. The following is
23 representative of the types of apparatus and processes which
24 have been patented:
26 1. United States Patent No. 4,188,893 issued to
27 Shimazaki in 1980 for "Device Of Detecting Cloth Feeding
28 Amount In Sewing Machines".
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3 2. United States Patent No. 3,377,968 issued to Story in
4 1968 for "Material Holding And Guide Attachment For Sewing
6 Machine".
7 3. United States Patent No. 4,429,364 issued to Maruyama
et al. in 1984 for "Sewing Machine-Pattern Data Processor".
4. United States Patent No. 1,958,893 issued to Kintner
11 et al. in 1934 for "Photosensitive Apparatus".
13 5. United States Patent No. 4,583,181 issued to Gerber
14 et al. in 1986 for "Fabric Flow Related System".
16 6. United States Patent No. 3,500,777 issued to Kalning
18 et al in 1970 for "Quilting Apparatus".
19 7. United States Patent No. 3,757,710 issued to Landoni
in 1973 for "Automatic Quilting Machine".
21 8. United States Patent No. 3,312,184 issued to Cash in
22 1967 for "Quilting Machine Of The Endless Guide Track Type".
23
9. United States Patent No. 4,526,116 issued to Mannel
226 in 1985 for "Method And Arrangement To Control An Automatic
28 Embroidery Machine".
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2 Patent No. 4,188,893 to Shimazaki discloses an apparatus
3 for test running a pattern by matting the X-Y grid on an
4 oscilloscope in order to test the pattern to be sure that the
proper pattern is run before actual cloth is used (and
6 wasted).
8 Patent No. 1,958,893 to Kintner et al. discloses the use
9 of a video camera in conjunction with a missile projecting
apparatus. The camera has a photosensitive eye for
11 regulating the activity of the apparatus, wherein the
12 position of the photo-sensitive eye and the projecting device
13 are so related that the missiles are projected in accordance
14 with the position of the target.
16 Patent No. 3,377,968 to Story illustrates a particular
17 type of guiding apparatus for holding material and guiding it
relative to the sewing machine.
Patent No. 3,500,777 to Xalning et al. illustrates what
21 is now the well known quilting machine with multiple sewing
22 heads.
23
2 Patent No. 3,312,184 to Cash illustrates a quilting
machine which allows independent movement of the quilt holder
26 in any direction. The machine is capable of sewing two or
27 three reproductions of the same sewing line into the same
2 guilt at the same time.
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3 Patent No. 4,526,116 to Mannel discloses an automatic
4 quilting machine wherein a video camera is used to pick up
certain patterns of a motif carrier and transmit them to the
6 sewing machine. Here, the pattern is automatic from a
8 predetermined pattern.
9 Patent No. 3,757,710 to Landoni discloses an automatic
quilting machine where the heads can be changed so that
certain patterns of stitching paths can be alternated with
12 one or more types of different patterns.
14 Patent No. 4,429,364 issued to Maruyama involves a
computer operated pattern input for a sewing machine.
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17 Patent No. 4,583,181 issued to Geber discloses a device
18 to assist an operator in dealing with flaws encountered
19 during the spreading of web material to be cut.
21 None of the known prior art apparatus including those
22 disclosed in the above patents enables an operator to
23 individually hand sew an individual pattern into a large
24 piece of fabric such as a bedspread or quilt while remaining
at a remote position from the fabric. In present day
26 operations, such hand sewn operations require the operator to
27 physically be above the quilting table, which can be almost
28 12 feet square, and hand sew the pattern into the fabric.
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1 This is a very expensive and time consuming process. The
3 only known apparatus for sewing patterns into the quilt is
4 disclosed in the Mannel patent wherein a video camera is used
to pick up certain patterns of a motif carrier and transmit
6 them to the sewing machine. Here, the pattern is automatic
7 from a predetermined pattern. More expensive and finer quilts
8 and bedspreads are those which have individual patterns sewn
9 into them and can be advertised as having "hand sewn"
individual patterns. Therefore, there is a significant need
for an apparatus and process which enables hand sewn
11 individual patterns to be sewn into large fabrics such as
12 quilts and bedspreads in an efficient manner where the worker
14 or workers do not have to be guided above the large laid out
7 brio and hand sew the patterns into the fabric.
