缝纫机sewing machine技术领域technical field
本发明涉及一种缝纫机。The present invention relates to a sewing machine.
背景技术Background technique
公知一种能够判断是否发生了缝制不良的缝纫机。日本特许第2821048号公报所公开的缝纫机具有增量检测器和张力测量装置。增量检测器输出与上轴的旋转相应的脉冲信号。张力测量装置输出表示面线张力随时间的变化的信号。缝纫机基于增量检测器和张力测量装置各自的检测结果来获取线张力函数。线张力函数表示依存于上轴角的面线张力。缝纫机获取上轴的各旋转周期内的线张力函数与先前的旋转周期内的线张力函数之差(称作张力差)。在获取到的张力差大于预定的大小时，缝纫机判断为发生了缝制不良。There is known a sewing machine capable of determining whether or not a sewing defect has occurred. The sewing machine disclosed in Japanese Patent No. 2821048 has an increment detector and a tension measuring device. The incremental detector outputs a pulse signal corresponding to the rotation of the upper shaft. The tension measuring device outputs a signal representing the change in the tension of the upper thread with time. The sewing machine obtains the thread tension function based on the respective detection results of the incremental detector and the tension measuring device. The thread tension function represents the upper thread tension dependent on the upper shaft angle. The sewing machine acquires the difference (called a tension difference) between the thread tension function in each rotation cycle of the upper shaft and the thread tension function in the previous rotation cycle. When the acquired tension difference is larger than a predetermined magnitude, the sewing machine determines that a sewing failure has occurred.
缝制不良包括发生后优选立即停止缝制动作的缝制不良和发生后可以不立即停止缝制动作的缝制不良。在上述缝纫机中，获取到的张力差与具体的多种缝制不良并不对应。因此，缝纫机无法识别多种缝制不良，有时无法判断是否应该在发生缝制不良后立即停止缝制动作。Sewing defects include those in which it is preferable to stop the sewing operation immediately after occurrence, and those in which the sewing operation cannot be stopped immediately after the occurrence of sewing defects. In the above-mentioned sewing machine, the obtained tension difference does not correspond to various specific sewing defects. Therefore, the sewing machine cannot recognize various kinds of sewing defects, and sometimes cannot judge whether the sewing operation should be stopped immediately after the occurrence of sewing defects.
发明内容SUMMARY OF THE INVENTION
本发明的目的在于提供一种能够基于面线张力的变化来识别缝制不良的缝纫机。An object of the present invention is to provide a sewing machine capable of identifying sewing defects based on changes in the tension of the upper thread.
技术方案1的缝纫机具有：针杆，机针装配于该针杆，该针杆能够上下运动；梭子，其捕捉贯穿所述机针的面线，将该面线与底线交织；挑线杆，其提起由所述梭子交织于所述底线的所述面线；夹线机构，其具有夹线盘，对所述面线赋予张力，所述面线在所述面线的至所述机针的供给路径上比所述挑线杆靠上游侧的位置穿过该夹线盘；线张力检测机构，其检测所述面线的张力即面线张力；缝制控制部，其控制所述针杆、所述梭子、所述挑线杆，对布料执行缝制；张力获取部，其基于所述线张力检测机构的检测结果来获取与由所述缝制控制部进行的缝制相伴随地周期性变动的所述面线张力；以及判断部，其通过对基于所述张力获取部获取到的在第N(N为自然数)周期变动的所述面线张力与作为在一周期内变动的基准的所述面线张力即基准面线张力进行比较，判断是否发生了在通过所述缝制控制部进行的缝制动作中未能形成正常的线迹的缝制不良，该缝纫机的特征在于，所述张力获取部对于以将单位设为时间的周期重复变动的所述面线张力，按每个周期获取所述面线张力，所述判断部通过使用分别与多种所述缝制不良相对应地预先设定的多个特定阈值对在所述第N周期内变动的所述面线张力和所述基准面线张力进行比较，判断是否发生了所述缝制不良。The sewing machine oftechnical solution 1 has: a needle bar to which the needle is assembled, and the needle bar can move up and down; a shuttle, which catches the upper thread passing through the needle, and interweaves the upper thread with the lower thread; and a thread take-up lever, It lifts the upper thread interwoven with the lower thread by the shuttle; the thread tensioning mechanism has a thread tensioning disc, which imparts tension to the upper thread, and the upper thread is between the upper thread and the needle. The thread tension detection mechanism detects the tension of the upper thread, that is, the tension of the upper thread, and the sewing control unit controls the needle a lever, the shuttle, and the thread take-up lever for performing sewing on the cloth; and a tension acquisition unit for acquiring a cycle accompanying the sewing performed by the sewing control unit based on the detection result of the thread tension detection mechanism The upper thread tension that fluctuates in a natural way; and a judgment unit that compares the upper thread tension that fluctuates in the Nth (N is a natural number) cycle acquired based on the tension acquiring unit with a reference for fluctuation in one cycle The upper thread tension, that is, the reference upper thread tension, is compared to determine whether or not a sewing defect in which normal stitches cannot be formed during the sewing operation performed by the sewing control unit has occurred. The sewing machine is characterized in that: The tension acquisition unit acquires the upper thread tension for each cycle with respect to the upper thread tension that repeatedly fluctuates in a cycle with a unit of time, and the determination unit is associated with a plurality of types of the sewing defects, respectively. The upper thread tension that fluctuates in the Nth cycle and the reference thread tension are compared with a plurality of predetermined thresholds correspondingly to determine whether or not the sewing defect has occurred.
判断部使用与多种缝制不良相对应地预先设定的多个特定阈值来判断有无发生缝制不良。因此，缝纫机能够识别出具体的缝制不良，能够基于面线张力的变化来识别缝制不良。The determination unit determines whether or not a sewing defect has occurred using a plurality of predetermined threshold values set in advance corresponding to the various types of sewing defects. Therefore, the sewing machine can recognize the specific sewing defect, and can recognize the sewing defect based on the change in the tension of the upper thread.
也可以是，在技术方案2的缝纫机中，所述缝制不良包括在缝制过程中所述面线断开的断线，所述判断部具有判断是否发生了所述断线的断线判断部，在所述第N周期的期间内所述面线张力第一次达到极大的期间是所述梭子捕捉所述面线的梭子捕捉期间，在所述第N周期的期间内所述面线张力第二次达到极大的期间是所述挑线杆提起所述面线的挑线杆提起期间，所述张力获取部获取所述第N周期的期间内的所述梭子捕捉期间的所述面线张力即第一面线张力和所述挑线杆提起期间的所述面线张力即第二面线张力，所述断线判断部在所述第一面线张力为第一阈值以下且所述第二面线张力为第二阈值以下时，判断为发生了所述断线。当发生断线时，第一面线张力为第一阈值以下，且第二面线张力为第二阈值以下。断线判断部能够判断有无发生断线，因此，作为缝制不良，缝纫机能够识别出断线。In the sewing machine ofclaim 2, the poor sewing may include a thread breakage in which the upper thread is disconnected during sewing, and the determination unit may include a thread breakage determination for determining whether or not the thread breakage has occurred. During the period of the Nth cycle, the period in which the tension of the upper thread reaches the maximum value for the first time is the shuttle capture period in which the shuttle catches the upper thread, and the needle thread during the period of the Nth cycle The period during which the thread tension reaches the maximum value for the second time is the period during which the thread take-up lever lifts the upper thread, and the tension acquiring unit acquires all of the shuttle catching period during the period of the Nth cycle. The upper thread tension, that is, the first upper thread tension, and the second upper thread tension, which is the upper thread tension during the period when the thread take-up lever is lifted, the thread breakage determination unit is when the first upper thread tension is equal to or less than a first threshold value When the second upper thread tension is equal to or less than a second threshold value, it is determined that the thread breakage has occurred. When thread breakage occurs, the first upper thread tension is equal to or less than the first threshold value, and the second upper thread tension is equal to or less than the second threshold value. Since the thread breakage determination unit can determine whether or not thread breakage has occurred, the sewing machine can recognize the thread breakage as poor sewing.
也可以是，在技术方案3的缝纫机中，所述缝制不良包括在缝制过程中所述梭子未捕捉到所述面线的跳针，所述判断部具有判断是否发生了所述跳针的跳针判断部，所述跳针判断部在所述第一面线张力为第三阈值以下且所述第二面线张力为第四阈值以上时，判断为发生了所述跳针。当发生跳针时，第一面线张力为第三阈值以下，且第二面线张力为第四阈值以上。跳针判断部能够判断有无发生跳针，因此，作为缝制不良，缝纫机能够识别出跳针。In the sewing machine ofclaim 3, the sewing failure may include skip stitches in which the upper thread is not caught by the shuttle during the sewing process, and the determination unit may have a function of determining whether the skip stitches have occurred. The skip stitch determination unit is provided, wherein the skip stitch determination unit determines that the skip stitch has occurred when the first upper thread tension is equal to or less than a third threshold value and the second upper thread tension is equal to or greater than a fourth threshold value. When skipped stitches occur, the first upper thread tension is equal to or less than the third threshold value, and the second upper thread tension is equal to or greater than the fourth threshold value. The skipped stitch determination unit can determine whether or not skipped stitches have occurred, so that the sewing machine can recognize skipped stitches as poor sewing.
也可以是，在技术方案4的缝纫机中，所述缝制不良包括所述挑线杆提起所述面线时形成线迹的所述面线和所述底线的均衡不良即收线不良，所述多个特定阈值包括第一特定阈值，所述判断部具有收线不良判断部，该收线不良判断部在所述第N周期内的所述面线张力第二次达到极大的产生时机相对于所述基准面线张力第二次达到极大的产生时机早所述第一特定阈值以上时，判断为发生了所述收线不良。当发生收线不良时，第二面线张力的产生时机变早。收线不良判断部能够判断有无发生收线不良，因此，作为缝制不良，缝纫机能够识别出收线不良。In the sewing machine ofclaim 4, the poor sewing may include poor balance between the upper thread and the lower thread that forms stitches when the thread take-up lever lifts the upper thread, that is, poor thread take-up. The plurality of specific thresholds include a first specific threshold, and the judging unit has a poor thread take-up judging unit that generates a timing when the upper thread tension in the Nth cycle reaches a maximum for the second time. The thread take-up failure is determined to have occurred when the timing at which the thread tension becomes the maximum value for the second time with respect to the reference surface is earlier than the first predetermined threshold value or more. When a thread take-up failure occurs, the timing of generating the second upper thread tension becomes earlier. The defective thread take-up determination unit can determine whether or not the defective thread take-up has occurred, so that the sewing machine can recognize the defective thread take-up as the sewing defect.
也可以是，技术方案5的缝纫机具有通过旋转使所述针杆和所述挑线杆上下运动的上轴，所述夹线机构具有使所述夹线盘旋转的夹线马达，该缝纫机具有：速度获取部，其在由所述缝制控制部进行缝制时，获取所述上轴的旋转速度；以及夹线控制部，其在所述速度获取部获取到的所述旋转速度为第一速度以下时，驱动所述夹线马达，使所述夹线盘向与沿着所述供给路径供给所述面线的方向相反的方向旋转。在缝纫机的缝制速度较慢时，第一面线张力和第二面线张力较低。在上轴的旋转速度为第一速度以下时，夹线控制部使夹线盘向与供给面线的方向相反的方向旋转，因此，不易产生面线的松弛。因此，缝纫机能够容易地产生第一面线张力和第二面线张力。The sewing machine ofclaim 5 may include an upper shaft that rotates the needle bar and the thread take-up lever to move up and down, the thread tensioning mechanism has a thread tensioning motor that rotates the thread tensioning disc, and the sewing machine has : a speed acquisition unit, which acquires the rotational speed of the upper shaft when sewing is performed by the sewing control unit; and a thread tension control unit, which acquires the rotational speed by the speed acquisition unit as the first When the speed is not more than one speed, the thread tension motor is driven to rotate the thread tension disc in a direction opposite to the direction in which the needle thread is supplied along the supply path. When the sewing speed of the sewing machine is slow, the first upper thread tension and the second upper thread tension are low. When the rotational speed of the upper shaft is equal to or lower than the first speed, the thread tension control unit rotates the thread tension disc in the direction opposite to the direction in which the needle thread is supplied, so that slack in the needle thread is less likely to occur. Therefore, the sewing machine can easily generate the first upper thread tension and the second upper thread tension.
也可以是，技术方案6的缝纫机具有加速度对应变更部，该加速度对应变更部在所述速度获取部获取到的所述旋转速度发生了变化时，与所述旋转速度的加速度相应地变更所述多个特定阈值、所述第一阈值、所述第二阈值、所述第三阈值以及所述第四阈值中的至少一个阈值。当上轴的旋转速度发生变化时，与加速度相应地，面线张力发生变化，发生缝制不良时的面线张力也发生变化。此时，加速度对应变更部与上轴的旋转速度的变化相应地变更阈值，因此，缝纫机能够恰当地检测缝制不良。The sewing machine of claim 6 may include an acceleration correspondence changing unit that changes the rotational speed according to the acceleration of the rotational speed when the rotational speed acquired by the speed acquisition unit changes. at least one of a plurality of specific thresholds, the first threshold, the second threshold, the third threshold, and the fourth threshold. When the rotation speed of the upper shaft changes, the upper thread tension changes according to the acceleration, and the upper thread tension also changes when sewing defects occur. At this time, since the acceleration response changing unit changes the threshold value in accordance with the change in the rotational speed of the upper shaft, the sewing machine can appropriately detect sewing defects.
也可以是，技术方案7的缝纫机具有速度对应变更部，该速度对应变更部与所述速度获取部获取到的所述旋转速度相应地变更所述多个特定阈值、所述第一阈值、所述第二阈值、所述第三阈值以及所述第四阈值中的至少一个阈值。与上轴的旋转速度相应地，面线张力发生变化，发生缝制不良时的面线张力也发生变化。此时，速度对应变更部与上轴的旋转速度相应地变更阈值，因此，缝纫机能够恰当地检测缝制不良。The sewing machine according toclaim 7 may include a speed correspondence changing unit that changes the plurality of specific thresholds, the first threshold, and all of the specific thresholds in accordance with the rotational speed acquired by the speed acquiring unit. at least one of the second threshold, the third threshold and the fourth threshold. The upper thread tension changes according to the rotation speed of the upper shaft, and the upper thread tension also changes when sewing defects occur. At this time, since the speed correspondence changing unit changes the threshold value according to the rotational speed of the upper shaft, the sewing machine can appropriately detect the sewing defect.
也可以是，在技术方案8的缝纫机中，所述判断部在缝制初始阶段之后，判断有无发生所述缝制不良，该缝制初始阶段是从由所述缝制控制部进行的缝制开始起到预定针数的缝制为止的阶段。在缝制初始阶段时，第一面线张力和第二面线张力较低。因此，当判断部在缝制初始阶段中判断有无缝制不良发生时，判断部有时在未发生缝制不良时也判断为发生了缝制不良。判断部不对缝制初始阶段的缝制不良的有无进行判断。因此，缝纫机能够抑制误判断为发生了缝制不良的情况。In the sewing machine ofclaim 8, the determination unit may determine whether or not the sewing defect has occurred after the initial stage of sewing, which is performed from the sewing performed by the sewing control unit. The stage from the start of sewing to the sewing of the predetermined number of stitches. At the initial stage of sewing, the first and second upper thread tensions are low. Therefore, when the determination unit determines that a sewing defect has occurred in the initial stage of sewing, the determination unit may determine that the sewing defect has occurred even when the sewing defect has not occurred. The judgment unit does not judge the presence or absence of defective sewing in the initial stage of sewing. Therefore, the sewing machine can suppress a misjudgment that a sewing defect has occurred.
也可以是，在技术方案9的缝纫机中，所述判断部在所述速度获取部获取到的所述旋转速度比第二速度大时，判断有无发生所述缝制不良。在缝纫机的缝制速度较慢时，第一面线张力和第二面线张力较低，缝纫机难以检测基于面线张力的缝制不良。缝制不良判断部在上轴的旋转速度为第二速度以下时，不判断有无缝制不良。因此，缝纫机能够更恰当地判断有无缝制不良。In the sewing machine of claim 9, the determination unit may determine whether or not the sewing defect has occurred when the rotational speed acquired by the speed acquisition unit is greater than the second speed. When the sewing speed of the sewing machine is slow, the tension of the first upper thread and the tension of the second upper thread are low, and it is difficult for the sewing machine to detect a sewing defect based on the tension of the upper thread. When the rotation speed of the upper shaft is equal to or lower than the second speed, the sewing failure determination unit does not determine that there is a sewing failure. Therefore, the sewing machine can more appropriately judge that there is a seam failure.
