Quilting device

Abstract

A quilting device (1) comprises a processing unit (5) which is mounted on a frame (3) so as to be manually displaceable in two movement directions (M1, M2) by an operator. A detection device (29) having sensors (27) detects the guiding force which is exerted in these movement directions (M1, M2) by the operator. A controller device (35) controls or regulates, respectively, auxiliary motors (33a, 33b) which support the guiding force, so as to depend on the detected guiding force.

Claims

1. A quilting device (1) comprising a processing unit (5) including a machine (11) for processing a two-dimensional structure, the machine being selected from a sewing machine, a device for punching or cutting, a device for drawing, or a device for applying decorative elements, a frame (3) on which the processing unit (5) is mounted for movement such that the processing unit is moveable by influence of a force adapted to be provided by an operator within a utilizable range of a guide plane in a first movement direction (M1) and in a second movement direction (M2), so as to process the two-dimensional structure at two dissimilar positions, a first auxiliary motor (33a) operatively connected to the processing unit (5), the first auxiliary motor is arranged to exert a first auxiliary force in the first movement direction (M1) on the processing unit (5), a detection device (29) including at least one sensor configured to detect a first guiding force which is exerted in the first movement direction (M1) on the processing unit (5) by the operator, and a controller (35) that receives a first input with respect to the first guiding force from the at least one sensor and controls the first auxiliary motor (33a) dependent upon the first guiding force detected by the at least one sensor.

2. The quilting device (1) according to claim 1, further comprising: a second auxiliary motor (33b) operatively connected to the processing unit (5), the second auxiliary motor is arranged to exert a second auxiliary force in the second movement direction (M2) on the processing unit (5), wherein the at least one sensor of the detection device (29) is configured to detect a second guiding force which is exerted in the second movement direction (M2) on the processing unit (5) by the operator, and the controller (35) receives a second input with respect to the second guiding force from the at least one sensor and controls the second auxiliary motor (33b) dependent upon the second guiding force detected by the detection device.

3. The quilting device (1) according to claim 2, wherein the processing unit (5) further comprises a first carriage (7), a second carriage (9), and the sewing machine (11) is provided, the first carriage (7), guided on longitudinal guides of the frame (3), is mounted for movement in the first movement direction (M1) and is drivable by the first auxiliary motor (33a), and the second carriage (9), guided on transverse guides of the first carriage (7) that are aligned so as to be orthogonal to the longitudinal guides, is mounted for movement in the second movement direction (M2) and is drivable by the second auxiliary motor (33b), and the sewing machine (11) is rigidly connected to the second carriage (9) such that an upper arm and a lower arm (19) of the sewing machine (11) are aligned parallel with the transverse guides.

4. The quilting device (1) according to claim 3, wherein the processing unit (5) comprises at least one handle (25a, 25b)by which the processing unit is movable by at least one of the first or second guiding forces applied in at least one of the first movement direction (M1) or the second movement direction (M2), said handle (25a, 25b) is rigidly connected to the sewing machine (11) or to the second carriage (9) at a force transmission point, and the at least one sensor comprises a force sensor (27) provided in a force transmission path from the at least one handle (25a, 25b) to the force transmission point, the force sensor (27) detects a force which by way of the handle (25a, 25) is exerted on the processing unit (5) in a specific direction.

5. The quilting device (1) according to claim 4, wherein at least one of a position or an alignment of the force sensor is variable, and the detection device (29) detects a position of the force sensor (27).

6. The quilting device (1) according to claim 5, wherein the at least one handle comprises two of the handles and each of the handles has an associated one of the force transmission points, and further comprising an additional force sensor such that there are two of the force sensors (27) that are provided in the force transmission path of each of the handles (25a, 25b) to each of the associated force transmission points, and the force sensors detect the force components which are exerted by way of the respective handles (25a, 25) on the processing unit (5) in two dissimilar directions.