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2 SUMMARY OF THE PRESENT INVENTION
4 The present invention relates to an automatic quilting
machine for use in stitching individual selected patterns
6 into a large fabric such as a bedspread or guilt. The
7 bedspread or quilt is stretched on a large metal frame which
is mounted on a table which can be moved in the X-direction,
8 the ~-direction, or any X-Y combination direction through an
automatic joy stick. The sewing machine head is mounted on a
11 cross beam which is aligned at the approximate center point
of the metal frame on which the fabric is stretched. The
12 needle of the sewing machine head can stitch a pattern into
13 any location in the fabric and the metal frame is moved in
any direction relative to the fixed sewing machine head in
order to bring the desired stitch location on the fabric into
17 alignment with the sewing machine head. The precise location
18 of the sewing machine needle and fabric is illuminated and a
19 color video camera which is mounted on the cross beam holding
the sewing machine head is also focused on this location. The
21 color video camera is connected to a television monitor so
22 that a visual image of the sewing machine needle and fabric
23 as a stitch is being made can be delivered to the monitor. A
machine operator can control the movement of the metal frame
24 through positioning by a remote joy stick and can see the
26 stitch being made by viewing the monitor. Therefore, instead
27 of being required to hang over the frame quilting machine to
28 observe the pattern being stitched, the operator can view the
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2 entire stitching process from a remote location be viewing
3 the stitch on the video monitor and can direct the movement
4 of the table relative to the fixed sewing machine head in
order to position the fabric for successive stitches while
6 remaining at a remote location from the frame quilting
8 machine.
9 In general, this is a frame quilting machine. A
bedspread, comforter, guilt, etc. is stretched securely on a
11 metal frame. It is placed on an X-Y positioning table for
12 movement controlled through a sewing machine. The sewing
13 machine has been modified and mounted on a steel frame (two
14 cross beams top and bottom) that can accommodate twelve feet
by twelve feet six inches of stitching dimensions. Of course
16 it can be made larger or smaller. The machine has been
17 engineered and built to satisfy increased production needs of
lô manufacturers who supply "custom, hand-guided, or outline
19 guilted patterns". The four key elements of the present
invention are: (a) sewing and auxiliary functions; (b) X-Y
21 movement of the table controlled by a remote joy stick; (c)
22 video camera and monitor; and (d) the electronic coordination
23 of movement and sewing speeds relative to direction and
224 distance of travel of the remote joy stick.
26 It has been discovered, according to the present
27 invention, that if a video camera connected to a television
28 monitor is focused on the location of the sewing needle and
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2 bedspread or quilt location where the needle is stitching the
3 thread into the bedspread or quilt, and the area is further
4 illuminated to provide a clear view, an operator can view the
entire stitching process from a remote location and does not
6 have to spend time consuming effort in positioning
7 himself over the frame quilting machine to determine the
position of the stitch.
It has further been discovered, according to the present
11 invention, that if a frame quilting machine can be moved
12 relative to a fixed sewing machine head in the X-direction,
13 the Y-direction or any X-Y combination direction by a remote
14 operating means such as a joy stick, and the frame quilting
machine comprises a metal table or frame on which a bedspread
16 or quilt is stretched such that the surface area of the
17 bedspread or quilt is open and unobstructed, and the metal
18 frame can move relative to and between a pair of cross beams
19 which hold a sewing machine head and plate, then an operator
can cause the bedspread or quilt to be precisely stitched in
21 any desired pattern by moving the metal frame or quilting
22 table relative to the fixed cross beams housing the sewing
23 machine components in any desired direction to arrive at any
24 desired location on the bedspread or frame where a stitch or
pattern is to be sewn. If the area of the sewing machine head
26 and stitch is further illuminated by a source of light and
27 visually displayed by a video camera fixed to one of the
28 cross beams and focused on the area of the sewing machine
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2 needle and bedspread or quilt, and the picture is
3 transmitted to a monitor, then an operator can be positioned
4 at a remote location and observe the precise formation of the
stitch and d.irection of the pattern being sewn into the
6 bedspread or quilt and can cause the quilting table to move
7 relative to the sewing machine head in order to bring any
8 desired location of the bedspread or quilt into alignment
9 with the sewing machine head so that any desired hand
selected pattern or individual pattern can be sewn into the
11 large bedspread or quilt in an efficient manner.