也可以是，技术方案10的缝纫机具有：切线机构，其用来切断所述面线和所述底线；以及切线控制部，其在由所述缝制控制部进行的缝制之后，控制所述切线机构，切断所述面线和所述底线，所述线张力检测机构具有：可动构件，其与所述面线相接触，与所述面线张力相应地移动；磁体，其设于所述可动构件；以及磁传感器，其检测所述磁体的磁通密度，输出与检测结果相应的电压，所述张力获取部基于所述磁传感器的输出电压来获取所述面线张力，所述张力获取部具有调整控制部，该调整控制部在通过所述切线控制部切断所述面线和所述底线时，执行重新设定作为所述磁传感器的基准的输出电压的零点调整。当通过缝制控制部重复缝制动作时，磁传感器的输出电压有时相对于作为基准的输出电压较大程度地变动。缝纫机在面线张力伴随着面线和底线的切断下降，磁传感器的输出电压下降时，由调整控制部执行零点调整，重新设定作为磁传感器的基准的输出电压。因此，缝纫机能够基于磁传感器的输出电压持续地高精度地获取面线张力。The sewing machine ofclaim 10 may include: a thread cutting mechanism for cutting the upper thread and the lower thread; and a thread cutting control unit for controlling the A thread cutting mechanism for cutting the upper thread and the lower thread, and the thread tension detection mechanism includes a movable member that is in contact with the upper thread and moves in accordance with the tension of the upper thread, and a magnet provided on the upper thread. the movable member; and a magnetic sensor that detects the magnetic flux density of the magnet and outputs a voltage corresponding to the detection result, the tension acquisition unit acquires the upper thread tension based on the output voltage of the magnetic sensor, the The tension acquisition unit includes an adjustment control unit that performs zero-point adjustment for resetting the output voltage as a reference of the magnetic sensor when the upper thread and the lower thread are cut by the thread cutting control unit. When the sewing operation is repeated by the sewing control unit, the output voltage of the magnetic sensor may fluctuate greatly with respect to the reference output voltage. In the sewing machine, when the upper thread tension decreases due to the cutting of the upper thread and the lower thread, and the output voltage of the magnetic sensor decreases, the adjustment control unit performs zero-point adjustment to reset the output voltage as a reference of the magnetic sensor. Therefore, the sewing machine can continuously acquire the upper thread tension with high accuracy based on the output voltage of the magnetic sensor.
附图说明Description of drawings
图1是缝纫机1的整体立体图。FIG. 1 is an overall perspective view of thesewing machine 1 .
图2是头部5的局部放大图。FIG. 2 is a partial enlarged view of thehead 5 .
图3是主夹线器60的剖视图。FIG. 3 is a cross-sectional view of themain gripper 60 .
图4是线张力检测机构130的立体图。FIG. 4 is a perspective view of the wiretension detection mechanism 130 .
图5是缝纫机1的电气框图。FIG. 5 is an electrical block diagram of thesewing machine 1 .
图6是表示磁传感器105和放大电路151的输出电压的图表。FIG. 6 is a graph showing the output voltages of themagnetic sensor 105 and theamplifier circuit 151 .
图7是表示正常地执行缝制动作时的变动张力的图表。FIG. 7 is a graph showing fluctuating tension when the sewing operation is normally performed.
图8是表示发生收线不良时的变动张力的图表。FIG. 8 is a graph showing fluctuating tension when a thread take-up failure occurs.
图9是表示发生跳针时的变动张力的图表。Fig. 9 is a graph showing fluctuating tension when skipped stitches occur.
图10是表示正常地形成线迹时的相关系数的图表。FIG. 10 is a graph showing correlation coefficients when stitches are normally formed.
图11是表示发生收线不良时的相关系数的图表。FIG. 11 is a graph showing the correlation coefficient when a thread take-up failure occurs.
图12是表示发生跳针时的相关系数的图表。FIG. 12 is a graph showing correlation coefficients when skipped stitches occur.
图13是表示发生断线时的相关系数的图表。FIG. 13 is a graph showing correlation coefficients when disconnection occurs.
图14是缝制处理的流程图。FIG. 14 is a flowchart of the sewing process.
图15是面线卷绕处理的流程图。FIG. 15 is a flowchart of the upper thread winding process.
图16是张力获取处理的流程图。FIG. 16 is a flowchart of the tension acquisition process.
图17是缝制不良判断处理的流程图。FIG. 17 is a flowchart of a sewing failure judgment process.
图18是收线不良判断处理的流程图。FIG. 18 is a flowchart of the wire take-up failure determination process.
图19是特定断线判断处理的流程图。FIG. 19 is a flowchart of a specific disconnection determination process.
图20是特定跳针判断处理的流程图。FIG. 20 is a flowchart of a specific skip stitch determination process.
图21是断线判断处理的流程图。FIG. 21 is a flowchart of disconnection determination processing.
图22是跳针判断处理的流程图。FIG. 22 is a flowchart of skip stitch determination processing.
具体实施方式Detailed ways
说明本发明的一实施方式的缝纫机1。以下说明使用图中由箭头所示的左右、前后、上下。Thesewing machine 1 which concerns on one Embodiment of this invention is demonstrated. The following description uses left and right, front and rear, and up and down indicated by arrows in the figure.
参照图1、图2，说明缝纫机1的构造。缝纫机1具有机座部2、支柱部3以及机臂部4。机座部2装配于工作台的开口，并沿左右方向延伸。机座部2在上表面装配针板7。操作者将布料载置于机座部2和针板7。针板7具有容针孔8和送布齿孔14。容针孔8在俯视时呈圆形形状。送布齿孔14在前后方向上具有长径，送布齿孔14分别位于容针孔8的左方、后方、右方、前方。支柱部3从机座部2的右端向上方延伸。机臂部4从支柱部3的上端向左方延伸，与机座部2的上表面相对。机臂部4在前表面左右方向大致中央部具有输入部24和显示部25。输入部24为三个输入按钮。操作者一边看着显示部25一边操作输入部24来输入各种指示。机臂部4在上表面左侧具有向上方突出的穿线杆(日文：糸立棒)20。穿线杆20供从线筒抽出的面线6贯穿。1 and 2, the structure of thesewing machine 1 will be described. Thesewing machine 1 includes abase portion 2 , asupport column portion 3 , and anarm portion 4 . Thestand portion 2 is fitted to the opening of the table and extends in the left-right direction. Aneedle plate 7 is mounted on the upper surface of thebase portion 2 . The operator places the cloth on thebase portion 2 and thethroat plate 7 . Theneedle plate 7 has aneedle receiving hole 8 and afeeding tooth hole 14 . The pin-accommodatinghole 8 has a circular shape in a plan view. Thefeed tooth hole 14 has a long diameter in the front-rear direction, and thefeed tooth hole 14 is located at the left, rear, right, and front of the needle-accommodatinghole 8 , respectively. Thepillar portion 3 extends upward from the right end of thebase portion 2 . Thearm portion 4 extends leftward from the upper end of thepillar portion 3 and faces the upper surface of thebase portion 2 . Thearm part 4 has aninput part 24 and adisplay part 25 in a substantially center part in the left-right direction of the front surface. Theinput unit 24 is three input buttons. The operator operates theinput unit 24 while looking at thedisplay unit 25 to input various instructions. Thearm part 4 has a threading rod (Japanese: 糸立 stick) 20 protruding upward on the left side of the upper surface. The threadingrod 20 is inserted through the upper thread 6 drawn out from the bobbin.
机臂部4在内部具有上轴15和主马达27(参照图5)。上轴15沿左右方向延伸，借助上轴带轮与主马达27的输出轴相连结。上轴带轮固定于上轴15的右端部。机臂部4在左端部具有头部5。头部5从机臂部4向下方突出，从上方与针板7相对。头部5以针杆11能够上下运动的方式支承该针杆11。针杆11的下端部供机针10装配，并从头部5向下方突出。针杆11借助上下运动机构与上轴15相连结。针杆11伴随着上轴15的转动，借助上下运动机构进行上下运动。机针10保持贯穿针眼的面线6，与针杆11一同上下运动。机针10能够从容针孔8穿过。机针10的可动范围下端为下死点，可动范围上端为上死点。Thearm part 4 has theupper shaft 15 and themain motor 27 inside (refer FIG. 5). Theupper shaft 15 extends in the left-right direction, and is connected to the output shaft of themain motor 27 via an upper shaft pulley. The upper shaft pulley is fixed to the right end of theupper shaft 15 . Thearm part 4 has thehead part 5 at the left end part. Thehead portion 5 protrudes downward from thearm portion 4 and faces theneedle plate 7 from above. Thehead 5 supports theneedle bar 11 so that theneedle bar 11 can move up and down. The lower end of theneedle bar 11 is fitted with theneedle 10 and protrudes downward from thehead 5 . Theneedle bar 11 is connected to theupper shaft 15 by a vertical movement mechanism. Theneedle bar 11 moves up and down by the up and down movement mechanism along with the rotation of theupper shaft 15 . Theneedle 10 holds the upper thread 6 penetrating the needle eye, and moves up and down together with theneedle bar 11 . Theneedle 10 can pass through theneedle hole 8 . The lower end of the movable range of theneedle 10 is the bottom dead center, and the upper end of the movable range is the upper dead center.
机座部2在内部具有梭子、切线机构17(参照图5)以及送布机构。梭子设于针板7的下方，收纳卷绕有底线的梭心。梭子具有梭尖，能够获得主马达27的动力进行转动，梭子利用梭尖捕捉贯穿机针10的针眼的面线6，将该面线6与底线交织。切线机构17(参照图5)具有固定刀、可动刀以及切线电磁元件17A。可动刀与切线电磁元件17A相连结。通过切线电磁元件17A的驱动，可动刀相对于固定刀移动，切线机构17通过可动刀和固定刀的协作来切断面线6和底线。Thebase part 2 has a shuttle, a thread cutting mechanism 17 (refer to FIG. 5 ), and a cloth feed mechanism inside. The shuttle is provided below theneedle plate 7 and accommodates the bobbin on which the lower thread is wound. The shuttle has a tip that can be rotated by the power of themain motor 27, and the tip of the shuttle catches the upper thread 6 passing through the eye of theneedle 10, and interlaces the upper thread 6 with the lower thread. The thread cutting mechanism 17 (see FIG. 5 ) includes a fixed blade, a movable blade, and a thread cuttingelectromagnetic element 17A. The movable blade is connected to the thread cuttingelectromagnetic element 17A. The movable knife moves relative to the fixed knife by driving the thread cuttingelectromagnetic element 17A, and thethread cutting mechanism 17 cuts the upper thread 6 and the lower thread by the cooperation of the movable knife and the fixed knife.
送布机构具有上下送布轴、送布台、送布齿、水平送布轴以及送布马达123(参照图5)。上下送布轴在机座部2的内部沿左右方向延伸，并借助带与上轴带轮相连结。送布台设为能够摆动，并与上下送布轴相连结。当上下送布轴在主马达27的驱动力的作用下进行旋转时，送布台沿上下方向移动。送布齿支承于送布台。水平送布轴在比上下送布轴靠前方的位置沿左右方向延伸，并将送布马达123和送布台连结起来。当水平送布轴在送布马达123的驱动力的作用下进行旋转时，送布台沿前后方向移动。送布台伴随着主马达27和送布马达123的驱动进行摆动，从而送布齿从送布齿孔14突出或退入到送布齿孔14中。The cloth feeding mechanism includes an upper and lower cloth feeding shaft, a cloth feeding table, a cloth feeding tooth, a horizontal cloth feeding shaft, and a cloth feeding motor 123 (refer to FIG. 5 ). The upper and lower cloth feed shafts extend in the left-right direction inside themachine base 2, and are connected to the upper shaft pulley via a belt. The cloth feed table is swingable and connected to the upper and lower cloth feed shafts. When the upper and lower cloth feed shafts are rotated by the driving force of themain motor 27, the cloth feed table moves in the vertical direction. The cloth feed teeth are supported on the cloth feed table. The horizontal feed shaft extends in the left-right direction at a position ahead of the upper and lower feed shafts, and connects thefeed motor 123 and the feed table. When the horizontal cloth feed shaft is rotated by the driving force of thecloth feed motor 123, the cloth feed table moves in the front-rear direction. The cloth feed table swings in accordance with the driving of themain motor 27 and thecloth feed motor 123 , so that the cloth feed teeth protrude from the cloth feed teeth holes 14 or retract into the cloth feed teeth holes 14 .
如图2所示，头部5从自线筒至机针10的面线6的供给路径的上游侧起，依次具有副夹线器26、主夹线器60、线引导部21、线张力检测机构130、挑线杆23以及引导钩29。As shown in FIG. 2 , thehead 5 includes asub gripper 26 , amain gripper 60 , athread guide 21 , and a thread tension in this order from the upstream side of the supply path of the upper thread 6 from the spool to theneedle 10 Thedetection mechanism 130 , the thread take-uplever 23 and theguide hook 29 .
副夹线器26设于头部5的前表面的右上部。主夹线器60设于副夹线器26的下方且是头部5的前表面。副夹线器26和主夹线器60分别对面线6赋予张力。副夹线器26对面线6赋予在由切线机构17切断面线6和底线时所需的张力。主夹线器60与缝纫机1的缝制相伴随地使作用于面线6的张力适当。主夹线器60的构造见后述。线引导部21设于主夹线器60的左方。线引导部21使经由主夹线器60的面线6朝向线张力检测机构130和挑线杆23折回。线张力检测机构130利用螺钉90固定于从头部5的前表面向后方凹陷的凹部5A，并位于处在副夹线器26与主夹线器60之间的上下位置。线张力检测机构130能够检测作用于面线6的张力。挑线杆23设于副夹线器26的左方，并具有供面线6贯穿的通孔23A。挑线杆23伴随着主马达27的驱动进行上下运动。引导钩29设于线张力检测机构130的左方。引导钩29将穿过挑线杆23的通孔23A的面线6朝向针杆11引导。Thesub gripper 26 is provided on the upper right portion of the front surface of thehead 5 . Themain gripper 60 is provided below thesecondary gripper 26 and is the front surface of thehead 5 . Thesub gripper 26 and themain gripper 60 apply tension to the upper thread 6, respectively. Thesub thread gripper 26 applies the tension required when the upper thread 6 and the lower thread are cut by thethread cutting mechanism 17 to the upper thread 6 . Themain thread clamp 60 adjusts the tension applied to the upper thread 6 in accordance with the sewing of thesewing machine 1 . The structure of themain gripper 60 will be described later. Thethread guide portion 21 is provided on the left side of themain thread gripper 60 . Thethread guide portion 21 returns the upper thread 6 passing through themain thread gripper 60 toward the threadtension detection mechanism 130 and the thread take-uplever 23 . The threadtension detection mechanism 130 is fixed to theconcave portion 5A recessed rearward from the front surface of thehead 5 with thescrew 90 , and is located at an upper and lower position between thesub gripper 26 and themain gripper 60 . The threadtension detection mechanism 130 can detect the tension applied to the upper thread 6 . The thread take-uplever 23 is provided on the left side of thesub thread gripper 26, and has a throughhole 23A through which the upper thread 6 passes. The thread take-uplever 23 moves up and down along with the driving of themain motor 27 . Theguide hook 29 is provided on the left side of the threadtension detection mechanism 130 . Theguide hook 29 guides the upper thread 6 passing through the throughhole 23A of the thread take-uplever 23 toward theneedle bar 11 .
如图3所示，主夹线器60具有夹线筒62、夹线座63、挑线弹簧65、夹线马达16以及夹线盘69。As shown in FIG. 3 , themain thread tensioner 60 has athread tension barrel 62 , athread tension seat 63 , a thread take-upspring 65 , athread tension motor 16 and athread tension disc 69 .
夹线筒62为环状，利用紧固构件固定在形成于头部5的前壁部5B的通孔5C的内侧。夹线座63为环状，利用螺钉19固定于夹线筒62的内侧。挑线弹簧65固定于夹线座63的外侧面，并卷绕在夹线座63与夹线筒62之间。挑线弹簧65的一端部在前方从前壁部5B暴露。通过夹线座63的转动，缝纫机1能够调整挑线弹簧65的弹簧压力。夹线马达16利用螺栓固定于机臂部4的内侧。夹线马达16的输出轴18经由夹线座63的中心孔突出到比前壁部5B靠前方的位置。夹线盘69利用螺钉28固定于输出轴18的前端部。面线6在夹线盘69卷绕一圈～两圈左右。夹线盘69在夹线马达16的驱动下旋转。夹线马达16具有编码器16A(参照图5)。编码器16A检测输出轴18的旋转位置。Thethread tension barrel 62 is annular, and is fixed to the inner side of the throughhole 5C formed in thefront wall portion 5B of thehead portion 5 by a fastening member. Thethread tensioning seat 63 is annular, and is fixed to the inner side of thethread tensioning barrel 62 with thescrew 19 . The thread take-upspring 65 is fixed on the outer side of thethread tensioning seat 63 and is wound between thethread tensioning seat 63 and thethread tensioning barrel 62 . One end portion of the thread take-upspring 65 is exposed forward from thefront wall portion 5B. Thesewing machine 1 can adjust the spring pressure of the thread take-upspring 65 through the rotation of thethread clamping base 63 . Thethread tension motor 16 is fixed to the inner side of thearm portion 4 with bolts. Theoutput shaft 18 of thethread tension motor 16 protrudes to a position forward of thefront wall portion 5B through the center hole of thethread tension holder 63 . Thetension disc 69 is fixed to the front end portion of theoutput shaft 18 with thescrew 28 . The upper thread 6 is wound around thethread tensioning reel 69 one to two times. Thethread tensioning disc 69 is rotated by thethread tensioning motor 16 . Thethread tension motor 16 has anencoder 16A (see FIG. 5 ). Theencoder 16A detects the rotational position of theoutput shaft 18 .