7. The quilting device (1) according to claim 4, wherein the force transmission point comprises a coupling element (31) which is fixedly connected to the sewing machine (11) or to the second carriage (9), respectively, and two of the force sensors (27) are disposed on said coupling element (31) such that the force sensors are adapted to detect components of the first and second guiding forces in the first movement direction (M1) and in the second movement direction (M2) independent of a configuration of the handle.

8. The quilting device (1) according to claim 7, wherein the controller device (35) comprises a setting element configured to at least one of set or modify an amplification factor, a transmission function, or both the amplification factor and the transmission function which predefines the force provided by the respective auxiliary motor (33a, 33b), so as to depend on the associated guiding force component.

9. A method for moving a processing unit (5) in a quilting device (1), the method comprising: providing a quilting device (1) including a processing unit (5) with a sewing machine, a frame (3) on which the processing unit (5) is mounted for movement such that the processing unit is moveable by influence of a force adapted to be provided by an operator within a utilizable range of a guide plane in a first movement direction (M1) and in a second movement direction (M2), so as to process a two-dimensional structure at two dissimilar positions, a first auxiliary motor (33a) operatively connected to the processing unit (5), the first auxiliary motor being arranged to exert a first auxiliary force in the first movement direction (M1) on the processing unit (5), a detection device (29) including at least one sensor configured to detect a first guiding force which is exerted in the first movement direction (M1) on the processing unit (5) by the operator, and a controller (35) that receives a first input with respect to the first guiding force from the at least one sensor and controls the first auxiliary motor (33a) based on the first guiding force detected by the at least one sensor, a second auxiliary motor (33b) operatively connected to the processing unit (5), the second auxiliary motor is arranged to exert a second auxiliary force in the second movement direction (M2) on the processing unit (5), the at least one sensor of the detection device (29) is configured to detect a second guiding force which is exerted in the second movement direction (M2) on the processing unit (5) by the operator, and the controller (35) receives a second input with respect to the second guiding force from the at least one sensor and controls the second auxiliary motor (33b) dependent upon the second guiding force detected by the detection device, the processing unit (5) further comprises a first carriage (7), a second carriage (9), the first carriage (7), guided on longitudinal guides of the frame (3), is mounted for movement in the first movement direction (M1) and is drivable by the first auxiliary motor (33a), and the second carriage (9), guided on transverse guides of the first carriage (7) that are aligned so as to be orthogonal to the longitudinal guides, is mounted for movement in the second movement direction (M2) and is drivable by the second auxiliary motor (33b), and the sewing machine (11) is rigidly connected to the second carriage (9) such that an upper arm and a lower arm (19) of the sewing machine (11) are aligned parallel with the transverse guides, the processing unit (5) further including at least one handle (25a, 25b) by which the processing unit is movable by at least one of the first or second guiding forces applied in at least one of the first movement direction (M1) or the second movement direction (M2), said handle (25a, 25b) is rigidly connected to the sewing machine (11) or to the second carriage (9) at a force transmission point, and the at least one sensor comprises a force sensor (27) provided in a force transmission path from the at least one handle (25a, 25b) to the force transmission point, the force sensor (27) detects a force which by way of the handle (25a, 25) is exerted on the processing unit (5) in a specific direction , the force transmission point comprises a coupling element (31) which is fixedly connected to the sewing machine (11) or to the second carriage (9), respectively, and two of the force sensors (27) are disposed on said coupling element (31) such that the force sensors are adapted to detect components of the first and second guiding forces in the first movement direction (M1) and in the second movement direction (M2) independent of a configuration of the handle; the detection device (29) detecting the guiding force component which is exerted on the processing unit (5) in at least one of the two movement directions (M1, M2) by an operator; and the controller device (35) controlling the respective auxiliary motor (33a, 33b) dependent on said guiding force component such that the force of the auxiliary motor (33a, 33b) supports the guiding force for moving the processing unit (5) within the utilizable range.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be described in more detail with reference to a few figures in which:

