Due to the demand for high industrial productivity, thread tension is of vital significance in embroidery machine systems. By appropriately adjusting the thread tension during the embroidering process, a lower thread-breakage rate can be achieved, and as a result, the embroidering speed and productivity will be greatly improved. In this research, we shall address the thread tension problem. First, we analyze the critical part of the thread, where breakage is most likely to occur during the embroidering process, using an image capturing and processing technique; then, a particular dynamics model of the thread motion in the critical part will be derived. From the model attained, mechanisms to reduce the peak tension and the thread breakage rate for embroidery machines will be developed....[ Read more ]

Due to the demand for high industrial productivity, thread tension is of vital significance in embroidery machine systems. By appropriately adjusting the thread tension during the embroidering process, a lower thread-breakage rate can be achieved, and as a result, the embroidering speed and productivity will be greatly improved. In this research, we shall address the thread tension problem. First, we analyze the critical part of the thread, where breakage is most likely to occur during the embroidering process, using an image capturing and processing technique; then, a particular dynamics model of the thread motion in the critical part will be derived. From the model attained, mechanisms to reduce the peak tension and the thread breakage rate for embroidery machines will be developed.

The thread breakage rate can be reduced from the improvement of the tension system. However, a reliable and economical breakage detection system is also indispensable for an embroidery machine system. But current design of the breakage detection system cannot meet the requirements of the embroidering process at higher and higher speeds. A new detection system is constructed in this research. Based on the detector mechanism of current design, an advanced breakage judgment rule is proposed. And, new designs in the detection logic unit and the communication network provide the high-performance detection function, which is desired in embroidery machine systems.