Automatic quilting machine for specialized quilting of patterns which can be created by utilizing computer graphics in conjunction with a reprogrammable computer

A frame quilting machine comprising:

• a. a frame member for retaining a fabric;
• b. said frame member mounted on a structure which can be moved in the X-direction, the Y-direction, or any X-Y combination direction;
• c. a first cross beam extending horizontally over said frame member;
• d. a second cross beam aligned parallel to said first cross beam and extending horizontally beneath said frame member;
• e. a first motor to generate movement of said frame member in the X-direction;
• f. an X axis controller connected to said first motor;
• g. a second motor to generate movement of said frame member in the Y-direction;
• h. a Y axis controller connected to said second motor;
• i. a remote control apparatus for controlling the movement of said structure and said frame member to enable the frame member and the fabric retained thereon to be moved horizontally in the X-direction, the Y-direction, and any combination X-Y direction between said first cross beam and said second cross beam;
• j. a scanner;
• k. a sewing machine head attached to said first cross beam and having a source of thread;
• l. a sewing needle extending from said sewing machine head and positioned to sew threads into said fabric while the frame member and structure move underneath said first cross beam and above said second cross beam;
• m. a sewing machine plate attached to said second cross beam and aligned with said sewing machine head and sewing needle;
• n. a process controller having an X input and a Y input connected to said remote control apparatus, the process controller also connected to said X axis controller through an X input and to said Y axis controller through a Y input;
• o. said remote control apparatus and said process controller connected to a source of power;
• p. said process controller further comprising a memory to store machine readable patterns;
• and
• s. said process controller further comprising a scanner interface card;
• t. whereby a predrawn pattern can be read by said scanner which automatically converts the pattern into machine readable language, the pattern is stored in the memory of the process controller and the pattern is be duplicated on the fabric through commands from the process controller to the remote control apparatus which causes said frame member to move relative to said first and second cross-beam to thereby bring locations on the fabric into alignment with said sewing needle as the pattern is sewn into said fabric.

A frame quilting machine comprising:

• a. a frame member for retaining a fabric;
• b. said frame member mounted on a structure which can be moved in the X-direction, the Y-direction, or any X-Y combination direction;
• c. a first cross beam extending horizontally over said frame member;
• d. a second cross beam aligned parallel to said first cross beam and extending horizontally beneath said frame member;
• e. a first motor to generate movement of said frame member in the X-direction;
• f. an X axis controller connected to said first motor;
• g. a second motor to generate movement of said frame member in the Y-direction;
• h. a Y axis controller connected to said second motor;
• i. a monitor;
• j. a sewing machine head attached to said first cross beam and having a source of thread;
• k. a sewing needle extending from said sewing machine head and positioned to sew threads into said fabric while the frame member and structure move underneath said first cross beam and above said second cross beam;
• l. a sewing machine plate attached to said second cross beam and aligned with said sewing machine head and sewing needle;
• m. a process controller connected to said X axis controller through an X input and to said Y axis controller through a Y input;
• n. said monitor and said process controller connected to a source of power;
• o. said process controller further comprising a graphics card to enable commands from the process controller to be viewed on said monitor;
• p. a graphic movement apparatus which enables a graphic cursor to draw patterns on said monitor;
• q. said process controller further comprising a memory to store machine readable patterns;
• and
• r. said process controller programmed with a computer aided design program which comprises menus of selected shapes which can be viewed on said monitor and used to sketch all or a portion of a desired pattern to be sewn into said fabric;
• s. whereby an operator may draw a pattern on said monitor through use of the graphic movement apparatus combined with the computer aided design program, convert the pattern into machine readable language through the computer aided design program, store the pattern in machine readable language in the memory of the computer and cause the pattern to be duplicated on the fabric through commands from the process controller which causes said frame member to move relative to said first and second cross-beam to thereby bring locations on the fabric into alignment with said sewing needle as the pattern is sewn into said fabric.

An apparatus for sewing thread into fabric comprising:

• a. a first structure supporting a sewing machine head having a sewing needle and a source of thread;
• b. a second structure supporting the fabric in a position relative to said sewing needle so that thread may be sewn into the fabric;
• c. said second structure capable of horizontal movement in the X-direction, the Y-direction, or any combination X-Y direction relative to said sewing needle;
• d. means for generating the horizontal movement of said second structure in the X-direction, the Y-direction, or any combination X-Y direction;
• e. a monitor;
• f. a process controller having an X input and a Y input connected to said means for generating horizontal movement of the second structure;
• g. a source of power connected to said monitor and to said process controller;
• h. said process controller further comprising a graphics card to enable commands from the process controller to be viewed on said monitor;
• i. a graphic movement apparatus which enables a graphic cursor to draw patterns on said monitor;
• j. said process controller further comprising a memory to store machine readable patterns;
• and
• k. said process controller programmed with a computer aided design program which comprises menus of selected shapes which can be viewed on said monitor and used to sketch all or a portion of a desired pattern to be sewn into said fabric;
• l. whereby an operator may draw a pattern on said monitor through use of the graphic movement apparatus combined with the computer aided design program, convert the pattern into machine readable language through the computer aided design program, store the pattern in machine readable language in the memory of the computer and cause the pattern to be duplicated on the fabric through commands from the process controller which causes said second structure to move relative to said first structure to thereby bring locations on the fabric into alignment with said sewing needle as the pattern is sewn into said fabric.