(2) FIG. 1 shows a schematically illustrated part of a quilting device; and

(3) FIG. 2 shows an assembly of two adjustable handles.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) FIG. 1 in a schematic illustration shows part of a quilting device 1 having a quilting frame, referred to as frame 3 for short, on which a processing device 5 is mounted so as to be traversable in a first movement direction M1 and in a second movement direction M2 which is orthogonal thereto. The first movement direction M1 corresponds to the longitudinal direction of the frame 3, the second movement direction M2 corresponds to the shorter width direction of the frame 3. The frame 3, as are conventional quilting frames, is configured for holding a portion of a two-dimensional textile structure tensioned in such a manner that this portion is disposed in one processing plane, so as to be at least approximately parallel with the two movement directions M1 and M2. The two-dimensional structure may comprise one or a plurality of layers. The latter are typically rewindable from supply rolls, which are disposed at the front on the frame 3 so as to be parallel with the longitudinal direction thereof, to a common take-up roll, this take-up roll being likewise disposed above the processing plane so as to be parallel with the longitudinal direction of the frame 3 (not illustrated). The processing device 5 comprises a first carriage 7, or a slide, respectively, which guided on longitudinal guides (not illustrated) of the frame 3 is movable in the first movement direction Ml. The length of the longitudinal guides of the frame 3, and the mounting elements (not illustrated) of the first carriage 7 delimit the maximum possible freedom of movement of the first carriage 7 in the first movement direction M1. Moreover, the processing device 5 comprises a second carriage 9 which is guided on transverse guide (not illustrated) which are disposed on the first carriage 7 in a manner orthogonal to the longitudinal guides of the frame 3 so as to be movable in the second movement direction M2. The length of the transverse guides on the first carriage 7, and the mounting elements (not illustrated) of the second carriage 9 delimit the maximum possible freedom of movement of the second carriage 9 in the second movement direction M2.

(5) A sewing machine 11, in particular a long-arm sewing machine, of which the stitch-forming tools 15 on the machine head 13 have a large spacing from the support 17 of preferably more than 30 cm, is fixedly or rigidly connected to the second carriage 9, respectively. The C-shaped support structure of the support 17, the lower arm 19, and the upper arm 21, in the case of such long-arm sewing machines is highly rigid.

(6) The sewing machine 11 is aligned such that the lower arm 19 thereof and the upper arm 21 thereof are disposed so as to be parallel with the width direction of the frame 3, or with the second movement direction M2, respectively. The machine head 13 and the needle plate 23 disposed therebelow on the lower arm 19 face the front longitudinal guide of the frame 3, or the operator side of the quilting device 1 lying at the front, respectively. The position of the needle plate 23 defines the processing plane in which that portion of the two-dimensional textile structure that is to be processed is held under tension.

(7) In an analogous manner, the processing device 5, as an alternative to a sewing machine 11, could also comprise another machine for processing the two-dimensional structure, for example a device for punching or cutting, or for drawing using a textile marker, or for applying decorative elements, such as sequins or rhinestones.