13 It has additionally been discovered, according to the
14 present invention, that if an operator can control the
movement of the frame table on which the fabric is stretched
16 and can see the precise location of the stitch being made in
17 the fabric from a remote location, the amount of training
18 time required to teach the operator to use the present system
19 is much less than the time used to teach an operator to sew
with the prior art frame quilting machines. In addltion, the
21 risk of injury to the operator is significantly reduced and
2223 the speed of production is significantly increased.
24 It is therefore an object of the present invention to
provide an apparatus by which an operator can remain at a
26 remote location from a large frame quilting machine and cause
27 a precise hand selected pattern to be sewn into the large
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2 bedspread, comforter, quilt, or other fabric which is held on
the metal frame or table of the frame quilting machine.
It is another object of the present invention to provide
6 an apparatus which enables frame quilting for specialized
7 hand selected patterns to be quickly and efficiently
8 performed with a minimum amount of training time of the9 operator.
It is a further object of the present invention to
11 provide an apparatus which can accommodate computerized
pattern quilting of a predetermined computer generated
13 patters and also accommodate specialized hand selected
patterns, or any combination thereof, in the same unit.
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17 It is an additional object of the present ir,vention to
increase the rate of production of hand guided patterns sewn
18 into large fabrics such as bedspreads or quilts.
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21 It is an additional object of the present invention to
22 enable a hand selected pattern to be sewn into a large fabric
23 such as a bedspread or comforter while an operator is
24 positioned at a distance remote from the moving parts of the
machine such as the frame table and sewing machine needle, to
26 thereby significantly reduce the risk of injury to an
28 operator.
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2 I Further novel features and other objects of the present
3 ¦ invention will become apparent from the following detailed
4 ¦ description, discussion and the appended claims, taken in
11 onjuncti~n with the drawings.
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2 DRAWING SUMMARY
4 Referring particularly to the drawings for the purpose
of illustration only and not limitation, there is
6 illustrated:
8 FIG. 1 is a perspective view of the present invention
9 automatic quilting machine for specialized quilting of
patterns which can be controlled by a remote joy stick and
11 monitored on a video screen.
FIG 2. is a block diagram of the components of the
13 electronic control components of the present invention
automatic quilting machine.
16
17 FIG. 3 is a top plan view of the main body of the
present invention automatic quilting machine.
18
FIG. 4 is a front elevational view of the present
21 invention automatic quilting machine.
22
23 FIG. 5 is an enlarged perspective view of the front
portion of the main support beam and attachments thereto.
26 FIG. 6 is an enlarged perspective view of the rear
27 portion of the main support beam and attachments thereto.
28
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2 DETAILED DESCRIPTION OF THE PREFERRED EMBODIME~T
4 Although specific embodiments of the invention will now
be described with reference to the drawings, it should be
6 understood that such embodiments are by way of example only
7 and merely illustrative of but a small number of the many
8 possible specific embodiments which can represent
9 applications of the principles of the invention. Various
changes and modifications obvious to one skilled in the art
to which the invention pertains are deemed to be within the
11
12 spirit, scope and contemplation of the invention as further
13 defined in the appended claims.
Referring to Figure 1, the main structural elements of
16 the present invention automatic quilting machine for
17 specialized quilting of patterns which can be controlled by a
18 remote joy stick and monitored on a video screen (hereinafter
19 referred to as "automatic quilting machine") will be
discussed first. The entire automatic quilting machine is
21 designated as 10. The main structural member of the automatic
22 guilting machine 10 is a pair of posts of box members,
23 comprising a left box member 12 and a right box member 14. By
24 way of example, the left box member 12 which serves only as a
support member can be made of quarter inch plate steel and
26 can have a base which is twenty inches wide by twenty-four
27 inches deep and fifty-two inches tall. The right box member
28 14 which includes the electronics and motors, as will be
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1 described later, in addition to acting as a support member,
3 can also be made of quarter inch plate steel and can have a
4 base which is forty-four inches wide by twenty-four inches
deep and fifty-two inches tall. The two support boxes 12 and
6 14 support a pair of cross beams; an upper cross beam 16 and
7 a lower cross beam 18. Upper cross beam 16 can be made of
quarter inch plate steel and can be twenty-four feet long,
8 four inches wide and eight inches tall. Lower cross beam 18
can be made of quarter inch plate steel and can be twenty-
four feet long, eight inches wide and eightinches tall. As
11 illustrated in Figure 1, the two beams 16 and 18 run parallel
2 to each other between support box members 12 and 14, and are
14 separated by a gap "H" which by way of example may be nine
and a half inches. The cross beams 16 and 18 are permanently
attached to the supporting box members 12 and 14 by
16 conventional means such as welding.