夹线马达16为脉冲马达，并具有输出轴18和编码器16A(参照图5)。输出轴18能够以前后方向为轴线方向进行转动。编码器16A设于头部5的内部。编码器16A所具有的码盘固定于输出轴18的后端部。编码器16A能够检测输出轴18的转动位置。输出轴18的前端部在机臂部4的右方支承夹线盘69。缝纫机1能够控制输出轴18的旋转角相位。Thethread tension motor 16 is a pulse motor, and has anoutput shaft 18 and anencoder 16A (see FIG. 5 ). Theoutput shaft 18 is rotatable in the front-rear direction as the axial direction. Theencoder 16A is provided inside thehead 5 . The code wheel included in theencoder 16A is fixed to the rear end portion of theoutput shaft 18 . Theencoder 16A can detect the rotational position of theoutput shaft 18 . The front end portion of theoutput shaft 18 supports atension disc 69 on the right side of thearm portion 4 . Thesewing machine 1 can control the rotational angle phase of theoutput shaft 18 .
图4所示的线张力检测机构130在面线6的供给路径上设于夹线盘69与挑线杆23之间。线张力检测机构130基于磁传感器105的输出电压来检测与面线张力相应地在前后方向上挠曲的板50的前后位置，从而检测面线6的张力即面线张力。The threadtension detection mechanism 130 shown in FIG. 4 is provided between thethread tension disc 69 and the thread take-uplever 23 on the supply path of the upper thread 6 . The threadtension detection mechanism 130 detects the tension of the upper thread 6 , that is, the upper thread tension by detecting the front-rear position of theplate 50 that flexes in the front-rear direction according to the upper thread tension based on the output voltage of themagnetic sensor 105 .
线张力检测机构130具有安装台140、传感器保持件80、磁传感器105、板50、引导构件160、磁体58以及基板135(参照图5)。The wiretension detection mechanism 130 includes amount 140, asensor holder 80, amagnetic sensor 105, aplate 50, aguide member 160, amagnet 58, and a base plate 135 (see FIG. 5).
安装台140具有安装部42和台座部410。安装部42和台座部410一体地形成。安装部42具有供螺钉90贯穿的长孔421。贯穿长孔421的螺钉90紧固于在凹部5A(参照图2)设置的螺纹孔。因此，安装台140安装于头部5。台座部410位于安装台140的左方。台座部410具有右突部410A和左突部410B。右突部410A和左突部410B分别为沿前后方向延伸的长方体状。The mounting table 140 has the mountingportion 42 and theseat portion 410 . The mountingportion 42 and thebase portion 410 are integrally formed. Theattachment portion 42 has anelongated hole 421 through which thescrew 90 is inserted. Thescrew 90 inserted through thelong hole 421 is fastened to the screw hole provided in the recessedportion 5A (see FIG. 2 ). Therefore, themount 140 is attached to thehead 5 . Thebase portion 410 is located on the left side of the mountingbase 140 . Thebase portion 410 has aright protrusion portion 410A and aleft protrusion portion 410B. Theright protruding portion 410A and theleft protruding portion 410B are each in the shape of a rectangular parallelepiped extending in the front-rear direction.
传感器保持件80为长方体状的非磁性体，并在右突部410A与左突部410B之间安装于台座部410。磁传感器105保持于传感器保持件80的前表面。磁传感器105包括霍尔元件。磁传感器105位于比右突部410A和左突部410B各自的前端靠后侧的位置。Thesensor holder 80 is a rectangular parallelepiped non-magnetic body, and is attached to thebase portion 410 between theright protrusion portion 410A and theleft protrusion portion 410B. Themagnetic sensor 105 is held on the front surface of thesensor holder 80 . Themagnetic sensor 105 includes a Hall element. Themagnetic sensor 105 is located behind the respective front ends of theright protrusion 410A and theleft protrusion 410B.
板50在前后方向上具有厚度，架设于右突部410A与左突部410B之间。引导构件160利用螺钉97、螺钉98安装于右突部410A和左突部410B。引导构件160在与右突部410A之间夹持板50的右端部，且在与左突部410B之间夹持板50的左端部。板50的左右方向中央部在与传感器保持件80的前表面之间具有间隙。因此，板50能够以左右方向的两端部为支点在前后方向上挠曲。Theplate 50 has a thickness in the front-rear direction, and is spanned between the right protrudingportion 410A and theleft protruding portion 410B. Theguide member 160 is attached to theright protrusion 410A and theleft protrusion 410B with thescrew 97 and thescrew 98 . Theguide member 160 sandwiches the right end of theplate 50 with theright protrusion 410A, and sandwiches the left end of theplate 50 with theleft protrusion 410B. The center portion in the left-right direction of theplate 50 has a gap with the front surface of thesensor holder 80 . Therefore, theplate 50 can be flexed in the front-rear direction with both end portions in the left-right direction as fulcrums.
磁体58为以前后方向为轴线方向的圆柱状，并利用粘接剂固定于板50的左右方向中央部的后表面。因此，当板50在前后方向上挠曲时，磁体58前后移动，与磁传感器105之间的距离发生变化。磁传感器105检测磁体58的磁通密度的变化。基板135(参照图5)设于头部5的内部。基板135经由FPC136与磁传感器105相连接。基板135获取磁传感器105的检测结果。Themagnet 58 has a columnar shape whose axial direction is the front-rear direction, and is fixed to the rear surface of the center portion in the left-right direction of theplate 50 with an adhesive. Therefore, when theplate 50 is deflected in the front-rear direction, themagnet 58 moves back and forth, and the distance from themagnetic sensor 105 changes. Themagnetic sensor 105 detects changes in the magnetic flux density of themagnet 58 . The base plate 135 (see FIG. 5 ) is provided inside thehead 5 . Thesubstrate 135 is connected to themagnetic sensor 105 via theFPC 136 . Thesubstrate 135 acquires the detection result of themagnetic sensor 105 .
引导构件160具有上引导槽182和下引导槽172。上引导槽182和下引导槽172隔着板50沿上下方向排列，并呈沿上下方向开口的钩状。上引导槽182具有上保持孔181，下引导槽172具有下保持孔171。上保持孔181和下保持孔171沿前后方向延伸。面线6贯穿上保持孔181和下保持孔171。位于上保持孔181与下保持孔171之间的面线6从前方与板50的前表面相接触。面线张力越增大，面线6越对板50向后方施力。因此，缝纫机1能够基于磁传感器105的输出电压来获取面线张力。Theguide member 160 has anupper guide groove 182 and alower guide groove 172 . Theupper guide groove 182 and thelower guide groove 172 are arranged in the up-down direction with theplate 50 interposed therebetween, and have a hook shape opened in the up-down direction. Theupper guide groove 182 has anupper holding hole 181 , and thelower guide groove 172 has alower holding hole 171 . Theupper holding hole 181 and thelower holding hole 171 extend in the front-rear direction. The upper thread 6 passes through theupper holding hole 181 and thelower holding hole 171 . The upper thread 6 located between theupper holding hole 181 and thelower holding hole 171 is in contact with the front surface of theboard 50 from the front. As the upper thread tension increases, the upper thread 6 urges theplate 50 backward. Therefore, thesewing machine 1 can acquire the upper thread tension based on the output voltage of themagnetic sensor 105 .
参照图5说明缝纫机1的电气结构。缝纫机1的控制装置30具有CPU91。CPU91控制缝纫机1的动作。CPU91与ROM92、RAM93、存储装置94、I/O接口(以下称作I/O)45相连接。ROM92存储用于执行后述的缝制处理(参照图14)等各种处理的程序等。RAM93临时存储各种值。存储装置94是非易失性的存储装置。The electrical configuration of thesewing machine 1 will be described with reference to FIG. 5 . Thecontrol device 30 of thesewing machine 1 includes theCPU 91 . TheCPU 91 controls the operation of thesewing machine 1 . TheCPU 91 is connected to aROM 92 , aRAM 93 , astorage device 94 , and an I/O interface (hereinafter referred to as I/O) 45 . TheROM 92 stores programs and the like for executing various processes such as the sewing process (refer to FIG. 14 ) which will be described later. TheRAM 93 temporarily stores various values. Thestorage device 94 is a nonvolatile storage device.
I/O45与驱动电路81～驱动电路83相连接。驱动电路81与主马达27相连接。驱动电路82与送布马达123相连接。驱动电路83与夹线马达16相连接。主马达27、送布马达123、夹线马达16分别具有编码器27A、编码器123A、编码器16A。编码器27A检测主马达27的输出轴的旋转位置。即，编码器27A的检测结果表示上轴15的旋转角相位即上轴相位。编码器123A检测送布马达123的输出轴的转动位置。编码器16A检测夹线马达16的输出轴18的转动位置。CPU91获取编码器27A、编码器123A、编码器16A的检测结果，并向驱动电路81～驱动电路83发送控制信号。因此，CPU91控制主马达27、送布马达123、夹线马达16的驱动。以下，在对主马达27和送布马达123进行统称时，称作驱动马达。The I/O 45 is connected to thedrive circuit 81 to thedrive circuit 83 . Thedrive circuit 81 is connected to themain motor 27 . The drive circuit 82 is connected to thefeed motor 123 . Thedrive circuit 83 is connected to thethread clamping motor 16 . Themain motor 27, thecloth feed motor 123, and thethread clamping motor 16 have anencoder 27A, anencoder 123A, and anencoder 16A, respectively. Theencoder 27A detects the rotational position of the output shaft of themain motor 27 . That is, the detection result of theencoder 27A indicates the upper shaft phase, which is the rotational angle phase of theupper shaft 15 . Theencoder 123A detects the rotational position of the output shaft of thefeed motor 123 . Theencoder 16A detects the rotational position of theoutput shaft 18 of thethread tension motor 16 . TheCPU 91 acquires the detection results of theencoder 27A, theencoder 123A, and theencoder 16A, and sends control signals to thedrive circuits 81 to 83 . Therefore, theCPU 91 controls the driving of themain motor 27 , thecloth feed motor 123 , and thethread clamping motor 16 . Hereinafter, when themain motor 27 and thecloth feed motor 123 are collectively referred to, they are referred to as drive motors.
I/O45与驱动电路84、驱动电路85、输入部24以及踏板38相连接。驱动电路84与切线电磁元件17A相连接。驱动电路85与显示部25相连接。CPU91通过向驱动电路84、驱动电路85发送控制信号来控制切线电磁元件17A和显示部25。输入部24将由操作者向输入部24输入的输入结果向CPU91输出。踏板38将由操作者对踏板38操作的操作方向和操作量向CPU91输出。The I/O 45 is connected to thedrive circuit 84 , thedrive circuit 85 , theinput unit 24 , and thepedal 38 . Thedrive circuit 84 is connected to the tangentialelectromagnetic element 17A. Thedrive circuit 85 is connected to thedisplay unit 25 . TheCPU 91 controls the line cuttingelectromagnetic element 17A and thedisplay unit 25 by sending control signals to thedrive circuit 84 and thedrive circuit 85 . Theinput unit 24 outputs the input result input to theinput unit 24 by the operator to theCPU 91 . The pedal 38 outputs to theCPU 91 the operation direction and the operation amount of the operation of the pedal 38 by the operator.
I/O45与基板135的CPU135A相连接。基板135具有CPU135A、RAM135B、存储装置135C、放大电路151、减法电路152以及计时器35。CPU135A与RAM135B、放大电路151、减法电路152以及计时器35相连接。计时器35将计时结果向CPU135A输出。放大电路151和减法电路152彼此连接，减法电路152与磁传感器105相连接。图6的两个图表分别将横轴设为时间，将纵轴设为电压。磁传感器105检测磁体58的磁通密度的变化。图6的左侧的图表表示磁传感器105的输出电压随时间的变化。磁传感器105将输出电压向减法电路152输出。减法电路152抽出磁传感器105的输出电压中的、相对于基准电压Vt而言为ΔV的范围的电压，并将抽出结果向放大电路151输出。基准电压Vt为面线张力为0时的磁传感器105的输出电压，是作为磁传感器105的基准的输出电压。图6的右侧的图表表示放大电路151将减法电路152的抽出结果放大后的输出电压随时间的变化。放大电路151将放大后的输出电压向CPU135A输出。将放大电路151的输出结果称作磁传感器105的检测结果。CPU135A能够对减法电路152执行零点调整(也称作偏置调整)。零点调整重新设定磁传感器105的基准电压Vt。零点调整的执行时机优选为面线张力为0时。The I/O 45 is connected to theCPU 135A of thesubstrate 135 . Thesubstrate 135 includes aCPU 135A, aRAM 135B, a storage device 135C, anamplifier circuit 151 , asubtraction circuit 152 , and atimer 35 . TheCPU 135A is connected to theRAM 135B, theamplifier circuit 151 , thesubtraction circuit 152 , and thetimer 35 . Thetimer 35 outputs the timing result to theCPU 135A. The amplifyingcircuit 151 and the subtractingcircuit 152 are connected to each other, and the subtractingcircuit 152 is connected to themagnetic sensor 105 . In the two graphs of FIG. 6 , the horizontal axis is time, and the vertical axis is voltage, respectively. Themagnetic sensor 105 detects changes in the magnetic flux density of themagnet 58 . The graph on the left side of FIG. 6 shows the change with time of the output voltage of themagnetic sensor 105 . Themagnetic sensor 105 outputs the output voltage to thesubtraction circuit 152 . Thesubtraction circuit 152 extracts a voltage in the range of ΔV with respect to the reference voltage Vt among the output voltages of themagnetic sensor 105 , and outputs the extraction result to theamplifier circuit 151 . The reference voltage Vt is the output voltage of themagnetic sensor 105 when the needle thread tension is zero, and is the output voltage of themagnetic sensor 105 as a reference. The graph on the right side of FIG. 6 shows the temporal change of the output voltage after theamplification circuit 151 amplifies the extraction result of thesubtraction circuit 152 . Theamplifier circuit 151 outputs the amplified output voltage to theCPU 135A. The output result of theamplifier circuit 151 is referred to as the detection result of themagnetic sensor 105 . TheCPU 135A can perform zero point adjustment (also referred to as offset adjustment) on thesubtraction circuit 152 . The zero point adjustment resets the reference voltage Vt of themagnetic sensor 105 . The timing for performing the zero point adjustment is preferably when the upper thread tension is zero.
存储装置135C存储断线标志、跳针标志以及收线不良标志。断线标志、跳针标志以及收线不良标志分别切换为0或1。断线、跳针以及收线不良见后述。存储装置135C存储第一断线阈值、第二断线阈值、第一跳针阈值、第二跳针阈值、收线不良特定阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值以及第二跳针特定阈值。各阈值是用于判断有无发生后述的缝制不良的值。存储装置135C存储各阈值的初始值。在后述的缝制不良判断处理(参照图17)中，CPU135A能够与上轴15的旋转速度即上轴旋转速度或上轴15的旋转加速度相应地变更存储于存储装置135C的阈值。存储装置135C存储的阈值的详细说明见后述。The storage device 135C stores a disconnection flag, a skipped stitch flag, and a bad thread take-up flag. The disconnection flag, skip stitch flag and bad thread take-up flag are switched to 0 or 1 respectively. Broken thread, skipped stitch and poor thread take-up will be described later. The storage device 135C stores the first wire breakage threshold, the second wire breakage threshold, the first skipped stitch threshold, the second skipped stitch threshold, the specific threshold for poor thread take-up, the first specific threshold for wire breakage, the second specific Jump stitch specific threshold and second jump stitch specific threshold. Each threshold value is a value for judging the presence or absence of a sewing defect which will be described later. The storage device 135C stores the initial value of each threshold value. In the sewing failure determination process (refer to FIG. 17 ) described later, theCPU 135A can change the threshold value stored in the storage device 135C according to the rotation speed of theupper shaft 15 , that is, the upper shaft rotation speed or the rotation acceleration of theupper shaft 15 . Details of the threshold values stored in the storage device 135C will be described later.