(8) In order for the processing device 5 to be manually moved in a guided manner by an operator in the two movement directions M1 and M2, the processing device 5 comprises at least one handle 25a, 25b. In the case of the embodiment of the quilting device 1 schematically illustrated in FIG. 1, two handles 25a, 25b behind the machine head 13 are connected to the upper arm 21 of the sewing machine 11. Operating elements (not illustrated) for controlling functions of the quilting device 1 may optionally be disposed on these handles 25a, 25b. Preferably, each of the handles 25a, 25b comprises one or a plurality of elements or portions, respectively, of which the relative position and/or alignment to the sewing machine 11 is adjustable or settable, respectively, such that the handle 25a, 25b is adaptable to individual requirements of the respective operator. Because of the high rigidity of the sewing machine 11 and of the second carriage 9, each of the handles 25a, 25b by way of which an operator may exert a force directly on the processing unit 5, so as to move the latter in at least one of the movement directions M1 or M2, respectively, may be disposed on any suitable points of the processing device 5. In particular, the fitting point or the force transmission point of the handle 25a, 25b, respectively, may be disposed on the sewing machine 11 or on the second carriage 9. Alternatively, the handle 25a, 25b at a plurality of force transmission points (not illustrated) may be connected to the sewing machine 11 and/or to the second carriage. 9. One or a plurality of sensors 27 of a detection device 29 are disposed in the handle 25a, 25b, or in each of the force transmission paths from the handle 25a, 25b, respectively, to the sewing machine 11, or to the second carriage 9, respectively, such that the detection device 29 from the measured values of these sensors 27 may determine a manual guiding force which is exerted by the operator on the processing unit 5 in at least one, preferably in both movement directions M1, M2. This manual guiding force results from superimposing all proportions of guiding forces which the operator by way of all force transmission paths exerts on the processing unit 5 in the respective movement direction M1, M2. Here, forces with an opposing effective direction have dissimilar mathematical signs.

(9) In the case of the assembly illustrated in FIG. 1, two handles 25a, 25b are fastened in a fixedly predefined position to the sewing machine 11, each of the handles 25a, 25b comprising one first force transmission leg which is aligned in a manner orthogonal to the first movement direction M1 and on which a strain gauge acting as the sensor 27 is disposed such that the measured value thereof corresponds to the respective proportion of guiding force in the first movement direction M1.

(10) In an analogous manner, each of the handles 25a, 25b may comprise one second force transmission leg which is aligned in a manner orthogonal to the second movement direction M2 and has a sensor 27 which is disposed such that the measured value thereof corresponds to the respective proportion of guiding force in the second movement direction M2.

(11) As is illustrated by double arrows A in FIG. 2, the handles 25a, 25b may comprise one or a plurality of movable, in particular rotatable and/or length-adjustable portions. Preferably, the sensors 27 which are configured for detecting the guiding force components in the two movement directions M1, M2 are disposed on a coupling element 31 which is fixedly connected to the sewing machine 11 or to the second carriage 9, respectively. In this way, the sensors 27 may detect the guiding force components which are transmitted by way of the handles 25a, 25b and act in the two movement directions M1, M2, so as to be independent of the configuration of the handles 25a, 25b.

(12) Should one or a plurality of sensors 27 be disposed in the force transmission path such that the position thereof, that is the position and/or alignment thereof in relation to the sewing machine 11 or to the second carriage 9, respectively, is variable so as to depend on the arrangement of the handles 25a, 25b, the detection device 29 when processing the measured values of these sensors 27 may consider additional items of information, in particular pertaining to the position of the sensors 27, so as to determine from the measured values of the sensors 27 proportions of the guiding force in the two movement directions M1 and M2. For this purpose, the detection device 29 may comprise elements or means for predefining or detecting the position of sensors. In particular, this may comprise further sensors which determine the position of those sensors 27 which detect the forces exerted on the processing device 5. Alternatively, this may comprise operating elements (not illustrated) for predefining the respective alignment or position of the sensors 27, respectively.

(13) In the case of further alternative embodiments, the detection device 29 may comprise controlling rules which in an initialization process allow items of information pertaining to the relative alignment of the sensors 27 to the movement directions M1 and M2 to be obtained and to be memorized. In particular, the operator here by way of the screen of a user interface (not illustrated) may be requested to move or to accelerate, respectively, the processing unit 5 in the first movement direction M1. The associated proportions of force in these two directions are determined and memorized at two sensors 27 which are configured for detecting forces in two orthogonal directions. In a manner analogous thereto, the associated proportions of force may also be determined and memorized upon movement or acceleration, respectively, in the second movement direction M2. The detection device 29 by use of these values calculates the position or orientation, respectively, of the sensors 27 in relation to the movement directions M1 and M2. This essentially corresponds to a transformation of coordinates between the coordinate system of the force sensors 27 and that of the movement directions M1 and M2.

