SYSTEM AND METHOD FOR MONITORING QUILTING

Abstract

A stitch monitoring system configured to provide one or more real-time views of stitching applied to a quilt during construction of the quilt on a long arm sewing machine. The stitch monitoring system including a camera having a housing configured to selectively adhere to an exterior of a sewing machine, an imaging module configured to convert photons to electrons for digital processing, a compound macro lens assembly comprising a first lens, a second lens, a third lens, and a spacer element positioned between the second lens and the third lens having a length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens, and a wireless transceiver module configured to wirelessly transmit data gathered by the imaging module via a wireless network to display real-time views of stitching applied to the quilt by the sewing machine.

Claims

1. A stitch monitoring system configured to provide one or more real-time views of stitching applied to a quilt during construction of the quilt on a long arm sewing machine, the stitch monitoring system comprising: a camera module comprising: a housing including at least one of a magnet or an adhesive strip configured to removably couple to an exterior of a long arm sewing machine to selectively position the camera module relative to stitching applied to a quilt by the long arm sewing machine during construction of the quilt; a power module configured to receive a supply of electrical power from an external source; an imaging module comprising a complementary metal oxide semiconductor sensor configured to convert photons to electrons for digital processing; a compound macro lens assembly comprising a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens, wherein the second magnification is greater than the first magnification, the first lens and the second lens having a combined fixed focal length, and the spacer element having a length substantially equal to the combined fixed focal length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens; and a wireless transceiver module configured to wirelessly transmit data gathered by the imaging module via a wireless network; and a user interface configured to receive the data transmitted by the wireless transceiver module to display real-time views of stitching applied to the quilt by the long arm sewing machine, as captured by the imaging module.

2. The stitch monitoring system of claim 1, wherein the stitch monitoring system includes a first camera module and a second camera module.

3. The stitch monitoring system of claim 2, wherein the first camera module is positioned below a quilting plane, and the second camera module is positioned above the quilting plane.

4. The stitch monitoring system of claim 2, wherein the first camera module and the second camera module are configured to transmit views of stitching applied to the quilt to the user interface to enable a user to simultaneously view the stitching from multiple angles.

5. The stitch monitoring system of claim 2, wherein the first camera module is removably coupled to a first long arm sewing machine, and the second camera module is removably coupled to a second long arm sewing machine to enable a user to simultaneously view the stitching from two separate long arm sewing machines.

6. A camera module configured to provide views of stitching applied to a quilt during construction of the quilt on a sewing machine, the camera module comprising: a housing configured to selectively adhere to an exterior of a sewing machine to position the camera module relative to stitching applied to a quilt by the sewing machine during construction of the quilt; an imaging module configured to convert photons to electrons for digital processing; a compound macro lens assembly comprising a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens having a defined length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens; and a wireless transceiver module configured to wirelessly transmit data gathered by the imaging module via a wireless network to display real-time views of stitching applied to the quilt by the sewing machine, as captured by the imaging module.

7. The camera module of claim 6, wherein the imaging module comprises a complementary metal oxide semiconductor sensor.

8. The camera module of claim 6, wherein the imaging module has a resolution output of about 1920 pixels by about 1080 pixels.

9. The camera module of claim 6, wherein the compound macro lens assembly is operably coupled to an exterior of the housing.

10. The camera module of claim 6, wherein the housing is configured to selectively adhere to an exterior of the sewing machine via at least one of a magnetic or an adhesive.

11. The camera module of claim 6, wherein the spacer element is constructed of at least one of an opaque or translucent material to reduce glare and distribute light evenly.

12. The camera module of claim 11, wherein the spacer element is constructed of a frosted acrylic material.

13. The camera module of claim 6, further comprising a light assembly configured to provide illumination in proximity to the compound macro lens assembly.

14. The camera module of claim 13, wherein the light assembly comprises a plurality of LEDs.

15. The camera module of claim 6, wherein the camera module is configured to be positioned at least one of below a quilting plane or above the quilting plane.

16. The camera module of claim 6, wherein the wireless transceiver module is configured to transmit data gathered by the imaging module to a remotely located user interface.