参照图1～图3，说明缝纫机1的动作概要。操作者将布料载置于针板7。通过驱动马达驱动，上轴15使针杆11和挑线杆23上下运动，梭子转动。在机针10刺入布料下降到下死点之后上升时，梭子利用梭尖捕捉机针10的针眼所保持的环状的面线6，将该面线6与底线交织。机针10从布料向上方退出。此时，在送布马达123和主马达27的驱动下，送布齿从送布齿孔14向上方突出并向后方摆动。因此，布料向后方移动。挑线杆23提起由梭子交织于底线的面线6，从而在布料形成线迹。通过上轴15、机针10、梭子、挑线杆23以及送布机构重复上述动作，对布料进行缝制。一针的缝制为一周期的缝制。1 to 3 , the outline of the operation of thesewing machine 1 will be described. The operator places the cloth on theneedle plate 7 . Driven by the drive motor, theupper shaft 15 moves theneedle bar 11 and the thread take-uplever 23 up and down, and the shuttle rotates. When theneedle 10 pierces the cloth and descends to the bottom dead center and then ascends, the shuttle catches the looped upper thread 6 held by the eye of theneedle 10 with the tip of the shuttle, and interlaces the upper thread 6 with the lower thread. Theneedle 10 is withdrawn upward from the material. At this time, driven by thefeed motor 123 and themain motor 27, the feed teeth protrude upward from the feed teeth holes 14 and swing rearward. Therefore, the cloth moves backward. The thread take-uplever 23 lifts up the upper thread 6 interlaced with the lower thread by the shuttle to form a stitch in the fabric. Theupper shaft 15, theneedle 10, the shuttle, the thread take-uplever 23, and the cloth feed mechanism repeat the above-mentioned operations to sew the cloth. One stitch of sewing is one cycle of sewing.
说明缝纫机1的缝制不良。缝制不良表示在缝制动作中未能形成正常的线迹。缝制不良包括收线不良、断线以及跳针。收线不良为挑线杆23提起面线6时在布料形成线迹的面线6和底线的均衡不良。例如，当面线6过于牢固地交织于底线时，线迹附近的布料收缩。断线是面线6在缝制中断开的不良，且是未能在布料形成线迹的不良。跳针是缝制中的梭子对面线6的捕捉失败，且是未能在布料形成正常的线迹的不良。Defective sewing of thesewing machine 1 will be described. Poor sewing means that normal stitches were not formed during the sewing action. Poor sewing includes poor thread take-up, broken thread, and skipped stitches. Poor thread take-up is a poor balance between the upper thread 6 and the lower thread that form stitches in the fabric when the thread take-uplever 23 lifts the upper thread 6 . For example, when the upper thread 6 is intertwined with the lower thread too strongly, the fabric near the stitch shrinks. The thread breakage is a defect that the upper thread 6 is broken during sewing, and is a defect that a stitch cannot be formed in the cloth. Skipping stitches are failures in which the shuttle during sewing failed to catch the upper thread 6 and normal stitches were not formed in the fabric.
在缝纫机1的一周期的缝制期间，依次有会合、梭子捕捉期间、挑线杆提起期间。会合是机针10从下死点上升并到达针下位置附近的时机。针下位置是梭子利用梭尖捕捉面线6的高度位置。梭子捕捉期间是梭子利用梭尖捕捉面线6、面线6穿过梭子的期间。挑线杆提起期间是从面线6自梭子退出时到挑线杆23提起面线6为止的期间。In a sewing period of one cycle of thesewing machine 1, there are a rendezvous, a shuttle catch period, and a thread take-up period in this order. The meeting is the timing when theneedle 10 rises from the bottom dead center and reaches the vicinity of the needle lower position. The needle-down position is the height position at which the shuttle catches the upper thread 6 with the tip of the shuttle. The shuttle catching period is a period during which the shuttle catches the upper thread 6 with the tip of the shuttle and the upper thread 6 passes through the shuttle. The thread take-up period is the period from when the upper thread 6 is withdrawn from the shuttle until the thread take-uplever 23 lifts up the upper thread 6 .
图7是将横轴设为时间且将纵轴设为变动张力的图表。变动张力是在将单位设为时间的周期内重复变动的面线张力。在本例中，变动张力是将一周期的缝制期间设为单位周期进行重复变动的面线张力。即，变动张力是从缝制开始起在第N周期(N为自然数)内变动的面线张力。图7表示第三周期、第四周期、第五周期的变动张力。像后述那样，在第一周期、第二周期内难以产生变动张力。另外，上轴旋转速度越快，各周期的期间(图7的横向尺寸)越短。在图7中，第三周期、第四周期、第五周期的期间彼此不同。FIG. 7 is a graph in which the horizontal axis represents time and the vertical axis represents fluctuating tension. The fluctuating tension is the upper thread tension that repeatedly fluctuates in a cycle whose unit is time. In this example, the fluctuating tension is the upper thread tension that is repeatedly fluctuated by setting a sewing period of one cycle as a unit cycle. That is, the fluctuating tension is the upper thread tension that fluctuates in the Nth cycle (N is a natural number) from the start of sewing. FIG. 7 shows fluctuating tension in the third cycle, the fourth cycle, and the fifth cycle. As will be described later, fluctuating tension is unlikely to occur in the first cycle and the second cycle. In addition, the higher the rotation speed of the upper shaft, the shorter the period of each cycle (the horizontal dimension in FIG. 7 ). In FIG. 7 , the periods of the third cycle, the fourth cycle, and the fifth cycle are different from each other.
第三周期内的梭子捕捉期间、挑线杆提起期间分别为T1、T2。在第N周期的期间内，梭子捕捉期间是面线张力第一次达到极大的期间，挑线杆提起期间是面线张力第二次达到极大的期间。以下，将梭子捕捉期间内的面线张力的极大值称作第一面线张力，将挑线杆提起期间内的面线张力的极大值称作第二面线张力。将从第N-1周期的第一面线张力减去第N周期的第一面线张力得到的值称作第一面线张力差，将从第N-1周期的第二面线张力减去第N周期的第二面线张力得到的值称作第二面线张力差。The shuttle catching period and the thread take-up period in the third cycle are T1 and T2, respectively. In the period of the Nth cycle, the shuttle catch period is the period when the upper thread tension reaches the maximum for the first time, and the thread take-up period is the period when the upper thread tension reaches the maximum for the second time. Hereinafter, the maximum value of the upper thread tension in the shuttle catching period is referred to as the first upper thread tension, and the maximum value of the upper thread tension in the period in which the thread take-up lever is raised is referred to as the second upper thread tension. The value obtained by subtracting the first upper thread tension of the N-th cycle from the first upper thread tension of the N-1 cycle is called the first upper thread tension difference, and subtracting the second upper thread tension of the N-1 cycle from the second upper thread tension of the N-1 cycle The value obtained from the second upper thread tension of the Nth cycle is called the second upper thread tension difference.
图8使用两点划线表示在第N-1周期正常形成了线迹时的变动张力，用实线表示在第N周期发生了收线不良时的变动张力。在发生收线不良时，第二面线张力的产生时机与基准面线张力下的第二面线张力的产生时机之差为后述的收线不良特定阈值以上。基准面线张力是作为一周期内的基准的变动张力。在进行第二周期以后的缝制时，对于第N周期缝制时的基准面线张力而言，第N-1周期的变动张力为基准面线张力。在进行第一周期的缝制时，由存储装置135C存储的基准数据所示的变动张力为基准面线张力。基准数据所示的变动张力表示在正常地执行第一周期的缝制时产生的变动张力。像后述那样，由于正常情况下缝制初始阶段的变动张力较小，因此，基准数据所示的变动张力比执行第三周期以后的缝制时的变动张力小。收线不良特定阈值是用于在收线不良判断处理(图17的S111)中由CPU135A判断有无发生收线不良的阈值。FIG. 8 shows the fluctuating tension when the stitch is normally formed in the N-1th cycle by a two-dot chain line, and the fluctuating tension when the thread take-up failure occurs in the Nth cycle is indicated by a solid line. When a thread take-up failure occurs, the difference between the timing of generating the second needle thread tension and the timing of generating the second needle thread tension at the reference needle thread tension is equal to or greater than a specific threshold value for the thread take-up defect, which will be described later. The thread tension on the reference surface is the fluctuating tension as a reference in one cycle. When performing the sewing after the second cycle, with respect to the reference thread tension at the time of sewing in the N-th cycle, the fluctuating tension in the N-1-th cycle is the reference thread tension. When the sewing of the first cycle is performed, the fluctuating tension indicated by the reference data stored in the storage device 135C is the reference thread tension. The fluctuating tension indicated by the reference data represents the fluctuating tension that occurs when the sewing of the first cycle is normally performed. As will be described later, since the fluctuating tension at the initial stage of sewing is normally small, the fluctuating tension indicated by the reference data is smaller than the fluctuating tension at the time of executing the third and subsequent sewing cycles. The bad take-up specific threshold is a threshold value for theCPU 135A to determine whether or not bad take-up has occurred in the poor take-up determination process (S111 in FIG. 17 ).
在发生断线时，面线张力在一周期的缝制期间内大致为0，不产生变动，不过以上内容未图示。因此，第一面线张力和第二面线张力都与正常时相比变得极小。在发生断线时，第一面线张力为第一断线阈值以下，且第二面线张力为第二断线阈值以下。在发生断线时，第一面线张力差为第一断线特定阈值以上，第二面线张力差为第二断线特定阈值以上。第一断线阈值和第二断线阈值是用于在断线判断处理(图17的S117)中由CPU135A判断有无发生断线的阈值。第一断线特定阈值和第二断线特定阈值是用于在特定断线判断处理(图17的S113)中由CPU135A判断有无发生断线的阈值。When thread breakage occurs, the tension of the upper thread is approximately 0 during one cycle of sewing, and does not fluctuate. However, the above content is not shown. Therefore, both the first upper thread tension and the second upper thread tension become extremely small compared to the normal state. When thread breakage occurs, the first upper thread tension is equal to or less than the first thread disconnection threshold, and the second upper thread tension is equal to or less than the second thread disconnection threshold. When thread breakage occurs, the first upper thread tension difference is greater than or equal to the first thread breakage specific threshold value, and the second upper thread tension difference is greater than or equal to the second thread breakage specific threshold value. The first disconnection threshold and the second disconnection threshold are thresholds for theCPU 135A to determine whether or not disconnection has occurred in the disconnection determination process (S117 in FIG. 17 ). The first disconnection specific threshold and the second disconnection specific threshold are thresholds for theCPU 135A to determine whether or not disconnection has occurred in the specific disconnection determination process (S113 in FIG. 17 ).
如图9所示，在发生跳针时，第一面线张力与正常时相比变得极小，第二面线张力为接近正常时的值。因此，在发生跳针时，第一面线张力为第一跳针阈值以下，第二面线张力为第二跳针阈值以上。在发生跳针时，第一面线张力差为第一跳针特定阈值以上，第二面线张力差为第二跳针特定阈值以下。第一跳针阈值和第二跳针阈值是用于在跳针判断处理(图17的S119)中由CPU135A判断有无发生跳针的阈值。第一跳针特定阈值和第二跳针特定阈值是用于在特定跳针判断处理(图17的S115)中由CPU135A判断有无发生跳针的阈值。As shown in FIG. 9 , when skipped stitches occur, the first upper thread tension becomes extremely small compared to the normal time, and the second upper thread tension is close to the normal value. Therefore, when skipped stitches occur, the first upper thread tension is equal to or less than the first skipped stitch threshold, and the second upper thread tension is equal to or greater than the second skipped threshold. When skipped stitches occur, the first upper thread tension difference is above the specific threshold value of the first skipped stitches, and the second upper thread tension difference is below the specific threshold value of the second skipped stitches. The first skip stitch threshold and the second skip stitch threshold are thresholds for theCPU 135A to determine whether or not skip stitches have occurred in the skip stitch determination process (S119 in FIG. 17 ). The first skip stitch specific threshold and the second skip stitch specific threshold are thresholds for theCPU 135A to determine whether or not skip stitches have occurred in the specific skip stitch determination process (S115 in FIG. 17 ).
CPU135A为了以周期单位获取第一面线张力、第二面线张力，以周期单位获取变动张力。CPU135A在后述的张力获取处理(参照图16)中获取磁传感器105的检测结果，持续地获取变动张力并依次存储于RAM135B。CPU135A通过对依次存储于RAM135B的变动张力执行自相关分析，能够获取一周期单位的变动张力。自相关分析是获取相关系数来发现数据的周期性的公知的分析手法，所述相关系数表示作为比较基准的数据与其他数据的相关的程度。相关系数在-1～1之间变动，相关系数的绝对值越接近1，两个数据的相同程度越高。CPU135A将基准面线张力设定为作为比较基准的数据。CPU135A将以周期单位获取的变动张力存储于RAM135B。TheCPU 135A acquires the variable tension in the cycle unit in order to obtain the first needle thread tension and the second needle thread tension in the cycle unit. TheCPU 135A acquires the detection result of themagnetic sensor 105 in a tension acquisition process (refer to FIG. 16 ) to be described later, continuously acquires the fluctuating tension, and sequentially stores it in theRAM 135B. TheCPU 135A can acquire the fluctuating tension in one cycle by performing autocorrelation analysis on the fluctuating tensions sequentially stored in theRAM 135B. Autocorrelation analysis is a well-known analysis technique for discovering periodicity of data by acquiring a correlation coefficient indicating the degree of correlation between data serving as a comparison reference and other data. The correlation coefficient varies between -1 and 1, and the closer the absolute value of the correlation coefficient is to 1, the higher the degree of similarity between the two data. TheCPU 135A sets the reference surface thread tension as data serving as a comparison reference. TheCPU 135A stores the fluctuating tension acquired in units of cycles in theRAM 135B.
图10～图13表示将横轴设为时间(ms)将纵轴设为相关系数的图表。图10表示正常形成线迹时的相关系数。CPU135A所获取的变动张力与基准面线张力的相关系数与时间的经过相应地变动。在25ms附近，相关系数大致为1，达到极大。因此，CPU135A基于相关系数大致为1达到极大的情况，能够判断为获取了一周期的变动张力。10 to 13 show graphs in which the horizontal axis is time (ms) and the vertical axis is a correlation coefficient. Fig. 10 shows the correlation coefficients when the stitches are normally formed. The correlation coefficient between the fluctuating tension and the reference surface thread tension acquired by theCPU 135A fluctuates according to the passage of time. In the vicinity of 25ms, the correlation coefficient is approximately 1 and reaches a maximum value. Therefore, theCPU 135A can determine that the fluctuation tension of one cycle is acquired based on the fact that the correlation coefficient is approximately 1 and reaches the maximum value.
图11表示发生收线不良时的相关系数，图12表示发生跳针时的相关系数。在发生收线不良、跳针中的任一情况时，相关系数都在25ms附近大致为1成为极大值。因此，CPU135A能够以与正常形成线迹时同样的判断基准判断为获取了一周期的变动张力。Fig. 11 shows the correlation coefficient when the thread take-up failure occurs, and Fig. 12 shows the correlation coefficient when the stitch skipping occurs. When any of the thread take-up failure and the skipped stitch occur, the correlation coefficient is approximately 1 and becomes a maximum value around 25 ms. Therefore, theCPU 135A can determine that the fluctuating tension of one cycle has been acquired based on the same determination criteria as when the stitch is normally formed.
图13表示发生断线时的相关系数。在发生断线时，在25ms附近，相关系数不是大致为1的情况，未成为极大值。即，在一周期的缝制完成的时机，相关系数不是大致为1的情况，未成为极大值。此时，CPU135A基于相当于一周期的时间经过，判断为获取了一周期的变动张力。相当于一周期表示对一周期前的一周期期间追加数ms的期间后的期间。FIG. 13 shows correlation coefficients when disconnection occurs. When a disconnection occurs, the correlation coefficient is not approximately 1 in the vicinity of 25 ms, and does not become a maximum value. That is, when one cycle of sewing is completed, the correlation coefficient is not substantially 1, and does not become a maximum value. At this time, theCPU 135A determines that the fluctuating tension of one cycle has been acquired based on the elapse of time corresponding to one cycle. Equivalent to one cycle means a period after adding a period of several ms to the one-cycle period before one cycle.
参照图14、图15说明缝制处理。在操作者接通缝纫机1的电源时，CPU91从ROM92读出程序，开始缝制处理。The sewing process will be described with reference to FIGS. 14 and 15 . When the operator turns on the power of thesewing machine 1, theCPU 91 reads out the program from theROM 92 and starts the sewing process.
CPU91基于踏板38的检测结果来判断缝纫机1是否开始缝制动作(S11)。CPU91在操作者踩下踏板38之前，判断为不开始缝制动作(S11：否)，并且待机。操作者在CPU91的待机过程中，将布料载置于针板7。CPU91在操作者踩下了踏板38时(S11：是)，驱动夹线马达16，将面线张力设为预定的面线张力(S12)。Based on the detection result of the pedal 38, theCPU 91 determines whether or not thesewing machine 1 has started the sewing operation (S11). TheCPU 91 determines that the sewing operation is not to be started until the operator depresses the pedal 38 ( S11 : NO), and stands by. The operator places the cloth on thethroat plate 7 while theCPU 91 is on standby. When the operator depresses the pedal 38 ( S11 : YES), theCPU 91 drives thethread tension motor 16 to set the upper thread tension to a predetermined upper thread tension ( S12 ).