A frame quilting machine comprising:

• a. a frame member for retaining a fabric;
• b. said frame member mounted on a structure which can be moved in the X-direction, the Y-direction, or any X-Y combination direction;
• c. a first cross beam extending horizontally over said frame member;
• d. a second cross beam aligned parallel to said first cross beam and extending horizontally beneath said frame member;
• e. a first motor to generate movement of said frame member in the X-direction;
• f. an X axis controller connected to said first motor;
• g. a second motor to generate movement of said frame member in the Y-direction;
• h. a Y axis controller connected to said second motor;
• i. a scanner;
• j. a sewing machine head attached to said first cross beam and having a source of thread;
• k. a sewing needle extending from said sewing machine head and positioned to sew threads into said fabric while the frame member and structure move underneath said first cross beam and above said second cross beam;
• l. a sewing machine plate attached to said second cross beam and aligned with said sewing machine head and sewing needle;
• m. a process controller connected to said X axis controller through an X input and to said Y axis controller through a Y input;
• n. said process controller connected to a source of power;
• o. said process controller further comprising a memory to store machine readable patterns;
• and
• p. said process controller further comprising a scanner interface card;
• q. whereby a predrawn pattern can be read by said scanner which automatically converts the pattern into machine readable language, the pattern is stored in the memory of the process controller and the pattern is duplicated on the fabric through commands from the process controller which causes said frame member to move relative to said first and second cross-beam to thereby bring locations on the fabric into alignment with said sewing needle as the pattern is sewn into said fabric.

An apparatus for sewing thread into fabric comprising:

• a. a first structure supporting a sewing machine head having a sewing needle and a source of thread;
• b. a second structure supporting the fabric in a position relative to said sewing needle so that thread may be sewn into the fabric;
• c. said second structure capable of horizontal movement in the X-direction, the Y-direction, or any combination X-Y direction relative to said sewing needle;
• d. means for generating the horizontal movement of said second structure in the X-direction, the Y-direction, or any combination X-Y direction;
• e. a scanner;
• f. a process controller having an X input and a Y input connected to said means for generating horizontal movement of the second structure;
• g. a source of power connected to said process controller;
• h. said process controller further comprising a memory to store machine readable patterns;
• i. said process controller further comprising a scanner interface card;
• and
• j. said sewing machine head is equipped with a computer to control the sewing and stitching functions;
• k. whereby a predrawn pattern can be read by said scanner which automatically converts the pattern into machine readable language, the pattern is stored in the memory of the process controller and the pattern is duplicated on the fabric through commands from the process controller which causes said second structure to move relative to said first structure to thereby bring locations on the fabric into alignment with said sewing needle as the pattern is sewn into said fabric and wherein an operator can trace a straight-line pattern into the process controller and a software program in the process controller combined with the computer on the sewing machine head will enable the pattern to be automatically modified into a zig-zag or any other desired pattern.

The method of repetitively sewing a pattern into a fabric having a large surface comprising:

• a. positioning a sewing machine head having a source of thread and a sewing needle relative to said fabric;
• b. retaining said fabric on a movable structure which can be made to move in a horizontal direction relative to the sewing needle and which can cause a portion of the surface of the fabric to be reached by the sewing needle so that thread can be sewn into the fabric;
• c. controlling the movement of the movable structure relative to the sewing needle by a process controller;
• d. creating a pattern on a monitor through use of a cursor and cursor movement apparatus combined with a computer aided design program which converts the pattern into machine readable language;
• e. storing the machine readable pattern in the memory of said process controller;
• and
• f. mapping the completed pattern on a computer grid to select where the pattern is to be duplicated on said fabric;
• g. whereby the process controller can cause the movement of the movable structure relative to the sewing needle to thereby duplicate the pattern stored in its memory at any multiplicity of desired locations.

The method of repetitively sewing a pattern into a fabric having a large surface comprising:

• a. positioning a sewing machine head having a source of thread and a sewing needle relative to said fabric;
• b. retaining said fabric on a movable structure which can be made to move in a horizontal direction relative to the sewing needle and which can cause a portion of the surface of the fabric to be reached by the sewing needle so that thread can be sewn into the fabric;
• c. controlling the movement of the movable structure relative to the sewing needle by a process controller;
• d. duplicating a predrawn pattern by causing it to be read by a scanner which then converts the pattern into machine readable language;
• e. storing the machine readable pattern in the memory of said process controller;
• f. mapping the completed pattern on a computer grid to select where the pattern is to be duplicated on said fabric;
• g. controlling the sewing and stitching functions by a separate computer in the sewing machine head which receives commands from said process controller;
• h. whereby the process controller can cause the movement of the movable structure relative to the sewing needle to thereby duplicate the pattern stored in its memory at any multiplicity of desired locations and can modify sewing and stitching functions by commands to the computer in the sewing machine head.