17. A method of monitoring stitching applied to a quilt during construction of the quilt on a long arm sewing machine, the stitch monitoring system comprising: providing a first camera module comprising an imaging module configured to convert photons to electrons for digital processing and a compound macro lens assembly comprising a first lens having a first magnification, a second lens having a second magnification, a third lens, and a spacer element positioned between the second lens and the third lens having a length to enable a sharp image of stitching applied to the quilt when the quilt is positioned adjacent to the third lens; transmitting data gathered by the imaging module to a user interface via a wireless network to display real-time views of stitching applied to the quilt by the long arm sewing machine, as captured by the imaging module.

18. The method of claim 17, further comprising providing a second camera module, and transmitting data gathered by the second camera module to the user interface via the wireless network.

19. The method of claim 18, wherein the first camera module and the second camera module are configured to transmit views of stitching applied to the quilt to the user interface to enable a user to simultaneously view the stitching from multiple angles.

20. The stitch monitoring system of claim 18, wherein the first camera module is adhered to a first long arm sewing machine, and the second camera module is adhered to a second long arm sewing machine to enable a user to simultaneously view the stitching from two separate long arm sewing machines.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which:

[0022] FIG. 1 is a perspective view of a stitch monitoring system, in accordance with an embodiment of the disclosure.

[0023] FIG. 2 is a perspective view of a stitch monitoring system, in accordance with an alternative embodiment of the disclosure.

[0024] FIG. 3 is a perspective view depicting a portion of the stitch monitoring system below a quilting plane, in accordance with an embodiment of the disclosure.

[0025] FIG. 4 is a schematic view depicting a camera module and user interface, in accordance with an embodiment of the disclosure.

[0026] FIG. 5A is an exploded, perspective view depicting a camera module, in accordance with an embodiment of the disclosure.

[0027] FIG. 5B is a profile view depicting the camera module in relation to a quilt during the monitoring of stitching, in accordance with an embodiment of the disclosure.

[0028] FIG. 6 is a perspective view of the user interface, in accordance with an embodiment of the disclosure.

[0029] While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

[0030] Referring to FIG. 1, a stitch monitoring system 100 adapted to monitor stitching performed by sewing machine 202, such as a long arm sewing machine, is depicted in accordance with an embodiment of the disclosure. In some embodiments, the stitch monitoring system 100 can include one or more camera modules 102 in communication with a user interface 104 (e.g., via a mobile computing device), configured to provide views of at least one of the under-side or upper-side of a quilt 204, while the quilt 204 is in mounted on the sewing machine 202 during construction (production) of the quilt 204. In embodiments, the one or more camera modules 102 can be selectively positioned in proximity to a quilting plane 206 of one or more long arm sewing machines 202, thereby enabling a capture of images and/or video of a quality of the stitching on one or more quilts 204 during construction.

[0031] The embodiments described herein have a wide application to a number of sewing machine applications, beyond the long arm sewing machine applications emphasized herein. While wide applications to different sewing machines in the sewing environment are possible, emphasis is placed on the application of the stitch monitoring system 100 for long arm sewing machines in the production of quilts, as that particular application is particularly benefited from the embodiments described herein with reference to the attached figures.

[0032] As depicted in FIGS. 1 & 2, in some embodiments, the sewing machine 202 can include a base 208 supporting a generally vertically oriented rear support member 210, which in turn can support a generally horizontally oriented arm 212. The arm 212 can include a needle 214 and thread feeder assembly 216 configured to selectively apply stitching during operation of the sewing machine 202 in the construction of a quilt 206. Collectively, the base 208, support member 210 and arm 212 can define a throat 218 shaped and sized to enable at least a portion of a quilting table assembly 220 to be positioned therein.

[0033] In some embodiments, the quilting table assembly 220 can include one or more rollers 222A/B upon which a portion of the quilt 204 can be wound. For example, in some embodiments an unstitched portion of the quilt 204 can be wound on a first roller 222A, while a stitched portion of the quilt 204 can be wound on a second roller 222B, or vice versa. In some embodiments, the quilting table assembly 220 can further include a carriage assembly (not depicted) configured to support the sewing machine 202. The carriage assembly can include a set of lateral rails configured to permit movement of the sewing machine 202 along an x-axis (e.g., laterally relative to the quilting table assembly 220), and a set of longitudinal rails configured to permit movement of the sewing machine 202 along a y-axis (longitudinally relative to the quilting table assembly 220), thereby permitting movement of the sewing machine 202 relative to the quilting table assembly 220 during the construction of a quilt 204.