17
1~ Referring to Figures 1 and 3, on the ground between the
29 supporting box members 12 and 14 and beneath the lowermost
21 cross beam 18 is the base track 20. The base track 20 is
22 comprised of track supports 22 and 24 which support thereon a
23 gear and rack system which will be described in greater later
24 on. Track support 22 further comprises a track 23 on which a
pair of rollers may roll. Track support 24 further comprises
26 a track 25 on which a pair of rollers may roll. The track
27 supports 22 and 24 are aligned parallel to each other and are
28 attached by means of transverse spacing members 26 and 28
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1 which also run parallel to each other, thereby forming a
2 generally square base which rests on the ground. Resting
4 immediately above the base track 20 is a first movable
support member track 30. The first movable support member
6 track 30 is comprised of a pair of parallel X-direction beams
7 32 and 34 and a pair of Y direction beams 36 and 38 which are
8 connected together for form a generally rectangular frame.
The frame comprised of members 32, 34, 36 and 38 of first
movable support member 30 support transverse roller members
40 and 42. Transverse roller member 40 is supported between Y
11 direction beams 36 and 38 and is generally parallel to X-
132 direction beams 32 and 34 and is aligned directly over track
14 support 22. Transverse roller member 40 further comprises a
pair of rollers 39 and 41. Transverse roller member 42 is
supported between Y-direction beams 36 and 38 and is
17 generally parallel to X-direction beams 32 and 34 and is
18 aligned directly over track support 24. Transverse roller
19 member 42 further comprises a pair of rollers (not shown).
First movable support track 30 can move in the X direction as
21 the rollers on transverse roller members 40 and 42 can roll
22 on the track 23 contained on track support 22 and on track 25
23 contained on track support 24 respectively. Y-direction beam
24 36 further comprises a track 35 and Y-direction beam 38
further comprises a track 37. Y-direction beams 36 and 38
26 further comprise gear and rack assemblies, as will be
27 described later.
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1 ¦ Resting immediately above the first movable support
3 ¦ member track 30 is a second movable support member track 50.
4 ¦ The second movable support member track 50 is comprised of a
¦ pair of parallel X-direction beams, one of which is shown at
5 ¦ 52 and a pair of Y direction beams, one of which is shown at
6 ¦ 58, which are connected together form a generally rectangular
¦ frame. The Y-direction beams on the second movable support
8 ¦ member track 50 each further comprise a pair of rollers which
¦ enable the second movable support track 50 to move in the Y-
10 ¦ direction. Y-direction beam 58 comprises a pair of rollers 59
11 ¦ and 61 which move on track 37 and Y-direction beam 56
12 ¦ comprises a pair of rollers (not shown) which move on track
14 1 35.
Second movable track member 50 further comprises four
17 posts at its corners, two of which, 60 and 62 are shown in
Figure 1. The four posts support quilt table 70 which is
18 comprised of X-direction table beams 72 and 74 and Y-
1 direction table beams 76 and 78, connected together by means
22o such as welding. X-direction table beam 72 is supported on
22 posts 60 and 62 and X direction table beam 74 is supported on
23 the two opposite posts (not shown). Y-direction table beams
24 76 and 78 are supported on the two X-direction table beams 76
and 78 adjacent their respective ends, as shown in Figures 1
26 and 3. The two X-direction table beams 72 and 74 are parallel
27 to each other and the two Y-direction table beams 76 and 78
28 are parallel to each other.
