Profile stitching apparatus and method

An automatic sewing machine, comprising:

• (a) at least one sewing head with at least one sewing needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece;
• (b) controllable drive means for driving said sewing head including an associated digital signal responsive control therefor;
• (c) an X-Y work holder adapted to hold a workpiece for operation thereon by said needle and having and X-Y motion table, controllable positioner means associated therewith and an associated digital signal responsive control for said positioner means;
• (d) means for providing control signals in the course of executing a pattern indicative of successively obtained positions of selected moving components of the machine;
• (e) circuit means including means for receiving said signals singularly or plurally, stored digital program logic adapted for analyzing the relation between the signals themselves and between the signals and other digital data including pattern data stored in said program logic developing a central processing unit digital control instruction sequence therefrom defining a central processing unit response corresponding to the results of such analysis;
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• (f) a central processing unit associated with said circuit means and adapted to serialize and execute said control instructions to direct its own operation and to control recognition and to recognize such said signals as are received in said circuit means and in coordination therewith to issue digital signals corresponding to said defined response for control of said drive means and positioner means whereby to reproduce by stitching with said needle the pattern represented in said pattern data.

An automatic sewing machine, comprising:

• (a) at least one sewing needle, thread supply and associated stitch forming apparatus to form successive stitches in a workpiece;
• (b) program controllable drive means for driving said sewing head;
• (c) a work holder including support structure mounting clamp means for holding a preloaded workpiece for operation thereon by said needle and having on said support structure an electrically operable connector to an associated X-Y motion table positioned by program controllable positioner means associated with said table;
• (d) needle and work holder position signaling means productive of control signals indicative of successive positions obtained by the needle and work holder in the course of executing a pattern;
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• (e) program means having a stored pattern program including a command signal coordinated with the execution of said pattern and adapted to receive and process said signals to control said drive and positioner means according to such pattern program and at the termination of such pattern utilizing said command signal being productive of a work holder release signal to release said connector thereby enabling said support structure to be released from said X-Y motion table for replacement by another said support structure mounting another said preloaded workpiece and similarly connectable to said table.

An automatic sewing machine, comprising:

• (a) a plurality of sewing heads arranged for being synchronously driven, each having a needle, thread supply, takeup means and associated stitch forming apparatus to form successive stitches in a workpiece to form a stitched pattern thereon;
• (b) signal controllable drive means for synchronously driving said sewing heads;
• (c) a motion table adapted for X-Y positioning and mounting thereon work holders for releasably holding a workpiece at each said sewing head and having associated therewith signal controllable X-Y bi-directional positioner means;
• (d) needle positioning, work holder positioning and stitch fault signaling devices productive of control signals indicative of successive positions obtained by the needle and work holder associated with each said sewing head and of stitch faults incurred at any of said sewing heads in the course of executing a pattern;
• (e) circuit means having interface logic and memory including means for receiving needle and work holder position signals singularly or plurally, stored program logic adapted for analyzing the relation between the signals themselves and between the signals and other data including pattern data stored in said program logic and means for developing a central processing unit digital control instruction sequence therefrom to define a central processing unit response corresponding to the results of such analysis;
• and
• (f) a central processing unit associated with said circuit means and adapted to serialize and execute said control instructions to direct its own operation and to control recognition and to recognize signals received in said circuit means and in coordination therewith to issue signals corresponding to said defined response for control of said needle and work holder positioning during execution of a pattern by said machine at each of said heads.

An automatic sewing machine, comprising:

• (a) a plurality of sewing heads arranged for being synchronously driven, each having a needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece;
• (b) signal controllable drive means for synchronously driving said sewing heads;
• (c) a motion table adapted for X-Y positioning and mounting thereon work holders for releasably holding a workpiece at each said sewing head and having associated therewith signal controllable X-Y positioner means;
• (d) needle positioning, workholder positioning and stitch fault signaling devices productive of control signals indicative of successive positions obtained by the needle and work holder associated with each said sewing head and of stitch faults incurred at any of said sewing heads in the course of executing a pattern;
• (e) circuit means for terminating and recording selected characteristics of signals from said signaling means and providing a route for selective access to the record of such recorded signals by a central processing unit;
• (f) randomly addressable memory means containing logical sequences of instructions for control of a central processing unit and pattern data interpretable by a central processing unit as directions for executing a pattern including as required for such pattern, directions for said drive means, directions for said positioner means, directions for selection of central processing unit control instruction sequences and directions for selecting sequences of pattern data;
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• (g) a central processing unit operatively associated with said memory means and adapted to serialize and execute said control instructions to direct its own operation and to control recognition and to recognize signals present in said circuit means and in coordination therewith to issue other signals for control of said sewing head drive and work holder positioner means whereby to reproduce by stitching with said needle the pattern represented in said pattern data.