(14) In order for a guiding force which is exerted by the operator on the processing device 5 to be detected directly, instead of or in addition to resistive force sensors such as strain gauges, force sensors which operate according to other physical measuring principles may also be used. Examples thereof are, in particular, piezoelectric, inductive, capacitive, or optical sensors 27.

(15) Alternatively, the guiding force exerted on the processing device 5 by the operator may also be indirectly determined in that the acceleration of the processing device 5, or of the components thereof, respectively, in both movement directions M1 and M2 are detected by means of an acceleration sensor. This acceleration, when multiplied with the inert mass of the processing device 5, results in the total force which acts on the processing device 5. All known forces which act on the processing device 5 in addition to the guiding force of the operator are subtracted therefrom. The prerequisite is that the further forces which act on the processing device 5 are known.

(16) In order for the movement or the drive, respectively, of the processing unit 5 to be supported, the quilting device 1 for at least one, preferably for both movement directions M1, M2 comprises one auxiliary motor 33a, 33b each. The first auxiliary motor 33a is operatively connected to the first carriage 7, the second auxiliary motor 33b being operatively connected to the second carriage 9. The transmission of force from the auxiliary motors 33a, 33b to the carriages 7, 9, respectively, may be performed in a known manner, for example by belts. Preferably, the first auxiliary motor 33a is disposed in a locationally fixed manner on the frame 33, the second auxiliary motor 33b being disposed in a locationally fixed manner on the first carriage 9.

(17) Each of these auxiliary motors 33a, 33b is controlled or regulated by a controller device 35, so as to depend on the associated guiding force detected by the sensors 27 or determined by the detection device 29, respectively. The detection device 29 which processes the measured values of the sensors 27 is preferably configured as a part of the controller device 35.

(18) Controlling or regulating, respectively, the auxiliary forces which are exerted by the auxiliary motors 33a, 33b on the associated carriages 7, 9 is performed by processing rules which are memorized in a program memory of the controller device 35. Preferably, further parameters such as, for example, the position of the processing device 5 and/or the speed thereof in relation to the frame 3, are detected and utilized for improved control in addition to the detected guiding forces in the two movement directions M1, M2. In particular, the controller device 35 may be configured via measured values or actuation values of the auxiliary motors 33a, 33b such as, for example, the actuation current thereof, to determine the torques or the forces thereof which are exerted on the processing device 5, respectively. A coefficient of dynamic friction may also be memorized in a memory of the controller device 35, for example. This enables the controller device 35 to calculate forces which act on the processing device 5 in addition to the force of an operator.

(19) Preferably, the controller device 5 is configured to monitor the position of the processing device 5 within a utilizable range. This may be performed, for example, by evaluating the signals from incremental rotary encoders or from absolute rotary encoders on the auxiliary motors 33a, 33b. As soon as the processing device 5 is located within a predefined or a predefinable minimum spacing from the periphery of the utilizable range, the supportive force of the respective auxiliary motor 33a, 33b is at least interrupted or modified so as to be a deceleration force acting in the opposite direction.

LIST OF REFERENCE SIGNS

(20) 1 Quilting device

(21) 3 Frame

(22) 5 Processing device

(23) 7 First carriage

(24) 9 Second carriage

(25) 11 Sewing machine

(26) 13 Machine head

(27) 15 Tool

(28) 17 Support

(29) 19 Lower arm

(30) 21 Upper arm

(31) 23 Needle plate

(32) 25a, 25b Handles

(33) 27 Sensors

(34) 29 Detection device

(35) 31 Coupling element

(36) 33a First auxiliary motor

(37) 33b Second auxiliary motor

(38) 35 Controlling device