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1 I
3 ¦ As illustrated in Figures 1 and 3, the posts on second
4 ¦ movable track member 50 support the table beams such that the
5 ¦ table beams 76 and 78 pass through gap H between cross beams
6 16 and 18 and table beams 72 and 74 can pass through the gap
7 H if the Y direction movement is of sufficient length. In
8 operation, a bedspread or quilt 100 is stretched across the
9 table beams 72, 74, 76, and 78, which by way of example can
form a table surface of approximately twelve feet in the X-
11 direction by twelve and a half feet in the Y-direction, such
12 that the quilt 100 is supported at its edges by the four
13 table beams 72, 74, 76 and 78 which result in a fully
14 accessible quilt over its entire interior upper and lower
surface. The table beams are caused to move in the
16 X-direction by first movable support track 30 as the rollers
17 on transverse roller members 40 and 42 move along tracks 23
18 and 25 respectively. The length "L" of gap "H" is preferably
19 at least twice the length of the two X-direction table beams
72 and 74. In this way, the entire X-direction area of the
21 quilt table 70 can be reached by the centermost position
22 along the cross beams 16 and 18. The table beams are caused
23 to move in the Y direction by second movable support member
24 track 50 when the rollers on its Y-direction beams move along
tracks 35 and 37. The length of tracks 35 and 37 is at least
26 twice the length of the two Y-direction table beams 76 and
27 78. In this way, the entire Y-direction area of the quilt
28 table 70 can be reached by the centermost position along the
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1 cross beams 16 and 18. Through this combination of X and Y
2 movements, the entire area of the quilt table 70 and the
3 quilt 100 spread thereon can be reached by the centermost
position of cross beams 16 and 18. In the preferred starting
6 position, the quilt table 70 is centered relative to the
7 cross beams 16 and 18 and can move in any X-Y direction
relative the the centermost position of the cross beams.
The quilt table 70 can be caused to move in the X and Y
11 directions as previously described by numerous conventional
12 types of means, such as a gear and rack assembly. One such
gear and rack assembly is illustrated in Figure 4. Track
13 support 22 supports track 23 on which rollers 39 and 41 can
roll in the X-direction. Track support 22 further contains on
its interior surface a rack assembly 80 having a conventional
16 multiplicity of teeth which can accommodate a gear.
Transverse roller member 40 further supports a rotatable gear
18 82 which is caused to rotate by a conventional gear drive
lzo mechanism 84 having smaller gears driven by a belt to drive
the rotatable gear 82. The gear drive mechanism is driven by
21 a conventional linkage hookup to a drive motor which causes a
2223 motor shaft to rotate and thereby drive the gear drive
mechanism 84 which in turn causes the rotatable gear 82 to
rotate. When the rotatable gear rotates in the clockwise
26 direction, the rotatable gear moves along the rack assembly
27 80 and causes the transverse roller member 40 (and opposite
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2 transverse roller member 42) to move to the right in the X-
3 direction. When the rotatable gear rotates in the
4 counterclockwise direction, the rotatable gear moves along
the rack assembly 80 and causes the transverse roller member
6 40 (and opposite transverse roller member 42) to move to the
7 left in the X-direction. It will be appreciated that a
8 comparable rack and gear assembly is supported on Y-direction
9 beam 38 and Y-direction beam 58, thereby enabling Y-direction
beams 58 (and the opposite Y-direction beam on second movable
support member track 59) to move back and forth in the Y-
11 direction.
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14 It will be appreciated that conventional adjustment
15 modifications can be incorporated int:o this system. For
16 example the overall height of the quilt table 70 can be
17 adjusted up and down by creating slidable adjustments in the
18 the posts (60, 62 and to two opposite posts) in order to
19 adjust the height of quilting table 70 relative to the cross
221 beams 16 and 18.
22 Referring to Figures 4, 5, and 6, a sewing machine head
23 110 is bolted stationary to upper cross beam 16. Any
24 industrial machine sewing head which is suitable for the
intended sewing purpose can be incorporated with the present
26 invention. By way of example, one type of sewing machine
27 head which can be used with the present invention is the
28 Mitsubishi Industrial Sewing Machine Model LS2-180 high
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1 speed, single needle lockstitch sewing machine. A
microprocessor connected to this type of sewing machine head
3 provides many auxiliary functions such as control of needle
position, presser foot lift, undertrim, and tension release
disk. The sewing machine head 110 is attached to the
67 underside of upper cross beam 16 such that the sewing needle
112 is at the approximate center of cross-beam 16. In this
8 manner, the sewing needle 112 can reach any portion of the
9 quilt table 70 and quilt 100 thereon by the X-Y movement of
the quilt table, as previously discussed. The sewing machine
11 plate 114 is formed into the top of lower cross beam 18 such
12 that the plate 114 is aligned with the needle 112, as best
13 illustrated in Figure 6.
