Embroidery apparatus, dyeing/embroidery system, and method for adjusting consumption amount of thread

A dyeing/embroidery system including

• a dyeing apparatus configured to dye a needle thread that is fed from the dyeing apparatus;
• and
• an embroidery apparatus configured to perform an embroidery operation on a cloth according to embroidery data using the need thread and a bobbin thread that is fed according to the needle thread being fed, the dyeing/embroidery system comprising:
• a thread consumption amount detection mechanism configured to detect an actual thread consumption amount of the needle thread in the embroidery operation;
• an assumed thread consumption amount calculator configured to calculate an assumed thread consumption amount of the needle thread, based on initial embroidery data input in advance;
• and
• a thread consumption amount adjuster configured to
• adjust the actual thread consumption amount by adjusting the initial embroidery data based on a difference between the assumed thread consumption amount and the actual thread consumption amount of the thread, and
• output adjusted embroidery data to a driver that drives and controls a drive motor of the embroidery apparatus, wherein
• the dyeing apparatus includes a dyer configured to apply changing colors to
• the needle thread in a conveying direction of the needle thread;
• the thread consumption amount detection mechanism is mounted in the dyeing apparatus or the embroidery apparatus;
• and
• the assumed thread consumption amount calculator and the thread consumption amount adjuster are mounted in the dyeing apparatus, in the embroidery apparatus, or in an upper level control apparatus configured to be connected to the dyeing/embroidery system,
• the thread consumption amount detection mechanism includes
• an optical detection sensor configured to detect a color change of the thread at a detection time t1 and
• a thread consumption amount calculator,
• a distance from a detection position, at which the optical detection sensor detects the color change, to a tip of a needle is set as an estimated stitching distance covered by a predetermined number of stitches,
• the optical detection sensor detects an actual color change position at the detection position,
• the thread consumption amount calculator invokes a fixed distance from a starting position to the actual color change position detected by the optical detection sensor, and sets the fixed distance as the actual consumption amount of the thread, and
• the assumed thread consumption amount calculator calculates the assumed thread consumption amount at the detection time t1, the assumed thread consumption amount being calculated from data indicating a number of stitches that have progressed in the embroidery operation, and a position in the initial embroidery data corresponding to the indicated number of stitches.

A method for adjusting a consumption amount of a thread, the method being performed in an embroidery apparatus configured to perform an embroidery operation on a cloth according to embroidery data, the method, comprising:

• calculating an assumed thread consumption amount of the thread in the embroidery operation based on initial embroidery data input in advance;
• detecting an actual thread consumption amount of the thread in the embroidery operation;
• adjusting the actual thread consumption amount by adjusting the initial embroidery data based on a difference between the assumed thread consumption amount and the actual thread consumption;
• and
• outputting adjusted embroidery data to a driver that drives and controls a drive motor of the embroidery apparatus, wherein
• the thread consumption amount detection mechanism includes
• an optical detection sensor configured to detect a color change of the thread at a detection time t1 and
• a thread consumption calculator,
• a distance from a detection position, at which the optical detection sensor detects the color change, to a tip of a needle is set as an estimated stitching distance covered by a predetermined number of stitches,
• the optical detection sensor detects an actual color change position at the detection position,
• the thread consumption amount calculator invokes a fixed distance from a starting position to the actual color change position detected by the optical detection sensor, and sets the fixed distance as the actual consumption amount of the thread, and
• the assumed thread consumption amount calculator calculates the assumed thread consumption amount at the detection time t1, the assumed thread consumption amount being calculated from data indicating a number of stitches that have progressed in the embroidery operation, and a position in the initial embroidery data corresponding to the indicated number of stitches.