CPU91使驱动马达的驱动开始(S13)，开始对布料的缝制动作。此时，CPU91将存储于RAM93的变量M覆盖为0。M是用于对从CPU91判断为结束缝制动作时起到执行面线6和底线的切断即切线为止的预定周期进行计数的计数值。预定周期预先存储于存储装置94。CPU91驱动夹线马达16，维持预定的面线张力。TheCPU 91 starts the drive of the drive motor ( S13 ), and starts the sewing operation of the cloth. At this time, theCPU 91 overwrites the variable M stored in theRAM 93 with 0. M is a count value for counting a predetermined period from when theCPU 91 determines that the sewing operation is ended until the cutting of the upper thread 6 and the lower thread, that is, thread trimming is performed. The predetermined period is stored in thestorage device 94 in advance. TheCPU 91 drives thethread tension motor 16 to maintain a predetermined upper thread tension.
CPU91基于编码器27A的检测结果来获取上轴旋转速度(S15)。CPU91通过获取两次编码器27A的检测结果来计算差，获取上轴旋转速度。TheCPU 91 acquires the upper shaft rotational speed based on the detection result of theencoder 27A ( S15 ). TheCPU 91 calculates the difference by acquiring the detection results of theencoder 27A twice, and acquires the rotation speed of the upper shaft.
CPU91执行面线卷绕处理(S16)。CPU91判断在S15中获取的上轴旋转速度是否为第一速度以下(S81)。CPU91在判断为上轴旋转速度比第一速度大时(S81：否)，结束面线卷绕处理，返回到缝制处理。CPU91在判断为上轴旋转速度为第一速度以下时(S81：是)，控制夹线马达16，使夹线盘69向卷绕方向旋转，将面线6卷绕(S83)。卷绕方向是与夹线盘69沿着供给路径供给面线6的方向相反的方向。CPU91使夹线盘69向卷绕方向旋转预定旋转量。因此，缝纫机1能够抑制面线6的松弛。CPU91结束面线卷绕处理，返回到缝制处理。TheCPU 91 executes the upper thread winding process (S16). TheCPU 91 determines whether or not the upper shaft rotational speed acquired in S15 is equal to or lower than the first speed (S81). When theCPU 91 determines that the upper shaft rotational speed is higher than the first speed (S81: NO), the upper thread winding process is terminated, and the process returns to the sewing process. When theCPU 91 determines that the upper shaft rotational speed is equal to or lower than the first speed ( S81 : YES), theCPU 91 controls thethread tension motor 16 to rotate thethread tension disc 69 in the winding direction to wind the upper thread 6 ( S83 ). The winding direction is the direction opposite to the direction in which thethread tension disc 69 supplies the needle thread 6 along the supply path. TheCPU 91 rotates thetension disc 69 by a predetermined rotation amount in the winding direction. Therefore, thesewing machine 1 can suppress the loosening of the upper thread 6 . TheCPU 91 ends the upper thread winding process and returns to the sewing process.
CPU91判断是否发生了缝制不良(S17)。CPU91基于在后述的张力获取处理中由CPU135A发送的缝制不良信息来判断是否发生了缝制不良。CPU91在断线标志、跳针标志、收线不良标志中的至少一个为1时，判断为发生了缝制不良(S17：是)，使处理转移到S23。CPU91在断线标志、跳针标志、收线不良标志都为0时，判断为未发生缝制不良(S17：否)。CPU91基于踏板38的检测结果来判断是否结束缝制(S18)。CPU91在操作者未踩回踏板38时，判断为不结束缝制(S18：否)，使处理转移到S15。TheCPU 91 judges whether or not a sewing defect has occurred (S17). TheCPU 91 determines whether or not a sewing defect has occurred based on the sewing defect information transmitted by theCPU 135A in a tension acquisition process described later. When at least one of the thread breakage flag, the skipped stitch flag, and the defective thread take-up flag is 1, theCPU 91 determines that a sewing defect has occurred ( S17 : YES), and moves the process to S23 . When the thread breakage flag, the skipped stitch flag, and the defective thread take-up flag are all 0, theCPU 91 determines that the sewing defect has not occurred ( S17 : NO). Based on the detection result of the pedal 38, theCPU 91 determines whether or not the sewing is to be completed (S18). When the operator has not stepped back on thepedal 38, theCPU 91 determines that the sewing is not to be completed (S18: NO), and transfers the process to S15.
例如在操作者踩回踏板38时，CPU91判断为结束缝制动作(S18：是)，基于存储于RAM93的M来判断是否到达了预定周期(S19)。CPU91在判断为小于预定周期时(S19：否)，在M上加1(S71)，使处理转移到S72。CPU91基于编码器27A的检测结果来获取上轴旋转速度(S72)，执行面线卷绕处理(S73)。S72、S73的处理与S15、S16的处理相同。CPU91判断是否发生了缝制不良(S74)。CPU91在判断为发生了缝制不良时(S74：是)，使处理转移到S75。CPU91在判断为未发生缝制不良时(S74：否)，使处理转移到S19。CPU91在判断为未到达预定周期时，重复处理(S19：否，S71、S72、S73、S74)。For example, when the operator steps back on thepedal 38, theCPU 91 determines that the sewing operation is ended (S18: YES), and determines whether or not a predetermined cycle has been reached based on M stored in the RAM 93 (S19). When theCPU 91 determines that it is less than the predetermined cycle ( S19 : NO), it adds 1 to M ( S71 ), and transfers the process to S72 . TheCPU 91 acquires the upper shaft rotational speed based on the detection result of theencoder 27A ( S72 ), and executes the upper thread winding process ( S73 ). The processing of S72 and S73 is the same as the processing of S15 and S16. TheCPU 91 judges whether or not a sewing defect has occurred (S74). When theCPU 91 determines that the sewing failure has occurred ( S74 : YES), the process proceeds to S75 . When theCPU 91 determines that the sewing failure has not occurred ( S74 : NO), the process proceeds to S19 . When theCPU 91 determines that the predetermined cycle has not been reached, it repeats the processing ( S19 : NO, S71 , S72 , S73 , and S74 ).
CPU91在判断为到达预定周期时(S19：是)，控制切线电磁元件17A，执行切线(S20)。在切断面线6后，面线张力大致为0。CPU91使驱动马达的驱动停止(S21)。When theCPU 91 determines that the predetermined cycle has been reached ( S19 : YES), theCPU 91 controls the thread cuttingelectromagnetic element 17A to perform thread cutting ( S20 ). After the upper thread 6 is cut, the tension of the upper thread is approximately zero. TheCPU 91 stops the driving of the drive motor (S21).
CPU91向CPU135A发送执行磁传感器105的输出电压的零点调整的指示(S22)。CPU91使处理转移到S220。TheCPU 91 transmits an instruction to execute zero-point adjustment of the output voltage of themagnetic sensor 105 to theCPU 135A ( S22 ). TheCPU 91 shifts the process to S220.
CPU91判断是否有切断缝纫机1的电源的操作(S220)。CPU91在判断为没有切断缝纫机1的电源的操作时(S220：否)，使处理转移到S11。在操作者替代缝制后的布料将未缝制的布料载置于针板7并踩下踏板38时(S11：是)，CPU91进行S12以后的处理。CPU91在判断为有切断缝纫机1的电源的操作时(S220：是)，结束缝制处理。TheCPU 91 determines whether or not there is an operation to cut off the power of the sewing machine 1 (S220). When theCPU 91 determines that there is no operation to cut off the power supply of the sewing machine 1 ( S220 : NO), the process proceeds to S11 . When the operator places the unsewn material on thethroat plate 7 in place of the sewn material and depresses the pedal 38 ( S11 : YES), theCPU 91 performs the processing after S12 . When theCPU 91 determines that there is an operation to cut off the power of the sewing machine 1 ( S220 : YES), theCPU 91 ends the sewing process.
参照图16～图22，说明张力获取处理。张力获取处理与缝制处理并行地由CPU135A执行。CPU135A通过张力获取处理，基于获取到的面线张力来判断有无发生缝制不良。在操作者接通缝纫机1的电源时，CPU135A开始张力获取处理。16 to 22, the tension acquisition process will be described. The tension acquisition process is executed by theCPU 135A in parallel with the sewing process. TheCPU 135A judges whether or not a sewing defect has occurred based on the acquired upper thread tension through the tension acquisition process. When the operator turns on the power of thesewing machine 1, theCPU 135A starts the tension acquisition process.
CPU135A执行初始化处理(S30)。CPU135A将存储于存储装置135C的断线标志、跳针标志、收线不良标志分别设为0。CPU135A将计时器35初始化为0。CPU135A将存储于RAM135B的变量N覆盖为1(S31)。CPU135A基于磁传感器105的检测结果来获取面线张力(S33)。磁传感器105的检测结果是例如图6的右侧的图表中的t1时的输出电压。CPU135A基于磁传感器105的输出电压和预定的关系式来获取面线张力。CPU135A将获取到的面线张力作为变动张力，依次存储于RAM135B。TheCPU 135A executes initialization processing (S30). TheCPU 135A sets the disconnection flag, the skipped stitch flag, and the thread take-up failure flag stored in the storage device 135C to 0, respectively. TheCPU 135A initializes thetimer 35 to zero. TheCPU 135A overwrites the variable N stored in theRAM 135B with 1 (S31). TheCPU 135A acquires the upper thread tension based on the detection result of the magnetic sensor 105 ( S33 ). The detection result of themagnetic sensor 105 is, for example, the output voltage at t1 in the graph on the right side of FIG. 6 . TheCPU 135A acquires the upper thread tension based on the output voltage of themagnetic sensor 105 and a predetermined relational expression. TheCPU 135A sequentially stores the acquired upper thread tension in theRAM 135B as the fluctuating tension.
CPU135A判断缝纫机1的缝制动作是否已开始(S35)。该判断是通过对缝制开始时的变动张力所示的面线张力与在S33中存储于RAM135B的变动张力进行比较的自相关分析来进行的。在缝制动作未开始时，面线张力不产生变动。因此，在自相关分析中对面线张力和变动张力进行比较时，相关系数不在1附近，未达到极大。在相关系数不在1附近未达到极大时，CPU135A判断为缝制动作未开始(S35：否)，使处理转移到S33。CPU135A在相关系数在1附近达到极大时，判断为缝制动作开始(S35：是)，使处理转移到S37。CPU135A使计时器35的计时开始(S37)。计时器35对从缝制动作开始起的经过时间进行计时。TheCPU 135A determines whether or not the sewing operation of thesewing machine 1 has started (S35). This determination is made by autocorrelation analysis in which the upper thread tension indicated by the fluctuating tension at the start of sewing is compared with the fluctuating tension stored in theRAM 135B in S33. When the sewing operation is not started, the tension of the upper thread does not fluctuate. Therefore, when comparing the thread tension and the fluctuating tension in the autocorrelation analysis, the correlation coefficient is not near 1 and does not reach a maximum value. When the correlation coefficient is not near 1 and does not reach the maximum value, theCPU 135A determines that the sewing operation has not been started ( S35 : NO), and moves the process to S33 . When the correlation coefficient reaches the maximum value in the vicinity of 1, theCPU 135A determines that the sewing operation is started ( S35 : YES), and transfers the process to S37 . TheCPU 135A starts the count of the timer 35 (S37). Thetimer 35 counts the elapsed time from the start of the sewing operation.
CPU135A获取基于磁传感器105的检测结果的面线张力和基于计时器35的计时结果的经过时间(S43)。CPU135A将获取到的经过时间和面线张力对应起来，作为变动张力存储于RAM135B。CPU135A判断是否获取到第N周期的变动张力(S45)。该判断是通过对基准面线张力和在S43中存储于RAM135B的变动张力进行比较的自相关分析来进行的。在相关系数不在1附近未达到极大时，CPU135A判断为未获取到第N周期的变动张力(S45：否)，使处理转移到S43。CPU135A在相关系数在1附近达到极大时(S45：是)，使处理转移到S47。另外，在S45中，CPU135A还在预定时间相关系数不在1附近未达到极大时，判断为获取到第N周期的变动张力(S45：是)。因此，CPU135A在发生断线时也能够判断是否获取到第N周期的变动张力。TheCPU 135A acquires the upper thread tension based on the detection result of themagnetic sensor 105 and the elapsed time based on the timing result of the timer 35 (S43). TheCPU 135A associates the acquired elapsed time with the upper thread tension, and stores it in theRAM 135B as the fluctuating tension. TheCPU 135A determines whether or not the fluctuating tension of the Nth cycle has been acquired ( S45 ). This determination is made by autocorrelation analysis that compares the thread tension of the reference surface and the fluctuating tension stored in theRAM 135B in S43. When the correlation coefficient is not in the vicinity of 1 and does not reach the maximum value, theCPU 135A determines that the fluctuation tension of the Nth cycle has not been acquired ( S45 : NO), and moves the process to S43 . When the correlation coefficient reaches a maximum value near 1 (S45: YES), theCPU 135A transfers the process to S47. In addition, in S45, theCPU 135A determines that the fluctuation tension of the Nth cycle is acquired when the predetermined time correlation coefficient is not near 1 and does not reach the maximum value (S45: YES). Therefore, theCPU 135A can determine whether or not the fluctuating tension of the Nth cycle has been acquired even when a disconnection occurs.
CPU135A在每次重复S43、S45时，将经过时间和面线张力(即变动张力)存储于RAM135B(S43)。CPU135A在相关系数在1附近达到极大时或者预定时间相关系数不在1附近未达到极大时(S45：是)，获取第N周期内的变动张力、第一面线张力、第二面线张力(S47)。CPU135A从RAM135B获取第N周期的变动张力。在S43中获取的面线张力是基于磁传感器105的检测结果的面线张力。因此，CPU135A基于线张力检测机构130的检测结果，获取第N周期内的变动张力、第一面线张力、第二面线张力(S47)。另外，在进行第一周期的缝制时，面线6容易松弛。因此，第一周期内的第一面线张力和第二面线张力难以成为图7所示的程度的较高的值。CPU135A执行缝制不良判断处理(S51)。TheCPU 135A stores the elapsed time and the upper thread tension (that is, the variable tension) in theRAM 135B each time S43 and S45 are repeated ( S43 ). TheCPU 135A acquires the fluctuating tension, the first upper thread tension, and the second upper thread tension in the Nth cycle when the correlation coefficient reaches the maximum value near 1 or when the correlation coefficient does not reach the maximum value near 1 for a predetermined time ( S45 : Yes) (S47). TheCPU 135A acquires the fluctuation tension of the Nth cycle from theRAM 135B. The upper thread tension acquired in S43 is the upper thread tension based on the detection result of themagnetic sensor 105 . Therefore, based on the detection result of the threadtension detection mechanism 130, theCPU 135A acquires the fluctuating tension in the Nth cycle, the first upper thread tension, and the second upper thread tension (S47). In addition, the upper thread 6 tends to loosen during the first cycle of sewing. Therefore, it is difficult for the first needle thread tension and the second needle thread tension in the first cycle to have high values as shown in FIG. 7 . TheCPU 135A executes a sewing failure determination process (S51).
缝制不良判断处理基于在S47中获取的变动张力来分别判断有无发生断线、跳针、收线不良。CPU135A与发生的缝制不良相应地，将断线标志、跳针标志、收线不良标志从0切换为1。CPU135A判断是否处于缝制初始阶段之中(S100)。缝制初始阶段是从缝制开始(S13)到预定针数为止的缝制。例如缝制初始阶段为从缝制开始到第二针为止的缝制，相当于到第二周期(N＝2)为止的缝制。CPU135A在N为2以下时(S100：是)，结束缝制不良判断处理，返回到张力获取处理。In the sewing failure determination process, the presence or absence of thread breakage, skipped stitches, or defective thread take-up is determined, respectively, based on the fluctuating tension acquired in S47. TheCPU 135A switches the thread breakage flag, the skipped stitch flag, and the defective thread take-up flag from 0 to 1 in accordance with the occurrence of defective sewing. TheCPU 135A judges whether or not it is in the initial stage of sewing (S100). The initial stage of sewing is sewing from the start of sewing (S13) to a predetermined number of stitches. For example, the initial stage of sewing is the sewing from the start of sewing to the second stitch, which corresponds to the sewing up to the second cycle (N=2). When N is 2 or less ( S100 : YES), theCPU 135A ends the sewing failure determination process and returns to the tension acquisition process.
CPU135A向CPU91发送表示缝制不良的有无的缝制不良信息(S53)。缝制不良信息为断线标志、跳针标志、收线不良标志。CPU135A判断是否收到了执行磁传感器105的输出电压的零点调整的指示(S55)。在缝制处理的S21中由CPU91发送了执行零点调整的指示时，CPU135A判断为接收到了执行零点调整的指示(S55：是)。CPU135A通过向减法电路152输入再次设定基准电压Vt(参照图6)的指示，执行零点调整(S57)。在切断面线6后，面线张力大致为0，因此，基准电压Vt能够设为面线张力为0时的磁传感器105的输出电压。在接收到执行零点调整的指示时，缝纫机1处于结束缝制处理的状态。CPU135A使处理转移到S30。TheCPU 135A transmits the defective sewing information indicating the presence or absence of defective sewing to the CPU 91 ( S53 ). Bad sewing information is broken thread mark, skip stitch mark, bad thread take-up mark. TheCPU 135A determines whether or not an instruction to perform zero-point adjustment of the output voltage of themagnetic sensor 105 has been received ( S55 ). In S21 of the sewing process, when theCPU 91 transmits the instruction to execute the zero point adjustment, theCPU 135A determines that the instruction to execute the zero point adjustment has been received ( S55 : YES). TheCPU 135A executes zero point adjustment by inputting an instruction to reset the reference voltage Vt (see FIG. 6 ) to the subtraction circuit 152 ( S57 ). After the needle thread 6 is cut, the needle thread tension becomes substantially 0. Therefore, the reference voltage Vt can be set as the output voltage of themagnetic sensor 105 when the needle thread tension is 0. Thesewing machine 1 is in a state of ending the sewing process when receiving the instruction to execute the zero point adjustment. TheCPU 135A shifts the process to S30.