The method of sewing a stitched pattern in a workpiece comprising the steps of:

• (a) locating the workpiece to be sewn on a sewing machine equipped with a driven needle and positionable work holder and with means to develop control signals indicative of positions obtained by and the instantaneous location of both the needle and work holder and of stitch faults incurred as the pattern progresses;
• (b) operating said machine and continuously monitoring and analyzing said control signals with program logic during each stitch as the pattern proceeds and with said program logic having the capability of modifying the pattern being stitched dependent on said analysis and without operator intervention;
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• (c) utilizing said program logic analysis without operator intervention for selective continuation, termination and modification of stitching said pattern as determined by the nature of each said fault and the analysis thereof by said logic.

An automatic sewing apparatus, comprising:

• (a) a selected number, at least one, of sewing heads each with a needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece as a pattern;
• (b) signal controllable drive means for driving a selected number of said sewing heads synchronously;
• (c) a corresponding number for work holders, one for each sewing head and adapted to hold a respective workpiece for operation thereon by a respective said needle and mounted on an X-Y motion table adapted to support said number of work holders and having controllable bi-directional positioner means associated therewith;
• (d) signaling means productive of signals indicative of successively obtained positions of said positioner means and each said needle;
• (e) circuit means for receiving and transmitting said signals singularly or plurally and developing recorded signals therefrom having characteristics corresponding thereto;
• (f) a stored program logic means adapted to access and analyze said signals, the relation between such signals and other operating conditions;
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• (g) computer means adapted to develop responses to said signals as the pattern proceeds to control said drive and positioner means and the execution of said pattern and during said execution adapted to utilize said program logic analysis without operation intervention for selective continuation, termination, and modification of said pattern as determined by the nature and analysis of said signals by said logic means.

An automatic sewing machine, comprising:

• (a) at least one sewing needle, thread supply and associated stitch forming apparatus to form successive stitches in a workpiece;
• (b) program controllable drive means for driving said sewing head;
• (c) a work holder arrangement including clamp means for holding a workpiece for operation thereon by said needle and having an electrically controllable connector to an associated X-Y motion table positioned by program controllable positioner means associated with said table, said work holder arrangement including a work holder frame with said clamp means secured thereto, said connector comprising a spring loaded releasable detent type connector having a movable member connected to a solenoid for releasing such detent connector and said release signal operating to energize said solenoid for releasing said connector;
• (d) needle and work holder position signaling means productive of control signals indicative of successive positions obtained by the needle and work holder in the course of executing a pattern;
• and
• (e) program means having a stored pattern program adapted to receive and process said signals to control said drive and positioner means according to such pattern program and at the termination of such pattern productive of a work holder release signal to release said connector.

The method of sewing a stitched pattern in a workpiece comprising the steps of:

• (a) locating the workpiece to be sewn on a sewing machine equipped with a driven needle and positionable work holder and with means to develop control signals indicative of positions obtained by the needle and work holder and of stitch faults incurred as the pattern progresses;
• (b) operating said machine and continuously monitoring and analyzing said control signals with program logic during each stitch as the pattern proceeds;
• (c) stitching and terminating stitching of said pattern utilizing said program logic analysis for control and according to said monitoring;
• (d) at the end of said pattern effecting an automatic programmed release of the workpiece from the work holder;
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• (e) during said pattern upon the occasion of receiving a stitch fault signal executing a reverse repeat of said pattern for some predetermined number of stitches and then stopping said machine.

The method of sewing a stitched pattern in a workpiece comprising the steps of:

• (a) locating the workpiece to be sewn on a sewing machine equipped with a driven needle and positionable work holder and with means to develop control signals indicative of positions obtained by the needle and work holder and of stitch faults incurred as the pattern progresses;
• (b) operating said machine and continuously monitoring and analyzing said control signals with program logic during each stitch as the pattern proceeds;
• (c) stitching and terminating stitching of said pattern utilizing said program logic analysis for control and according to said monitoring;
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• (d) terminating said control signals in a logic circuit, developing and recording other signals characteristic of the terminated signals and utilizing a central processing unit having access to such recorded signals to effect said analysis.