[0034] With additional reference to FIG. 3, an underside of a sewing machine 202 (e.g., a portion of the sewing machine 202 positioned beneath the quilting plane 206) is depicted in accordance with an embodiment of the disclosure. In some embodiments, one or more camera modules 102 can be operably coupled to an exterior surface of the base 208. In other embodiments, the one or more camera modules 102 can be operably coupled to the arm 212 (e.g., to be positioned above the quilting plane 206). The coupling of the one or more camera modules 102 to other surfaces of the sewing machine 202 is also contemplated.

[0035] As depicted in FIG. 3, in some embodiments, the one or more camera modules 102 can be electrically coupled to a power source via a power cord 106. For example, in some embodiments, the one or more camera modules 102 can be operably coupled to a wall outlet, outlet on the sewing machine 202 or other fixed power source. In other embodiments, the one or more cameras 202 can be wireless and/or battery-powered.

[0036] In some embodiments, the one or more camera modules 102 can be selectively positioned beneath the sewing machine 202 via one or more magnets or adhesive 108 configured to selectively couple to an exterior surface of the sewing machine 202, thereby enabling the one or more camera modules 102 to be easily removed and/or repositioned as desired. In other embodiments, the one or more camera modules 102 can be fixedly coupled to the sewing machine 202 in a more semi-permanent manner, for example via an adhesive or other coupling method. In some embodiments, a light assembly 110 (e.g., a plurality of LEDs) can be positioned in proximity to the one or more wireless camera modules 102 for improved lighting and visibility during image capture. In some embodiments, the one or more wireless camera modules 102 can include an outlet power port 134 configured to provide power for an optional light assembly 110.

[0037] With additional reference to FIG. 4, a schematic diagram for a camera module 102 is depicted in accordance with an embodiment of the disclosure. In some embodiments, the camera module 102 can include a power module 112, an imaging module 114, and a wireless transceiver module 116, and a camera housing 118. In some embodiments, the camera housing 118 can be constructed of a rigid material defining an interior configured to house the power module 112, imaging module 114, and wireless transceiver module 116. In other embodiments, at least one of the power module 112 and wireless transceiver module 116 can be positioned exterior to the camera housing 118.

[0038] In some embodiments, the power module 112 can be configured to receive a supply of electrical power to power other components of the camera module 102. For example, in some embodiments, the power module 112 can be configured to receive a 120 or 220 VAC power supply, or other electrical power supply (e.g., via an electrical outlet on the sewing machine 202). In other embodiments, the power module 112 can be a battery pack or other electrical storage device. In some embodiments, the power module 112 can include a power converter configured to reduce or otherwise convert the incoming electrical power supplied to a usable voltage and/or current. In some embodiments, the power supply 112 can include an electrical output 134, for example in the form of a USB port, to selectively provide a reduced power output (e.g., 5 VDC/1000 mA) to optional accessories, such as a light assembly 110.

[0039] In some embodiments, the wireless transceiver module 116 can be configured to transmit and receive data from the user interface 104, for example via a wireless network. In some embodiments, the user interface 104 can be provided via a mobile computing device 224, such as a cellular telephone, electronic tablet, laptop, personal electronic device, etc.), thereby enabling a user to view a live stream of stitching being performed by the sewing machine 202 in real-time. Moreover, in some embodiments, the user interface 104 can be configured to enable the monitoring of the stitching from multiple angles (e.g., above the quilting plane, below the quilting plane, from the left side, from the right side, from the front, from the back, etc.) and on multiple sewing machines 202, remotely, thereby enabling the user to perform other tasks (separated from the sewing machine 202 by some distance), while the one or more sewing machines 202 execute programmed stitching operations. Accordingly, in some embodiments, the stitch monitoring system 100 can serve as a useful tool to improve productivity in the quilting process, particularly where multiple sewing machines 202 are employed.

[0040] Accordingly, systems methods of the present disclosure do not require a monitor or display to be installed on the sewing machine itself. Rather, the display can be mobile and remote, thereby enabling a user to freely move around the machine (and even away from the machine) while continuing to monitor the quality of the stitching, for example where a number of sewing machines are being operated by the user simultaneously. As depicted in FIG. 6, in some embodiments, multiple views from different cameras can be displayed on the user interface 104 simultaneously, thereby enabling the simultaneous viewing of the stitching from various angles. By touching the user interface 104 in a particular way, any of the images can be made larger or smaller, thereby enabling a zoom in/zoom out feature.