CPU135A在判断为未收到执行零点调整的指示时(S55：否)，判断驱动马达是否处于停止驱动的状态(S59)。CPU135A基于在S47中获取的变动张力，在面线张力未变动时，判断为驱动马达处于停止驱动的状态。CPU135A在判断为驱动马达处于停止驱动的状态时(S59：是)，使处理转移到S30。CPU135A在判断为驱动马达未处于停止驱动的状态时(S59：否)，在N上加1(S61)，使处理转移到S43，重复S43、S45。例如CPU135A在获取第二周期的变动张力之后(S45：是)，将第二周期的变动张力、第一面线张力以及第二面线张力存储于RAM135B(S47)。第二周期的缝制处于缝制初始阶段之中，第二周期内的第一面线张力和第二面线张力难以成为图7所示的程度的较高的值。通过同样的处理，CPU135A在获取第三周期的变动张力之后(S45：是)，将第三周期的变动张力、第一面线张力以及第二面线张力存储于RAM135B(S47)。在图7中，用附图标记203示出第三周期的变动张力。CPU135A执行缝制不良判断处理(S51)。S101以后的缝制不良判断处理的详细说明见后述。CPU135A通过重复上述处理，获取第四周期以后的变动张力、第一面线张力以及第二面线张力(S47)。在图7中，用附图标记204示出第四周期的变动张力。When theCPU 135A determines that the instruction to execute the zero point adjustment has not been received ( S55 : NO), theCPU 135A determines whether or not the driving of the drive motor is stopped ( S59 ). TheCPU 135A determines that the drive motor is in a stopped state when the upper thread tension does not fluctuate based on the fluctuating tension acquired in S47. When theCPU 135A determines that the drive motor is in a state where the drive is stopped ( S59 : YES), the process proceeds to S30 . When theCPU 135A determines that the drive motor is not in the state of being stopped ( S59 : NO), it adds 1 to N ( S61 ), transfers the process to S43 , and repeats S43 and S45 . For example, after acquiring the fluctuating tension of the second cycle ( S45 : YES), theCPU 135A stores the fluctuating tension of the second cycle, the first needle thread tension, and the second needle thread tension in theRAM 135B ( S47 ). The sewing of the second cycle is in the initial stage of sewing, and it is difficult for the first and second upper thread tensions in the second cycle to have high values as shown in FIG. 7 . Through the same process, after acquiring the fluctuating tension of the third cycle ( S45 : YES), theCPU 135A stores the fluctuating tension of the third cycle, the first needle thread tension, and the second needle thread tension in theRAM 135B ( S47 ). In FIG. 7 , the fluctuating tension of the third cycle is indicated byreference numeral 203 . TheCPU 135A executes a sewing failure determination process (S51). The details of the sewing defect judgment processing after S101 will be described later. TheCPU 135A repeats the above-described processing to acquire the variable tension after the fourth cycle, the first upper thread tension, and the second upper thread tension ( S47 ). In FIG. 7 , the fluctuating tension of the fourth cycle is indicated byreference numeral 204 .
说明S101以后的缝制不良判断处理的详细内容。在不为缝制初始阶段时(S100：否)，CPU135A获取上轴旋转速度(S101)。CPU135A基于存储于RAM135B的第N周期的经过时间，获取从第N周期的缝制开始时到缝制结束时为止的时间来作为缝制期间。在第N周期的缝制期间内，上轴15旋转的角度是已知的。因此，CPU135A能够使用获取到的缝制时间和预定的关系式，获取上轴旋转速度。CPU135A判断在S101中获取到的上轴旋转速度是否为第二速度以下(S103)。第二速度为预先设定的速度，存储于存储装置135C。第二速度比第一速度慢。CPU135A在判断为上轴旋转速度为第二速度以下时(S103：是)，结束缝制不良判断处理。The details of the defective sewing judgment processing after S101 will be described. When it is not the initial stage of sewing ( S100 : NO), theCPU 135A acquires the upper shaft rotational speed ( S101 ). Based on the elapsed time of the Nth cycle stored in theRAM 135B, theCPU 135A acquires the time from the sewing start time of the Nth cycle to the sewing end time as the sewing period. During the sewing period of the Nth cycle, the angle by which theupper shaft 15 is rotated is known. Therefore, theCPU 135A can acquire the upper shaft rotational speed using the acquired sewing time and a predetermined relational expression. TheCPU 135A determines whether or not the upper shaft rotational speed acquired in S101 is equal to or lower than the second speed ( S103 ). The second speed is a preset speed and is stored in the storage device 135C. The second speed is slower than the first speed. When theCPU 135A determines that the rotation speed of the upper shaft is equal to or lower than the second speed ( S103 : YES), it ends the sewing failure determination process.
CPU135A在判断为上轴旋转速度比第二速度大时(S103：否)，判断上轴15的旋转是否产生了加减速(S105)。CPU135A利用与S101同样的方法，获取第N-1周期的缝制和第N周期的缝制中各自的上轴旋转速度。CPU135A在各自的上轴旋转速度之差为预定范围以上时，视为产生了加减速。CPU135A在各自的上轴旋转速度之差小于预定范围时，视为未产生加减速。CPU135A在判断为产生了加减速时(S105：是)，与加减速的程度相应地变更收线不良特定阈值(S121)。CPU135A基于第N-1周期的缝制和第N周期的缝制中各自的上轴旋转速度，确定上轴15的旋转的加速度。CPU135A以上轴15的加速度越大收线不良特定阈值越小的方式变更收线不良特定阈值。CPU135A在上轴15减速时，增大收线不良特定阈值。此时的收线不良特定阈值为正的值。When theCPU 135A determines that the rotation speed of the upper shaft is higher than the second speed ( S103 : NO), it determines whether acceleration/deceleration has occurred in the rotation of the upper shaft 15 ( S105 ). TheCPU 135A acquires the rotation speed of the upper shaft in the sewing of the N-1th cycle and the sewing of the Nth cycle, respectively, by the same method as in S101. TheCPU 135A considers that acceleration/deceleration has occurred when the difference between the respective upper shaft rotational speeds is equal to or greater than a predetermined range. When the difference between the respective upper shaft rotational speeds is smaller than the predetermined range, theCPU 135A considers that no acceleration/deceleration has occurred. When theCPU 135A determines that the acceleration/deceleration has occurred ( S105 : YES), theCPU 135A changes the take-up failure specific threshold value according to the degree of the acceleration/deceleration ( S121 ). TheCPU 135A determines the acceleration of the rotation of theupper shaft 15 based on the rotation speeds of the upper shaft in the sewing of the N-1th cycle and the sewing of the Nth cycle. The poor wire take-up specific threshold value is changed so that the higher the acceleration of theshaft 15 above theCPU 135A, the smaller the wire take-up failure specific threshold value becomes. TheCPU 135A increases the take-up failure specific threshold value when theupper shaft 15 is decelerated. In this case, the specific threshold for poor take-up is a positive value.
CPU135A在判断为未产生加减速时(S105：否)，与在S101中获取到的上轴旋转速度相应地，变更存储于存储装置135C的第一断线阈值、第二断线阈值、第一跳针阈值以及第二跳针阈值(S109)。例如CPU135A在第一断线阈值、第二断线阈值、第一跳针阈值以及第二跳针阈值上分别乘以与上轴旋转速度具有比例关系的正的系数。即，CPU135A以上轴旋转速度越大使第一断线阈值、第二断线阈值、第一跳针阈值以及第二跳针阈值越大的方式进行变更。When theCPU 135A determines that acceleration/deceleration has not occurred ( S105 : NO), theCPU 135A changes the first disconnection threshold, the second disconnection threshold, the first disconnection threshold and the first disconnection threshold stored in the storage device 135C in accordance with the upper shaft rotational speed acquired in S101 . Threshold for skipping stitches and a second threshold for skipping stitches (S109). For example, theCPU 135A multiplies the first thread breakage threshold, the second thread breakage threshold, the first jump stitch threshold, and the second jump stitch threshold by a positive coefficient proportional to the rotational speed of the upper shaft. That is, the higher the rotational speed of the shaft of theCPU 135A or higher, the change is made so that the first thread breakage threshold, the second thread breakage threshold, the first jump stitch threshold, and the second jump stitch threshold become larger.
CPU135A执行收线不良判断处理(S111)。CPU135A参照RAM135B，获取第N-1周期的第二面线张力的产生时机(即基准面线张力的第二面线张力的产生时机)和第N周期的第二面线张力的产生时机(S124)。CPU135A判断在S124中获取到的第N周期的第二面线张力的产生时机与第N-1周期的第二面线张力的产生时机之差是否为收线不良特定阈值以上(S125)。此时，收线不良特定阈值是在S121中进行了变更后的收线不良特定阈值。CPU135A在判断为第N周期的第二面线张力的产生时机与第N-1周期的第二面线张力的产生时机之差小于收线不良特定阈值时(S125：否)，判断为未发生收线不良，结束收线不良判断处理，返回到缝制不良判断处理。CPU135A在判断为第N周期的第二面线张力的产生时机与第N-1周期的第二面线张力的产生时机之差为收线不良特定阈值以上时(S125：是)，判断为发生了收线不良，将收线不良标志变更为1(S127)。CPU135A结束收线不良判断处理，返回到缝制不良判断处理。TheCPU 135A executes the wire take-up failure determination process (S111). TheCPU 135A refers to theRAM 135B, and acquires the generation timing of the second needle thread tension in the N-1th cycle (that is, the generation timing of the second needle thread tension of the reference needle thread tension) and the generation timing of the second needle thread tension in the Nth cycle (S124). ). TheCPU 135A determines whether or not the difference between the timing of generating the second needle thread tension in the N-th cycle and the timing of generating the second needle thread tension in the N-1-th cycle acquired in S124 is equal to or more than a specific threshold for poor thread take-up ( S125 ). At this time, the thread-reeling failure specific threshold value is the thread-reeling defect specific threshold value changed in S121. When theCPU 135A determines that the difference between the generation timing of the second needle thread tension in the Nth cycle and the generation timing of the second needle thread tension in the N−1th cycle is smaller than the specific threshold value of poor thread take-up ( S125 : NO), it is determined that the difference has not occurred If the thread take-up is defective, the thread take-up defective judgment processing is terminated, and the process returns to the sewing defective judgment processing. When theCPU 135A determines that the difference between the timing of generating the second needle thread tension in the Nth cycle and the timing of generating the second needle thread tension in the N-1th cycle is equal to or greater than the specified threshold value of poor thread take-up ( S125 : YES), it is determined that the difference has occurred If the wire take-up is defective, the wire take-up defective flag is changed to 1 (S127). TheCPU 135A ends the thread take-up failure determination process, and returns to the sewing failure determination process.
CPU135A执行特定断线判断处理(S113)。CPU135A判断第一面线张力差是否为第一断线特定阈值以上(S131)。CPU135A获取存储于RAM135B的第N-1周期的第一面线张力和第N周期的第一面线张力，获取第一面线张力差。CPU135A在判断为第一面线张力差小于第一断线特定阈值时(S131：否)，判断为在第N周期的缝制时未发生断线，结束特定断线判断处理，返回到缝制不良判断处理。CPU135A在判断为第一面线张力差为第一断线特定阈值以上时(S131：是)，判断第二面线张力差是否为第二断线特定阈值以上(S133)。CPU135A获取存储于RAM135B的第N-1周期的第二面线张力和第N周期的第二面线张力，获取第二面线张力差。CPU135A在判断为第二面线张力差小于第二断线特定阈值时(S133：否)，判断为在第N周期的缝制时未发生断线，结束特定断线判断处理，返回到缝制不良判断处理。CPU135A在判断为第二面线张力差为第二断线特定阈值以上时(S133：是)，判断为在第N周期的缝制时发生了断线。CPU135A将断线标志变更为1(S137)，结束特定断线判断处理，返回到缝制不良判断处理。TheCPU 135A executes a specific disconnection determination process (S113). TheCPU 135A determines whether or not the first upper thread tension difference is equal to or greater than the first thread breakage specific threshold value ( S131 ). TheCPU 135A acquires the first needle thread tension of the N-1th cycle and the first needle thread tension of the Nth cycle stored in theRAM 135B, and acquires the first needle thread tension difference. When theCPU 135A determines that the first upper thread tension difference is smaller than the first thread breakage specific threshold value ( S131 : NO), it determines that no thread breakage has occurred during the sewing of the Nth cycle, ends the specific thread breakage determination process, and returns to sewing Bad judgment. When theCPU 135A determines that the first upper thread tension difference is equal to or greater than the first thread breakage specific threshold ( S131 : YES), theCPU 135A determines whether or not the second upper thread tension difference is equal to or greater than the second thread breakage specific threshold ( S133 ). TheCPU 135A acquires the second needle thread tension of the N-1th cycle and the second needle thread tension of the Nth cycle stored in theRAM 135B, and acquires the second needle thread tension difference. When theCPU 135A determines that the second upper thread tension difference is smaller than the second thread breakage specific threshold value (S133: NO), it determines that no thread breakage has occurred during the sewing of the Nth cycle, ends the specific thread breakage determination process, and returns to sewing Bad judgment. When theCPU 135A determines that the second upper thread tension difference is equal to or greater than the second thread breakage specific threshold value (S133: YES), it determines that a thread breakage has occurred during the sewing of the Nth cycle. TheCPU 135A changes the thread breakage flag to 1 (S137), ends the specific thread breakage determination process, and returns to the sewing defect determination process.
CPU135A执行特定跳针判断处理(S115)。CPU135A判断第一面线张力差是否为第一跳针特定阈值以上(S141)。第一面线张力差的获取方法与S131相同。CPU135A在判断为第一面线张力差小于第一跳针特定阈值时(S141：否)，判断为在第N周期的缝制时未发生跳针，结束特定跳针判断处理，返回到缝制不良判断处理。CPU135A在判断为第一面线张力差为第一跳针特定阈值以上时(S141：是)，判断第二面线张力差是否为第二跳针特定阈值以下(S143)。第二面线张力差的获取方法与S133相同。CPU135A在判断为第二面线张力差比第二跳针特定阈值大时(S143：否)，判断为在第N周期的缝制时未发生跳针，结束特定跳针判断处理，返回到缝制不良判断处理。CPU135A在判断为第二面线张力差为第二跳针特定阈值以下时(S143：是)，判断为在第N周期的缝制时发生了跳针。CPU135A将跳针标志变更为1(S147)，结束特定跳针判断处理，返回到缝制不良判断处理。TheCPU 135A executes a specific jump stitch determination process (S115). TheCPU 135A determines whether or not the first upper thread tension difference is equal to or greater than the first jump stitch specific threshold value ( S141 ). The method of acquiring the first upper thread tension difference is the same as that in S131. When theCPU 135A determines that the first upper thread tension difference is smaller than the first skip stitch specific threshold (S141: NO), it determines that skip stitches have not occurred during the sewing of the Nth cycle, ends the specific skip stitch determination processing, and returns to sewing Bad judgment. When theCPU 135A determines that the first upper thread tension difference is equal to or greater than the first jump stitch specific threshold (S141: YES), it determines whether the second upper thread tension difference is equal to or less than the second jump stitch specific threshold (S143). The method for obtaining the second upper thread tension difference is the same as that in S133. When theCPU 135A determines that the second upper thread tension difference is greater than the second skip stitch specific threshold (S143: NO), it determines that skip stitches have not occurred during the sewing of the Nth cycle, ends the specific skip stitch determination processing, and returns to sewing Handling bad judgments. When theCPU 135A determines that the second upper thread tension difference is equal to or less than the second skip stitch specific threshold value (S143: YES), it determines that skip stitches have occurred during the sewing of the Nth cycle. TheCPU 135A changes the skip stitch flag to 1 ( S147 ), ends the specific skip stitch determination process, and returns to the sewing defect determination process.
在发生断线时，第一面线张力差有时为第一跳针特定阈值以上(S141：是)。此时，第二面线张力差比第二跳针特定阈值大(S143：否)。因此，缝纫机1能够抑制实际发生了断线却误判断为发生了跳针的情况。When thread breakage occurs, the first upper thread tension difference may be equal to or greater than the first skip stitch specific threshold value (S141: YES). At this time, the second upper thread tension difference is larger than the second skip stitch specific threshold value (S143: NO). Therefore, thesewing machine 1 can suppress a situation where a thread breakage actually occurs but it is erroneously judged that a skip stitch has occurred.