16 A source of light 120 is attached, preferably to the
17 upper cross beam 16 and directed such that the beam of light
falls directly on the intersection area between the sewing
18 needle 112 and the sewing machine plate 114. The source of
light 120 may have an adjustment means 122 so that the
21 direction of the beam can be altered, depending upon need. In
22 this way, the area being stitched is brightly illuminated. A
23 bobbin 124 is supported by a frame member 126 attached to one
2 edge of upper cross beam 16. Thread 128 is wound on the
bobbin 118 and is guided by conventional means through the
sewing machine head 110 and to the needle 112.
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2 A color video camera 130 is mounted to an adjustable
3 mounting bracket 132 which in turn is mounted to the upper
4 cross beam 16. By way of example, adjustable mounting bracket
132 may contain an internal slide 134 and the video camera
6 can be positioned along the slide at any desired location and
7 rotated such that the focus of the color video camera 130 is
8 directly at the intersection of the sewing needle 112 and the
9 sewing machine plate 114. In this way, since the area is
illuminated by the source of light 120, a clear picture of
11 the sewing machine needle 112 performing a sewing or
12 stitching operation can be picked up by the color video
13 camera 130. The color video camera 130 is a high quality full
14 color resolution camera. While a black and white video camera
can be used, a color video camera is pref~rred for
16 distinguishing shades in the fabric pattern. Extra wide
17 angle lenses and/or telephoto lenses may be attached to the
color video camera in order to display larger areas or more
18 precise minute areas, as required for the specific
operation.
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22 The color video camera 130 is in turn connected to the
23 input of a color monitor 140 and the monitor is connected to
24 an alternating current power source 150. When the color
monitor 140 is turned on, the power to the color monitor 140
26 generates power to the color video camera 130 and the image
of the sewing needle 112 and the stitching or sewing
27
28 operation being performed is picked up by the video camera
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l ¦ 130 and transmitted to the color monitor 140 where it can be
2 ¦ easily viewed by an operator. Therefore, instead of
4 ¦ requiring an operator to be physically above the large
quilting table in order to see exactly where the sewing
machine needle is stitching a pattern and seeing what pattern
6 is being stitched, the operator merely needs to look at the
monitor 140 in order to determine exactly where the needle is
8 located and in what direction it is going so that the
subsequent stitches can be accurately guided and made. As
with the camera, a black and white monitor can be used, but a
11 color monitor is preferred.
12
13 While it would be possible to physically move the
14 quilting table 70 as the needle is sewing the pattern, it is
not practical since the table is heavy and could not be moved
17 fast enough by hand to quickly guide the portion of quilt lO0
to the area where the sewing needle 112 is sewing the next
lô stitch. Therefore, an automatic electrical system for moving
l9 the quilting table 70 and quilt 100 thereon into position for
22o appropriate sewing of the pattern is required. A block
22 diagram of the electronics for performing this operation is
presented in Figure 2. A source of alternating current power
24 150 energizes the entire system. As previously discussed, in
one connection, the source of alternating current power 150
226 is connected to the monitor 140 which in turn energizes the
27 video camera 130. In a second connection, the alternating
28 current source is connected to an alternating current to
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2 direct current transformer 160. The transformer 160 is
3 connected to an X-electronic interface card 162 which in turn
4 is connected to an X-direction direct current motor 164. The
transformer 160 is also connected to a Y-electronic interface
6 card 166 which in turn is connected to a Y-direction direct
7 current motor 168. The X-electronic interface card 162 and
the Y-electronic interface card 166 are both connected to a
8 joy stick electronic interface card 170. The joy stick
electronic interface card 170 is connected to a joy stick
11 180. The joy stick electronic interface card 170 is also
connected to the AC to DC transformer 160 and is also
2 connected to the sewing machine head 110. The joy stick 180
14 is a bi-directional joy stick with a variable speed range to
permit the operator to make high-speed and low-speed moves of
16 the table. By way of example, the high-speed may be set to a
17 maximum diagonal speed of approximately twenty-five feet per
minute. Limit switches may be included to prevent the table's
18
19 overtravel. The joy stick 180 through the joy stick interface
card 170 can also be used to control the speed of the sewing
21 needle 110. The DC motors 164 and 168 may be variable speed
22 motors which are coupled to the quilt table through
2~ conventional drive belts, gears and racks, as previously
24 described. The mechanical portion of the drive system can be
suitable for adaptation to a computer controlled servo
26 system. The electronic control components including the AC
27 to DC transformer 160, the X-electronic interface card 162,
28 the Y-electronic interface card 166, the X-direction motor
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lli lZ70051
2 164, the Y-direction motor 168 and the joy stick interface
3 card 170 can all be housed in the larger supporting box
4 member 14.