[0041] In some embodiments, the imaging module 114 can be a digital camera configured to convert optical images to pixelated data. For example, in one embodiment, the imaging module 114 can include a complementary metal oxide semiconductor (CMOS) sensor configured to convert photons to electrons for digital processing. In some embodiments, the imaging module 114 can be configured to reduce high definition quality figures, having a resolution output of about 1920 pixels (width) by about 1080 pixels (height); although other pixel counts are also contemplated. In some embodiments, the imaging module 114 can be configured to capture video. In other embodiments, the imaging module 114 can be configured to capture a series of still images to provide a time lapse video.

[0042] With additional reference to FIGS. 5A-B, in some embodiments, the camera module 102 can include a compound macro lens assembly 132 including have a first lens 120, second lens 122, third lens 130, and a spacer element 126; although other lens configurations are also contemplated.

[0043] In some embodiments, the first lens 120 can have a first magnification. For example, in one embodiment, the first lens 120 (alone) can include structure configured to enable a viewing angle of about 110 degrees with a focal length of about 2.8 mm. In some embodiments, the second lens 122 can have a second magnification, wherein the second magnification is greater than the first magnification (e.g., objects viewed through the second lens 122 alone appear larger than the same objects viewed through the first lens 120 alone). In some embodiments, the first lens 120 can be housed within the housing 118, while the second lens 122 can be adhered to an exterior of the housing 118. In some embodiments, the second lens 122 can be operably coupled to the housing 118 via one or more magnets or an adhesive, thereby enabling the second magnifying lens 122 to be rapidly coupled and decoupled to the camera module 102 as desired. In other embodiments, the lens compound macro lens assembly 132 (or components thereof) can be at least partially secured within the housing 118. Other methods of securing be second lens 122 in position relative to the first lens 120 are also contemplated. In some embodiments, the first lens 120 and the second lens 122 can have a combined fixed focal length, for example in the range of between about 20 mm to about 100 mm.

[0044] The third lens 130 can be a clear plane, with no magnification. For example, in some embodiments, the third lens 130 can be constructed of a substantially flat plane of glass or plastic. In some embodiments, the third lens 130 can be well adapted to inhibiting lint, and other cloth debris from accumulating on the first and second lenses 120, 122 during operation. As depicted in FIG. 5B, in some embodiments, a portion of the quilt 204 can be dragged over the third lens 130 (e.g., a portion of the quilt 204 can remain in contact with and/or be adjacent to the third lens 130) during operation, thereby effectively continuously wiping and/or cleaning the third lens 130 as the quilt 204 passes over the third lens 130.

[0045] In some embodiments, the spacer element 126 can be positioned between the second lens 122 and the third lens 130, to provide a desired distance between the second lens 122 and the third lens 130. In some embodiments, the spacer element 126 can have a length substantially equal to the combined fixed focal length of the combined first lens 120 and the second lens 122, thereby enabling a sharp image of objects positioned adjacent to the third lens 130. Further, in some embodiments. Further, in some embodiments the spacer element 126 can be constructed of an opaque or translucent material to reduce glare and distribute light evenly. For example, in some embodiments, the tube portion 126 can be constructed of a frosted acrylic; although other construction materials are also contemplated.

[0046] Accordingly, in some embodiments the length of the spacer element 126 can be adjusted to match the focal length of the combination of lenses, such that an object positioned at a distal end 128 of the spacer element 126 (e.g., fabric including stitching) is positioned at an ideal focal distance from the imaging module 114 to ensure that images captured by the imaging module 114 of the object continuously remain in focus. Accordingly, in some embodiments, the one or more camera modules 102 can be positioned such that the clear cover 130 presses slightly against the surface of the quilt 204 during the quilting process, such that the fabric of the quilt slides over the clear cover 130 to ensure that fabric containing the stitching continuously remains at within the ideal focal range, thereby enabling a sharp view of the stitching at all times, particularly where stitching, creases, and/or bends in the fabric would otherwise cause the applied stitching to move in and out of focus.

[0047] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0048] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0049] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0050] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0051] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(f) are not to be invoked unless the specific terms means for or step for are recited in a claim.