CPU135A执行断线判断处理(S117)。CPU135A判断断线标志是否为1(S151)。CPU135A在判断为断线标志为1时(S151：是)，结束断线判断处理，返回到缝制不良判断处理。CPU135A在判断为断线标志为0时(S151：否)，判断存储于RAM135B的第N周期的第一面线张力是否为第一断线阈值以下(S153)。在S153中参照的第一断线阈值为在S109中进行了变更后的第一断线阈值。CPU135A在判断为第一面线张力比第一断线阈值大时(S153：否)，判断为在第N周期未发生断线，结束断线判断处理，返回到缝制不良判断处理。CPU135A在判断为第一面线张力为第一断线阈值以下时(S153：是)，判断存储于RAM135B的第N周期的第二面线张力是否为第二断线阈值以下(S155)。在S155中参照的第二断线阈值为在S109中进行了变更后的第二断线阈值。CPU135A在判断为第二面线张力比第二断线阈值大时(S155：否)，判断为在第N周期未发生断线，结束断线判断处理，返回到缝制不良判断处理。CPU135A在判断为第二面线张力为第二断线阈值以下时(S155：是)，判断为在第N周期发生了断线，将断线标志变更为1(S159)。CPU135A结束断线判断处理，返回到缝制不良判断处理。TheCPU 135A executes disconnection determination processing (S117). TheCPU 135A determines whether the disconnection flag is 1 (S151). When theCPU 135A determines that the thread breakage flag is 1 ( S151 : YES), the thread breakage determination process is terminated, and the process returns to the sewing defect determination process. When theCPU 135A judges that the thread breakage flag is 0 (S151: NO), it judges whether or not the first needle thread tension of the Nth cycle stored in theRAM 135B is equal to or less than the first thread breakage threshold (S153). The first disconnection threshold referred to in S153 is the first disconnection threshold changed in S109. When theCPU 135A determines that the first upper thread tension is greater than the first thread breakage threshold (S153: NO), it determines that no thread breakage has occurred in the Nth cycle, ends the thread breakage determination process, and returns to the sewing failure determination process. When theCPU 135A determines that the first needle thread tension is equal to or less than the first thread breakage threshold (S153: YES), it determines whether the second needle thread tension of the Nth cycle stored in theRAM 135B is equal to or less than the second thread break threshold (S155). The second disconnection threshold referred to in S155 is the second disconnection threshold changed in S109. When theCPU 135A determines that the second upper thread tension is greater than the second thread breakage threshold (S155: NO), it determines that no thread breakage has occurred in the Nth cycle, terminates the thread breakage determination process, and returns to the sewing failure determination process. When theCPU 135A determines that the second needle thread tension is equal to or less than the second thread breakage threshold ( S155 : YES), it determines that a thread break has occurred in the Nth cycle, and changes the thread break flag to 1 ( S159 ). TheCPU 135A ends the thread breakage determination process, and returns to the sewing failure determination process.
CPU135A执行跳针判断处理(S119)。CPU135A判断跳针标志是否为1(S161)。CPU135A在判断为跳针标志为1时(S161：是)，结束跳针判断处理，返回到缝制不良判断处理。CPU135A在判断为跳针标志为0时(S161：否)，判断存储于RAM135B的第N周期的第一面线张力是否为第一跳针阈值以下(S163)。在S163中参照的第一跳针阈值为在S109中进行了变更后的第一跳针阈值。CPU135A在判断为第一面线张力比第一跳针阈值大时(S163：否)，判断为在第N周期未发生跳针，结束跳针判断处理，返回到缝制不良判断处理。CPU135A在判断为第一面线张力为第一跳针阈值以下时(S163：是)，判断存储于RAM135B的第N周期的第二面线张力是否为第二跳针阈值以上(S165)。在S163中参照的第二跳针阈值为在S109中进行了变更后的第二跳针阈值。CPU135A在判断为第二面线张力小于第二跳针阈值时(S165：否)，判断为在第N周期未发生跳针，结束跳针判断处理，返回到缝制不良判断处理。CPU135A在判断为第二面线张力为第二跳针阈值以上时(S165：是)，判断为在第N周期发生了跳针，将跳针标志变更为1(S169)。CPU135A结束跳针判断处理，返回到缝制不良判断处理。TheCPU 135A executes skip stitch determination processing (S119). TheCPU 135A determines whether the skip stitch flag is 1 (S161). When theCPU 135A determines that the skip stitch flag is 1 ( S161 : YES), theCPU 135A ends the skip stitch determination process, and returns to the sewing defect determination process. When theCPU 135A judges that the skip stitch flag is 0 (S161: NO), it judges whether or not the first needle thread tension of the Nth cycle stored in theRAM 135B is equal to or less than the first skip stitch threshold value (S163). The first jump stitch threshold referred to in S163 is the first jump stitch threshold changed in S109. When theCPU 135A determines that the first upper thread tension is greater than the first skip stitch threshold (S163: NO), it determines that skip stitches have not occurred in the Nth cycle, terminates the skip stitch determination process, and returns to the sewing failure determination process. When theCPU 135A determines that the first upper thread tension is equal to or less than the first jump stitch threshold (S163: YES), it determines whether the second upper thread tension of the Nth cycle stored in theRAM 135B is equal to or higher than the second jump stitch threshold (S165). The second jump stitch threshold referred to in S163 is the second jump stitch threshold changed in S109. When theCPU 135A determines that the second upper thread tension is smaller than the second skip stitch threshold (S165: NO), it determines that skip stitches have not occurred in the Nth cycle, terminates the skip stitch determination processing, and returns to the sewing failure determination processing. When theCPU 135A determines that the second upper thread tension is equal to or greater than the second skip stitch threshold (S165: YES), it determines that skip stitches have occurred in the Nth cycle, and changes the skip stitch flag to 1 (S169). TheCPU 135A ends the skip stitch determination processing and returns to the sewing failure determination processing.
在发生断线时，第一面线张力有时为第一跳针阈值以下(S163：是)。此时，第二面线张力比第二跳针阈值小(S165：否)。因此，缝纫机1能够抑制实际发生了跳针却误判断为发生了断线的情况。When thread breakage occurs, the first upper thread tension may be equal to or less than the first skip stitch threshold value (S163: YES). At this time, the second upper thread tension is smaller than the second skip stitch threshold (S165: NO). Therefore, thesewing machine 1 can suppress a situation in which skipped stitches actually occur, but it is erroneously judged that the thread is broken.
CPU135A执行阈值初始化处理(S120)。CPU135A使存储于存储装置135C的第一断线阈值、第二断线阈值、第一跳针阈值、第二跳针阈值、收线不良特定阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值以及第二跳针特定阈值恢复为初始值。CPU135A结束缝制不良判断处理，返回到张力获取处理。TheCPU 135A executes the threshold value initialization process (S120). TheCPU 135A specifies the first disconnection threshold, the second disconnection threshold, the first jump stitch threshold, the second jump stitch threshold, the poor thread take-up specific threshold, the first disconnection specific threshold, and the second disconnection threshold stored in the storage device 135C. The threshold, the first jump stitch specific threshold, and the second jump stitch specific threshold are restored to the initial values. TheCPU 135A ends the sewing failure determination process, and returns to the tension acquisition process.
如图16所示，CPU135A发送缝制不良信息(S53)。如图14所示，CPU91在判断为发生了缝制不良时(S17：是)，判别所发生的缝制不良(S23)。CPU91通过在断线标志、跳针标志、收线不良标志中确定1的标志，来判别所发生的缝制不良。CPU91通知判别出的缝制不良(S24)。例如CPU91将判别出的缝制不良显示于显示部25。CPU91判断是否使驱动马达停止驱动(S25)。CPU91在判别出的缝制不良为断线或跳针时，判断为使驱动马达停止驱动。CPU91在判断为使驱动马达停止驱动时(S25：是)，使驱动马达停止驱动(S26)，使处理转移到S220。CPU91在判断为不使驱动马达停止驱动时(S25：否)，使处理转移到S18。此时，CPU91在判断为发生收线不良的情况下(S17：是)，也不使驱动马达停止(S25：否)。操作者既可以在显示部25确认发生收线不良之后继续踩下踏板38(S18：否)也可以踩回踏板38(S18：是)。As shown in FIG. 16, theCPU 135A transmits the sewing failure information (S53). As shown in FIG. 14 , when theCPU 91 determines that the sewing defect has occurred ( S17 : YES), theCPU 91 determines that the sewing defect has occurred ( S23 ). TheCPU 91 determines the occurrence of a sewing defect by specifying a flag of 1 among the thread breakage flag, the skipped stitch flag, and the defective thread take-up flag. TheCPU 91 notifies the identified poor sewing (S24). For example, theCPU 91 displays the identified sewing defect on thedisplay unit 25 . TheCPU 91 determines whether or not to stop the driving of the drive motor (S25). TheCPU 91 determines to stop the driving of the drive motor when it is determined that the sewing defect is a broken thread or a skipped stitch. When theCPU 91 determines to stop the driving of the drive motor ( S25 : YES), theCPU 91 stops the drive of the drive motor ( S26 ), and transfers the process to S220 . When theCPU 91 determines that the driving of the drive motor is not to be stopped ( S25 : NO), the process proceeds to S18 . At this time, when theCPU 91 determines that the failure of the take-up has occurred ( S17 : YES), theCPU 91 does not stop the drive motor ( S25 : NO). The operator may continue to depress the pedal 38 after thedisplay unit 25 confirms the occurrence of defective wire take-up ( S18 : NO), or may depress the pedal 38 back ( S18 : YES).
CPU91在判断为在缝制结束时且M到达预定周期之前发生了缝制不良时(S74：是)，判别所发生的缝制不良(S75)，通知判别出的缝制不良(S76)。CPU91判断是否使驱动马达停止驱动(S77)。CPU91在判断为使驱动马达停止驱动时(S77：是)，使驱动马达停止驱动(S78)，使处理转移到S220。CPU91在判断为不使驱动马达停止驱动时(S77：否)，使处理转移到S19。S75～S78的处理与S23～S26的处理相同。因此，CPU91在判断为发生收线不良的情况下(S74：是)，也不使驱动马达停止(S77：否)。此时，CPU91在M到达预定周期之前继续进行处理。When theCPU 91 determines that a sewing defect has occurred at the end of sewing and before M reaches the predetermined cycle (S74: YES), it determines the sewing defect that has occurred (S75), and notifies the determined sewing defect (S76). TheCPU 91 determines whether or not to stop the driving of the drive motor (S77). When theCPU 91 determines to stop the driving of the drive motor ( S77 : YES), theCPU 91 stops the drive of the drive motor ( S78 ), and transfers the process to S220 . When theCPU 91 determines not to stop the driving of the drive motor ( S77 : NO), the process proceeds to S19 . The processing of S75 to S78 is the same as the processing of S23 to S26. Therefore, when theCPU 91 determines that the failure of the take-up has occurred (S74: YES), theCPU 91 does not stop the drive motor (S77: NO). At this time, theCPU 91 continues processing until M reaches a predetermined period.
如以上说明的那样，CPU135A基于线张力检测机构130的磁传感器105的检测结果来获取变动张力(S47)。CPU135A执行收线不良判断处理(S111)、特定断线判断处理(S113)、特定跳针判断处理(S115)。CPU135A通过对第N周期的面线张力和基准面线张力即第N-1周期的面线张力进行比较，来判断有无缝制不良。即，CPU135A使用收线不良特定阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值、第二跳针特定阈值对在S47中获取到的第N周期的变动张力和基准面线张力即第N-1周期的变动张力进行比较，判断是否发生了缝制不良。收线不良特定阈值是与收线不良相对应地预先设定的阈值。第一断线特定阈值、第二断线特定阈值是与断线相对应地预先设定的阈值。第一跳针特定阈值、第二跳针特定阈值是与跳针相对应地预先设定的阈值。CPU135A使用各特定阈值来判断有无缝制不良。因此，缝纫机1能够识别出具体的缝制不良，能够基于面线张力的变化来识别缝制不良。As described above, theCPU 135A acquires the fluctuating tension based on the detection result of themagnetic sensor 105 of the thread tension detection mechanism 130 ( S47 ). TheCPU 135A executes a thread take-up failure determination process ( S111 ), a specific disconnection determination process ( S113 ), and a specific jump stitch determination process ( S115 ). TheCPU 135A judges that there is a seam failure by comparing the needle thread tension of the Nth cycle with the reference needle thread tension, that is, the needle thread tension of the N-1th cycle. That is, theCPU 135A uses the thread take-up specific threshold value, the first thread breakage specific threshold value, the second thread breakage specific threshold value, the first skip stitch specific threshold value, and the second skip stitch specific threshold value to the fluctuation tension of the N-th cycle acquired in S47 It is compared with the reference thread tension, that is, the fluctuating tension in the N-1 cycle, to determine whether or not sewing defects have occurred. The defective wire take-up specific threshold is a threshold value set in advance corresponding to the poor wire take-up. The first disconnection specific threshold and the second disconnection specific threshold are predetermined thresholds corresponding to disconnection. The first skip stitch specific threshold and the second skip stitch specific threshold are preset thresholds corresponding to skip stitches. TheCPU 135A judges that there is a seamless manufacturing defect using each specific threshold value. Therefore, thesewing machine 1 can recognize a specific sewing defect, and can recognize a sewing defect based on a change in the tension of the upper thread.
当发生断线时，第一面线张力为第一断线阈值以下，且第二面线张力为第二断线阈值以下。CPU135A在断线判断处理(S117)时，在第N周期的第一面线张力为第一断线阈值以下(S153：是)且第N周期的第二面线张力为第二断线阈值以下时(S155：是)，判断为发生了断线，将断线标志变更为1(S159)。缝纫机1能够判断有无发生断线，因此，作为缝制不良能够识别出断线。When a thread breakage occurs, the first upper thread tension is equal to or less than the first thread disconnection threshold, and the second upper thread tension is equal to or less than the second thread disconnection threshold. When theCPU 135A performs the thread breakage determination process ( S117 ), the first needle thread tension in the Nth cycle is equal to or less than the first thread disconnection threshold ( S153 : YES), and the second needle thread tension in the Nth cycle is equal to or less than the second thread disconnection threshold If it is ( S155 : YES), it is determined that a disconnection has occurred, and the disconnection flag is changed to 1 ( S159 ). Since thesewing machine 1 can determine whether or not the thread breakage has occurred, the thread breakage can be recognized as a sewing failure.
当发生跳针时，第一面线张力为第一跳针阈值以下，且第二面线张力为第二跳针阈值以上。CPU135A在跳针判断处理(S119)时，在第N周期的第一面线张力为第一跳针阈值以下(S163：是)且第N周期的第二面线张力为第二跳针阈值以上时(S165：是)，判断为发生了跳针，将跳针标志变更为1(S169)。缝纫机1能够判断有无跳针，因此，作为缝制不良能够识别出跳针。When skip stitches occur, the first upper thread tension is below the first skip stitch threshold, and the second top thread tension is above the second skip stitch threshold. When theCPU 135A performs the skip stitch determination process (S119), the first upper thread tension in the Nth cycle is equal to or less than the first skip stitch threshold (S163: YES), and the second upper thread tension in the Nth cycle is equal to or greater than the second skip stitch threshold If it is ( S165 : YES), it is determined that a skip stitch has occurred, and the skip stitch flag is changed to 1 ( S169 ). Since thesewing machine 1 can determine the presence or absence of skipped stitches, skipped stitches can be recognized as sewing defects.
当发生收线不良时，面线6的消耗量增加，因此，第二面线张力的产生时机变早。CPU135A在收线不良判断处理(S111)时，在第N周期的第二面线张力的产生时机相对于第N-1周期的第二面线张力的产生时机而言早收线不良特定阈值以上时(S125：是)，判断为发生了收线不良，将收线不良标志变更为1(S127)。缝纫机1能够判断有无发生收线不良，因此，作为缝制不良能够识别出收线不良。When the thread take-up failure occurs, the consumption of the upper thread 6 increases, and therefore, the timing for generating the second upper thread tension becomes earlier. TheCPU 135A sets the timing of generating the second needle thread tension in the N-th cycle earlier than the timing of generating the second needle thread tension in the N-1-th cycle by a predetermined threshold value or more for defective thread take-up in the thread take-up failure determination process ( S111 ). If it is ( S125 : YES), it is determined that a thread take-up failure has occurred, and the thread-reel defect flag is changed to 1 ( S127 ). Since thesewing machine 1 can determine whether or not a thread take-up defect has occurred, the thread take-up defect can be recognized as a sewing defect.
在缝制速度较慢时，面线6的消耗量较低，因此，第一面线张力和第二面线张力较低。CPU91在判断为在S15中获取到的上轴旋转速度为第一速度以下时(S81：是)，控制夹线马达16，使夹线盘69向卷绕方向旋转，将面线6卷绕(S83)。因此，不易产生面线6的松弛，缝纫机1能够容易地产生第一面线张力和第二面线张力。When the sewing speed is slow, the consumption of the upper thread 6 is lower, and therefore, the tension of the first upper thread and the tension of the second upper thread is lower. When theCPU 91 determines that the upper shaft rotational speed acquired in S15 is equal to or lower than the first speed (S81: YES), theCPU 91 controls thethread tension motor 16 to rotate thethread tension disc 69 in the winding direction to wind the upper thread 6 ( S83). Therefore, the slack of the upper thread 6 does not easily occur, and thesewing machine 1 can easily generate the first upper thread tension and the second upper thread tension.