6 Therefore, through use of the present invention, an
7 operator can hold the joy stick 180 in his/her hand and watch
8 the color video monitor 140. With the color video camera 130,
9 equipped if desired with a wide angle or telephoto lens,
focusing on the area where the sewing needle 112 is sewing
11 the quilt 100, and the area illuminated by the source of
12 light 120, the operator receives a detailed and clear view of
13 the sewing needle as it is sewing the stitch into the quilt.
14 Through use of the joy stick 180 and joy stick interface card
170 connected to the sewing machine head 100, the speed of
16 the needle can be varied according to the stitch desired. An
17 individual pattern can be sewn as if by hand since the
18 quilting table 70 can be guided in an X-direction or Y-
19 direction or combination X-Y diagonally oriented direction by
use of the joy stick 180 which through the joy stick
21 interface card 170 activates the X-direction motor and the Y-
22 direction motor to engage the gear and rack system and cause
23 the quilting table 70 to be moved in the X-direction, the Y-
24 direction, and the XY combined direction, as previously
described. Therefore, by watching the image on the monitor
26 140, the operator can cause the quilting table 70 and quilt
27 100 thereon to be moved in any desired direction relative to
28 the sewing needle 112 so that an individual pattern of any
12~0051
1 desired shape and size can be sewn into the quilt 100. A
3 microprocessor in the joy-stick interface card helps to
4 control the speed of sewing and the movement of the bedspread
5 or quilt affixed to the quilting table 70. As the quilting
6 table 70 is moved, the bedspread or quilt 100 passes through
7 the gap H and since the bedspread or quilt 100 is held only
8 by its edges, the sewing machine needle 112 can sew through
9 the bedspread or quilt 100 at any location in an unimpeded
manner.
12 Through use of the present invention, the rate of
13 production is at least three to five times greater than that
14 of hand-guided skilled operators. The training time required
to teach the operator to use the present system is only one
16 week, as opposed to four to six months for a conventional
17 system. The present system can even be used by a non-skilled
18 operator instead of the high-skilled operators required to
19 operate present day systems. The high resolution color video
camera and monitor allow the operator to see close-up views
21 of the sewing operation from any distance. The risk of
22 injury to the operator is significantly reduced since the
23 operator is positioned at a remote location from the sewing
24 needle and the moving table and therefore does not come in
contact or near contact with moving parts.
26
27 The present system can also be combined with well known
28 preprogrammed computer controlled systems. The attachment
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2 from the joy stick interface card 170 can be attached to a
3 computer which receives preprogrammed patterns. The computer
4 can be programmed to move the quilting table 70 and quilt loo
relative to the sewing needle 112 and can be therefore
6 programmed to stitch a preprogrammed pattern into the quilt
7 or bedspread. Therefore, the preprogrammed patterns can be
8 stitched into part of the quilt or bedspread and the precise
9 individual hand sewn patterns can be sewn into another
portion of the bedspread. After the programmed patterns are
11 completed, the computer is disconnected and the joy stick
12 reconnected to the joy stick interface card and the precise
13 hand sewinq is performed. Of course, the hand sewing can be
14 done first and then the preprogrammed pattern can be sewn
16 afterward by attachment of the computer.
17 Defined more broadly, the present invention is a frame
18 quilting machine comprising: (a) a frame member for retaining
19 a fabric; (b) said frame member mounted on a structure which
can be moved in the X-direction, the Y-direction, or any X-Y
21 combination direction; (c) a first cross beam extending
22 horizontally over said frame member; (d) a second cross beam
2 aligned parallel to said first cross beam and extending
2 horizontally beneath said frame member; (e) a remote control
apparatus for controlling the movement of said structure and
2 said frame member to enable the frame member and the fabric
27 retained thereon to be moved horizontally in the X-direction,
2 the Y-direction, and any combination X-Y direction between
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1 1270()51
2 said first cross beam and said second cross beam; (f) a
3 sewing machine head attached to said first cross beam and
4 having a source of thread; (g) a sewing needle extending from
said sewing machine head and positioned to sew threads into
6 said fabric while the frame member and structure move
7 underneath said first cross beam and above said second cross
8 beam; (h) a sewing machine plate attached to said second
9 cross beam and aligned with said sewing machine head and
sewing needle; (i) a source of illumination focused on the
11 intersection of said sewing machine needle and fabric; (j) a
12 video camera movably secured to said first cross beam and
13 focused on the intersection of said sewing machine needle and
fabric; and (k) said video camera connected to a monitor; (1)
14 whereby an operator may view the needle sewing thread into
16 the fabric on the video monitor and may control the movement
17 of the frame and fabric relative to the sewing needle by said
18 remote apparatus. The source of illumination can be attached
19 to said first cross beam. The video camera is preferable a
color video camera. In an optional feature, the video camera
21 is equipped with a wide angle lens. The monitor is preferably
22 a color monitor. The apparatus may further comprise a
23 programmable computer connected to said apparatus whereby
24 a preprogrammed pattern directed by the computer will cause
the second structure to move in a desired pattern relative to
26 said sewing needle. The fabric may be a bedspread or a quilt.