An automatic sewing apparatus, comprising:

• (a) a plural number of sewing heads divided into plural sets of sewing heads with each set being adapted to operate synchronously, each with a needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece as a pattern;
• (b) signal controllable drive means providing separate drive means for independently driving each said set and the sewing heads thereof synchronously;
• (c) plural sets of work holders for each set of sewing heads, one for each sewing head and adapted to hold a respective workpiece for operation thereon by a respective said needle, each set of work holders being mounted on an X-Y motion table associated with a respective set of sewing heads and with each said X-Y motion table having independent, controllable bi-directional positioner means associated therewith;
• (d) signaling means comprising a set of signal means for each set of sewing heads and with each set of signaling means being productive of signals indicative of successfully obtained positions of the positioner means and needles associated with a respective set of sewing heads;
• (e) circuit means for receiving and transmitting said signals singularly or plurally and developing recorded signals therefrom having characteristics corresponding thereto, said circuit means including means for receiving and terminating said signals from all sets of said sewing heads;
• (f) a stored program logic means adapted to access and analyze said signals, the relation between such signals and other operating conditions, said stored program logic means including logic means adapted to access and analyze said signals from all of said sewing heads;
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• (g) computer means adapted to develop responses to said signals as the pattern proceeds to control said machine and the execution of said pattern, said computer means being adapted to develop responses to all of said signals from all of said sets of sewing heads as individual patterns proceed on each individual set of sewing heads to control operations of all of said sets of sewing heads and the execution of all of said patterns thereon.

An automatic sewing apparatus, comprising:

• (a) a selected number, at least one, of sewing heads each with a needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece as a pattern;
• (b) signal controllable drive means for driving a selected number of said sewing heads synchronously;
• (c) a corresponding number of work holders, one for each sewing head and adapted to hold a respective workpiece for operation thereon by a respective said needle and mounted on an X-Y motion table adapted to support said number of work holders and having controllable bi-directional positioner means associated therewith;
• (d) signaling means productive of signals indicative of successively obtained positions of said positioner means and each said needle;
• (e) circuit means for receiving and transmitting said signals singularly or plurally and developing recorded signals therefrom having characteristics corresponding thereto, said circuit means comprising interface logic circuit means constructed in a manner enabling associated program logic to develop either an immediate response to a said control signal, a delayed response to a said control signal while other machine operations are performed or to ignore any said control signal;
• (f) a stored program logic means adapted to access and analyze said signals, the relation between such signals and other operating conditions, said stored program logic means being associated with said interface logic circuit means adapting said stored program logic means to develop either said immediate response, said delayed response, or said ignoring of said signal;
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• (g) computer means adapted to develop responses to said signals as the pattern proceeds to control said machine and the execution of said pattern.

An automatic sewing apparatus, comprising:

• (a) a selected number, at least one, of sewing heads each with a needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece as a pattern;
• (b) signal controllable drive means for driving a selected number of said sewing heads synchronously;
• (c) a corresponding number of work holders, one for each sewing head and adapted to hold a respective workpiece for operation thereon by a respective said needle and mounted on an X-Y motion table adapted to support said number of work holders and having controllable bi-directional positioner means associated therewith;
• (d) signaling means productive of signals indicative of successively obtained positions of said positioner means and each said needle;
• (e) circuit means for receiving and transmitting said signals singularly or plurally and developing recorded signals therefrom having characteristics corresponding thereto;
• (f) a stored program logic means adapted to access and analyze said signals, the relation between such signals and other operating conditions, said stored program logic being adapted to store priority indicators for said control signals and in developing said responses acts to analyze said priorities to determine recognition of any said signal and establish whether recognition should occur;
• and
• (g) computer means adapted to develop responses to said signals as the pattern proceeds to control said machine and the execution of said pattern.

An automatic sewing machine, comprising:

• (a) at least one sewing head with at least one sewing needle, thread supply, take-up means and associated stitch forming apparatus to form successive stitches in a workpiece;
• (b) signal controllable drive means for driving said sewing head;
• (c) a work holder adapted to hold a workpiece for operation thereon by said needle and mounted on a X-Y motion table having controllable positioner means associated therewith, said work holder including an electrically releasable mounting means therefor;
• (d) work holder release control means associated with said work holder operable to release said work holder mounting means from said machine;
• (e) signaling means productive of signals indicative of successively obtained positions of said positioner means and the needle;
• (f) circuit means for terminating and recording selected characteristics of signals from said signaling means and for providing selective access to the record of such signals by a central processing unit;
• (g) randomly addressable memory means containing logical sequences of instructions for control of a central processing unit and pattern data interpretable by a central processing unit as directions for executing a pattern including, as required for such pattern, directions for said drive means, directions for said positioner means, directions for selection of central processing unit control instruction sequences, directions for release of said work holder mounting means from the machine and directions for selecting sequences of pattern data;
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• (h) a central processing unit operatively associated with said memory means and adapted to serialize and execute said control instructions to direct its own operation and to control recognition and to recognize signals present in said circuit means and in coordination therewith to issue other signals for control of said sewing head drive and work holder positioner means whereby to reproduce by stitching with said needle the pattern represented in said pattern data.