CPU135A在由上轴15进行加减速导致上轴旋转速度发生了变化时(S105：是)，与上轴15的加速度相应地变更收线不良特定阈值(S121)，在S125中使用进行了变更后的收线不良特定阈值。当上轴旋转速度发生变化时，与加速度相应地，面线张力发生变化，发生缝制不良时的面线张力也发生变化。详细而言，当在发生收线不良的情况下上轴15加速时，第二面线张力的产生时机比上轴15以低速旋转时的第二面线张力的产生时机晚。此时，缝纫机1与上轴旋转速度的变化相应地变更收线不良特定阈值，因此，能够恰当地检测收线不良。When the upper shaft rotational speed has changed due to the acceleration and deceleration of the upper shaft 15 ( S105 : YES), theCPU 135A changes the take-up failure specific threshold value according to the acceleration of the upper shaft 15 ( S121 ), and uses the change in S125 The specific threshold for bad take-up. When the rotation speed of the upper shaft changes, the tension of the upper thread changes according to the acceleration, and the tension of the upper thread when a sewing defect occurs also changes. Specifically, when theupper shaft 15 is accelerated when the thread take-up failure occurs, the timing of generating the second needle thread tension is later than the timing of generating the second needle thread tension when theupper shaft 15 is rotated at a low speed. At this time, thesewing machine 1 changes the thread take-up failure specific threshold value according to the change in the rotation speed of the upper shaft, so that the thread take-up failure can be appropriately detected.
当上轴旋转速度发生变化时，面线张力发生变化，发生缝制不良时的面线张力也发生变化。具体而言，在上轴15以低速旋转时，变动张力较小，发生缝制不良时的面线张力也较小。在上轴15以高速旋转时，变动张力较大，发生缝制不良时的面线张力也较大。CPU135A在发生缝制不良时的面线张力发生变化时，与在S100中获取到的上轴旋转速度相应地变更阈值(S109)。因此，CPU135A能够恰当地检测缝制不良。When the rotation speed of the upper shaft changes, the tension of the upper thread changes, and the tension of the upper thread changes when sewing defects occur. Specifically, when theupper shaft 15 is rotated at a low speed, the fluctuating tension is small, and the upper thread tension when sewing failure occurs is also small. When theupper shaft 15 is rotated at a high speed, the fluctuating tension is large, and the upper thread tension when sewing failure occurs is also large. TheCPU 135A changes the threshold value in accordance with the upper shaft rotational speed acquired in S100 when the upper thread tension at the time of the occurrence of sewing failure changes ( S109 ). Therefore, theCPU 135A can appropriately detect sewing defects.
CPU135A在缝制不良判断处理中，在缝制初始阶段之后(S100：否)执行S111～S120。面线6在缝制初始阶段容易松弛。即，第一面线张力和第二面线张力难以成为恰当的值。因此，当在缝制初始阶段的情况下CPU135A判断有无缝制不良时，有时在未发生缝制不良时也判断为发生了缝制不良。CPU135A不对缝制初始阶段的缝制不良的有无进行判断(S100：是)。因此，缝纫机1能够抑制误判断为发生了缝制不良的情况。TheCPU 135A executes S111 to S120 after the initial stage of sewing (S100: NO) in the sewing failure determination process. The upper thread 6 tends to loosen at the initial stage of sewing. That is, it is difficult for the first upper thread tension and the second upper thread tension to be appropriate values. Therefore, when theCPU 135A determines that there is a sewing defect in the initial stage of sewing, it may be determined that the sewing defect has occurred even when the sewing defect has not occurred. TheCPU 135A does not judge whether there is a sewing defect in the initial stage of sewing ( S100 : YES). Therefore, thesewing machine 1 can suppress a misjudgment that a sewing defect has occurred.
CPU135A在判断为在S101中获取的上轴旋转速度比第二速度大时(S103：否)，执行S111～S119，判断有无缝制不良。在缝制速度较慢时，第一面线张力和第二面线张力较低，难以恰当地产生第一面线张力和第二面线张力。因此，缝纫机1难以检测基于面线张力的缝制不良。CPU135A在判断为上轴旋转速度为第二速度以下时(S103：是)，不判断有无缝制不良。因此，缝纫机1能够更恰当地判断有无缝制不良。When theCPU 135A determines that the upper shaft rotational speed acquired in S101 is greater than the second speed ( S103 : NO), theCPU 135A executes S111 to S119 and determines that there is a seamless manufacturing defect. When the sewing speed is slow, the first and second upper thread tensions are low, and it is difficult to properly generate the first and second upper thread tensions. Therefore, it is difficult for thesewing machine 1 to detect a sewing defect based on the tension of the upper thread. When theCPU 135A determines that the rotation speed of the upper shaft is equal to or lower than the second speed ( S103 : YES), it does not determine that there is a seamless manufacturing defect. Therefore, thesewing machine 1 can more appropriately judge that there is a seam failure.
在执行切线时(S20)，CPU135A从CPU91接收零点调整的指示(S22)，执行零点调整(S57)。当重复缝制动作时，有时因面线6和板50的滑动的重复使得磁传感器105的温度上升，导致磁传感器105的输出电压相对于基准电压Vt较大程度地变动。此时，在面线张力伴随着切线的执行下降，磁传感器105的输出电压下降时，CPU135A执行零点调整(S57)。缝纫机1重新设定磁传感器105的基准电压Vt。因此，缝纫机1能够基于磁传感器105的输出电压来持续地高精度地获取面线张力。CPU135A在执行零点调整时，不判断有无缝制不良。因此，缝纫机1能够抑制误判断为发生了缝制不良的情况。When performing thread trimming ( S20 ), theCPU 135A receives an instruction of zero point adjustment from the CPU 91 ( S22 ), and executes zero point adjustment ( S57 ). When the sewing operation is repeated, the temperature of themagnetic sensor 105 may rise due to the repetition of the sliding of the upper thread 6 and theplate 50, and the output voltage of themagnetic sensor 105 may fluctuate greatly with respect to the reference voltage Vt. At this time, theCPU 135A executes zero point adjustment when the upper thread tension decreases with the execution of the thread trimming and the output voltage of themagnetic sensor 105 decreases ( S57 ). Thesewing machine 1 resets the reference voltage Vt of themagnetic sensor 105 . Therefore, thesewing machine 1 can continuously acquire the upper thread tension with high accuracy based on the output voltage of themagnetic sensor 105 . When theCPU 135A executes the zero point adjustment, it does not judge that there is a seamless system failure. Therefore, thesewing machine 1 can suppress a misjudgment that a sewing defect has occurred.
主夹线器60是本发明的夹线机构的一个例子。板50是本发明的可动构件的一个例子。执行S13、S21时的CPU91是本发明的缝制控制部的一个例子。执行S47时的CPU135A是本发明的张力获取部的一个例子。执行S51时的CPU135A是本发明的判断部的一个例子。执行S117时的CPU135A是本发明的断线判断部的一个例子。执行S119时的CPU135A是本发明的跳针判断部的一个例子。执行S111时的CPU135A是本发明的收线不良判断部的一个例子。执行S15、S72、S101时的CPU91、CPU135A是本发明的速度获取部的一个例子。执行S83时的CPU91是本发明的夹线控制部的一个例子。执行S121时的CPU135A是本发明的加速度对应变更部的一个例子。执行S109时的CPU135A是本发明的速度对应变更部的一个例子。执行S20时的CPU91是本发明的切线控制部的一个例子。执行S57时的CPU135A是本发明的调整控制部的一个例子。收线不良特定阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值、第二跳针特定阈值是本发明的特定阈值的一个例子。收线不良特定阈值是第一特定阈值的一个例子。第一断线阈值是本发明的第一阈值的一个例子。第二断线阈值是本发明的第二阈值的一个例子。第一跳针阈值是本发明的第三阈值的一个例子。第二跳针阈值是本发明的第四阈值的一个例子。Themain thread gripper 60 is an example of the thread gripping mechanism of the present invention. Theplate 50 is an example of the movable member of the present invention. TheCPU 91 at the time of executing S13 and S21 is an example of the sewing control unit of the present invention. TheCPU 135A at the time of executing S47 is an example of the tension acquisition unit of the present invention. TheCPU 135A at the time of executing S51 is an example of the determination unit of the present invention. TheCPU 135A at the time of executing S117 is an example of the disconnection determination unit of the present invention. TheCPU 135A at the time of executing S119 is an example of the skip stitch determination unit of the present invention. TheCPU 135A at the time of executing S111 is an example of the wire take-up failure determination unit of the present invention. TheCPU 91 and theCPU 135A at the time of executing S15, S72, and S101 are an example of the speed acquisition unit of the present invention. TheCPU 91 at the time of executing S83 is an example of the thread tension control unit of the present invention. TheCPU 135A at the time of executing S121 is an example of the acceleration correspondence changing unit of the present invention. TheCPU 135A at the time of executing S109 is an example of the speed correspondence changing unit of the present invention. TheCPU 91 at the time of executing S20 is an example of the thread cutting control unit of the present invention. TheCPU 135A at the time of executing S57 is an example of the adjustment control unit of the present invention. The specific threshold for poor thread take-up, the first specific threshold for thread breakage, the second specific threshold for thread breakage, the first specific threshold for skipping stitches, and the specific threshold for second skipping stitches are examples of specific thresholds in the present invention. The poor take-up specific threshold is an example of the first specific threshold. The first disconnection threshold is an example of the first threshold of the present invention. The second disconnection threshold is an example of the second threshold of the present invention. The first skip threshold is an example of the third threshold of the present invention. The second stitch threshold is an example of the fourth threshold of the present invention.
本发明并不限定于上述实施例。也可以是，CPU135A与上轴旋转速度的加速度相应地变更第一断线阈值、第二断线阈值、第一跳针阈值、第二跳针阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值、第二跳针特定阈值(S121)。例如，也可以是，在上轴15减速时(S105：是)，变动张力容易变小，因此，CPU135A以分别使第一断线阈值、第二断线阈值、第一跳针阈值、第二跳针阈值变小的方式对它们进行变更，且以分别使第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值、第二跳针特定阈值变大的方式对它们进行变更(S121)。The present invention is not limited to the above-described embodiments. TheCPU 135A may change the first wire breakage threshold, the second wire breakage threshold, the first jumper threshold, the second jumper threshold, the first wire breakage specific threshold, and the second wire breakage in accordance with the acceleration of the upper shaft rotational speed. A specific threshold, a first jump stitch specific threshold, and a second jump stitch specific threshold (S121). For example, when theupper shaft 15 is decelerated ( S105 : YES), the fluctuating tension may be easily reduced, so theCPU 135A may set the first thread breakage threshold, the second thread breakage threshold, the first skip threshold, the second thread breakage threshold, and the second thread breakage threshold, respectively. These are changed so that the jump stitch threshold value becomes smaller, and the first wire breakage specific threshold value, the second wire breakage specific threshold value, the first jump stitch specific threshold value, and the second jump stitch specific threshold value are respectively increased. change (S121).
也可以是，CPU135A除了与上轴旋转速度的速度相应地变更第一阈值、第二阈值、第三阈值之外，还与上轴旋转速度的速度相应地变更第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值、第二跳针特定阈值(S109)。也可以是，CPU135A除了与上轴15的旋转加速度相应地变更第一特定阈值之外，还与上轴15的旋转加速度相应地变更第一阈值、第二阈值、第三阈值(S121)。In addition to changing the first threshold value, the second threshold value, and the third threshold value in accordance with the speed of the upper shaft rotational speed, theCPU 135A may also change the first disconnection specific threshold value, the second The disconnection specific threshold, the first jump stitch specific threshold, and the second jump stitch specific threshold (S109). TheCPU 135A may change the first threshold value, the second threshold value, and the third threshold value in accordance with the rotational acceleration of theupper shaft 15 in addition to changing the first specific threshold value in accordance with the rotational acceleration of the upper shaft 15 ( S121 ).
也可以是，CPU135A在判断为上轴旋转速度发生了加减速时(S105：是)，变更第一断线阈值、第二断线阈值、第一跳针阈值、第二跳针阈值、第一断线特定阈值、第二断线特定阈值、第一跳针特定阈值以及第二跳针特定阈值，来替代收线不良特定阈值(S121)。例如，也可以是，在上轴15减速时(S105：是)，CPU135A减小第一断线阈值。缝制初始阶段既可以是从缝制开始到第一周期的缝制为止，也可以是到第三周期的缝制为止。规定缝制初始阶段的预定针数也可以根据缝制不良有所不同。例如，也可以是，CPU135A在判断有无跳针时，将到第二周期为止的期间作为缝制初始阶段，在进行第三周期以后的缝制时判断有无跳针，在判断有无收线不良时，将到第一周期为止的期间作为缝制初始阶段，在进行第二周期以后的缝制时，判断有无收线不良。TheCPU 135A may change the first thread breakage threshold, the second thread breakage threshold, the first jumping stitch threshold, the second jumping The wire breakage specific threshold, the second wire breakage specific threshold, the first skip stitch specific threshold, and the second skip stitch specific threshold are used instead of the bad thread take-up specific threshold (S121). For example, when theupper shaft 15 is decelerating ( S105 : YES), theCPU 135A may decrease the first disconnection threshold value. The initial stage of sewing may be from the start of sewing to the sewing of the first cycle, or may be to the sewing of the third cycle. The predetermined number of stitches that define the initial stage of sewing may also vary according to poor sewing. For example, when judging the presence or absence of skipped stitches, theCPU 135A may take the period up to the second cycle as the initial stage of sewing, determine the presence or absence of skipped stitches when stitching after the third cycle, and determine whether there are skipped stitches or not. When the thread is defective, the period up to the first cycle is regarded as the initial stage of sewing, and the presence or absence of defective thread take-up is determined when the second cycle and subsequent sewing are performed.
CPU135A也可以基于计时器35的计时结果来判断是否获取了第一周期的变动张力(S45)。例如，也可以是，RAM135B存储完成第一周期的变动张力的获取所需的时间，CPU135A通过判断计时器35的计时结果是否经过了所需时间，来判断是否完成了第一周期的变动张力。也可以是，CPU91伴随着针杆11的上下运动，基于编码器27A的检测结果向CPU135A输出针上位置或针下位置的信号。针上位置为机针10的上死点附近的位置。此时，CPU135A既可以基于针上位置或针下位置的信号在S35的处理中判断缝制动作是否已开始，也可以基于针上位置或针下位置的信号在S45的处理中判断是否获取到第N周期的变动张力，还可以基于针上位置或针下位置的信号在S101的处理中获取上轴旋转速度。TheCPU 135A may determine whether or not the fluctuating tension of the first cycle has been acquired based on the timing result of the timer 35 ( S45 ). For example, theRAM 135B may store the time required to complete the acquisition of the fluctuating tension of the first cycle, and theCPU 135A may determine whether the fluctuating tension of the first cycle has been completed by judging whether the time counted by thetimer 35 has elapsed for the required time. TheCPU 91 may output a signal of the needle up position or the needle down position to theCPU 135A based on the detection result of theencoder 27A in accordance with the vertical movement of theneedle bar 11 . The needle up position is a position near the top dead center of theneedle 10 . At this time, theCPU 135A can either determine whether the sewing operation has started based on the signal of the needle up position or the needle down position in the process of S35, or can judge whether the sewing operation has been acquired based on the signal of the needle up position or the needle down position in the process of S45. For the fluctuating tension of the Nth cycle, the rotation speed of the upper shaft can also be obtained in the process of S101 based on the signal of the needle up position or the needle down position.
当操作者踩回踏板38时，CPU91判断为结束缝制动作(S18：是)。也可以是，缝纫机1将N个周期的缝制数据存储于存储装置94，缝制N个周期的缝制数据之后，结束缝制动作。此时，也可以省略S19、S71～S78的处理。When the operator steps back on thepedal 38, theCPU 91 determines that the sewing operation is ended (S18: YES). Thesewing machine 1 may store the sewing data of N cycles in thestorage device 94, and may end the sewing operation after sewing the sewing data of N cycles. In this case, the processes of S19 and S71 to S78 may be omitted.
CPU91也可以使夹线盘69向卷绕方向旋转与上轴旋转速度相应的旋转量(S83)。磁传感器105也可以包括磁阻抗元件、磁阻效应元件等来替代霍尔元件。此时，磁传感器105能够检测磁体58的磁通密度的变化。TheCPU 91 may rotate thetension disc 69 in the winding direction by an amount corresponding to the rotation speed of the upper shaft ( S83 ). Themagnetic sensor 105 may also include a magneto-impedance element, a magneto-resistance effect element, or the like instead of the Hall element. At this time, themagnetic sensor 105 can detect a change in the magnetic flux density of themagnet 58 .