27 In the preferred embodiment, said sewing machine head and
28 said frame member are aligned such that said sewing needle is
28
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2 ¦ at the approximate center point of said fabric and said frame
3 I member can move relative to said sewing machine head and said
4 ¦ sewing needle so as to permit the sewing needle to reach any
5 I portion of the surface area of the fabric. In the preferred
6 I e~bodiment, said remote control apparatus is a remote joy
7 ¦ stick. The speed of said sewing needle may be controlled by
¦ said remote control apparatus.
8 l
lO ¦ The present invention may be even more broadly defined
¦ as an apparatus for sewing ~hread into fabric comprising: (a)
ll ¦ a first structure supporting a sewing machine head having a
12 ¦ sewing needle and a source of thread; (b) a second structure
14 ¦ supporting the fabric in a position relative to said sewing
needle so that thread may be sewn into the fabric; (c) said
second structure capable of horizontal movement in the X-
17 direction, the Y-direction, or any combination X-Y direction
18 relative to said sewing needle; (d) a video camera focused
l9 on the location of the intersection of said sewing needle and
said fabric; (e) said video camera connected to a monitor;
21 and (f) a remote control apparatus for moving said second
22 structure and the fabric retained thereon relative to said
23 sewing needle so that said sewing needle may sew a pattern
24 with said thread into said fabric; (g) whereby an operator
may view the needle sewing thread into the fabric on the
26 video monitor and may control the movement of the second
27 structure and fabric relative to the sewing needle by said
28 remote control apparatus. The apparatus may further comprise
l 127005~
2 a source of illumination focused~on the intersection of said
3 sewing needle and said fabric, which source of illumination
4 is preferably attached to said first structure. A video
camera can be movably attached to said first structure.
7 As clearly shown in the above described apparatus, the
8 present invention also encompasses the method of sewing a
9 pattern into a fabric having a large surface comprising: (a)
positioning a sewing machine head having a source of thread
11 and a sewing needle relative to said fabric; (b) retaining
12 said fabric on a movable structure which can be made to move
13 in a horizontal direction relative to the sewing needle and
14 which can cause a portion of the surface of the fabric to be
reached by the sewing needle so that thread can be sewn into
16 the fabric; (c) obtaining a video image of the intersection
17 of the sewing needle and fabric; and (d) controlling the
movement of the movable structure relative to the sewing
18
19 needle by a remote control apparatus and determining the
direction of movement based upon the video image of the
21 intersection of the sewing needle and fabric. The method may
22 further comprise illuminating the intersection of said sewing
23 needle and said fabric. The method may further include a
24 programmable computer whereby a preprogrammed pattern
directed by the computer will cause the pattern to be sewn
26 into the fabric by the sewing needle.
27
28
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~2'700~;~
2 Of course the present invention is not intended to be
3 restricted to any particular form or arrangement, or any
4 specific embodiment disclosed herein, or any specific use,
since the same may be modified in various particulars or
6 relations without departing from the spirit or scope of the
7 claimed invention hereinabove shown and described of which
8 the apparatus is intended only for illustration and for
9 disclosure of an operative embodiment and not to show all of
the various forms or modification in which the invention
12 might be embodied or operated.
13 The invention has been described in considerable detail
14 in order to comply with the patent laws by providing full
public disclosure of at least one of its forms. However, such
16 detailed description is not intended in any way to limit the
17 broad features or principles of the invention, or the scope
18 of patent monopoly to be granted.
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