The inherent technology of computerized sewing products is closely related to addressing key factors such as seamability, functional requirements, operability, reliability, and durability of the sewing machine, as well as the overall product quality. It represents the continuous development of the product's own technology, aiming for higher speed and greater automation. Technical solutions like specialization and integration are connected to the methods and tools used in implementing these solutions. These elements collectively form the core technical knowledge of computerized sewing machines.
Mastering the core technology of industrial computerized pattern machines requires deep professional knowledge, including expertise from related fields. Only through thorough analysis and true understanding of the core technology can we develop and design products with independent intellectual property. Continuous technical accumulation allows us to build a product design database and a sewing machine mechanism map, laying the foundation for future innovation in industrial sewing machine design.
It’s important to note that the core technology of sewing machine products is not static—it evolves with the maturation of existing technologies, the introduction of new innovations, product upgrades, function expansion, and even the creation of new stitch types. While specific core technologies may change over time, many common techniques can still be referenced and applied when analyzing and mastering the technology of particular products. This is especially crucial when developing a series of related products, highlighting the significance of technological accumulation and practical experience.
As an example, let's explore some core technologies that high-speed lockstitch machines should understand or master:
1. **Lightweight Technology**
- Analysis and testing of the main vibration sources in the casing
- Use of lightweight materials and surface coating technologies
- Impact of casing cross-sectional shape on vibration
2. **Factors Influencing Low-Tension Sewing**
3. **Upper Thread Dynamic Tension Measurement Technology**
4. **Rotary Hook Design Technology**
The industrial computerized pattern machine industry has developed standardized line types. The basic mechanisms that enable various stitching patterns have matured through long-term use, and the mechanical structure tends to stabilize. Improvements in product quality, variety expansion, and technological advancement are all based on the original product designs. The integration of mechatronics technology provides more room for gradual and continuous innovation, but it must still be rooted in the original product, adding automation, integration, or systemic functions.
It's unlikely that the fundamental types of industrial sewing machines will be completely replaced. Even if cam mechanisms are replaced by electronic control systems, it's just a shift in control mode aimed at simplifying the mechanism. Reverse engineering is also a form of innovative design. It involves comprehensive, in-depth, and systematic analysis of advanced existing products using scientific testing methods. Understanding the structural characteristics, mechanism principles, functionality, quality level, and design parameters of the product is essential. At the same time, evaluating the new technologies, processes, and materials used in the product based on digestion and absorption helps identify areas for improvement and user needs, serving as a starting point for innovative design.
Therefore, reverse engineering is a pioneering, practical, and comprehensive approach to product innovation.
(1) **Market Demand**
All sewing machine product developments originate from market demand. The guiding principle is to contribute most effectively to the company’s development strategy, ensuring the highest success rate. It involves recognizing the marketability, economy, and quality of the product, making choices that meet different levels of market needs.
(2) **Prototype Selection**
Choose a base product as a prototype to facilitate the development of future serialized products. Pay attention to the prototype's advanced features, select well-known brand products, consider user quality requirements and potential expectations, and emphasize the establishment of a product data (sample) library.
(3) **Prototype Evaluation Projects**
Evaluation items vary depending on the type of industrial computerized pattern machine. They include:
- Separability evaluation: broken wire, broken needle, skipped stitches, floating thread, misaligned lines, stitch tension, uniformity of high and low-speed stitches, material migration, wrinkling, vibration, noise, torque, etc.
- Functional evaluation: functional parameters and reliability
- Durability evaluation: performance of key components
- Adjustment evaluation: adjustability, stability, ease of operation
- Safety evaluation: operational safety
- Sewing process design parameter rationality evaluation
- Assembly evaluation of cycle diagrams and motion diagrams of functional mechanisms
- Evaluation of new materials, processes, and technologies, including positioning references and assembly clearances
- Feature analysis and design evaluation (including component structure and size)
(4) **Evaluation Method**
Compare with existing products or advanced foreign products, as well as internal control standards of leading companies. Use the conclusions as technical indicators and evaluation basis for innovative product design.
(V) **Examples of Innovative Solutions**
1. Feeding mode innovation: lower feeding, needle feeding, upper and lower feeding, differential feeding, variable up-and-down feeding, new structures for independent movement of upper and lower feeding, comprehensive feeding, roller feeding, etc.
2. Thread take-up mechanism innovation: cam take-up, connecting rod take-up, sliding rod take-up, rotating disc take-up, etc.
3. Needle mechanism innovation: center crank slider, rocker slider, linkage mechanism, transition from pivot to translation mode for needle bar swing.
4. Upper and lower shaft transmission mode innovation: connecting rod method, gear method, synchronous belt method, and feeding mechanism innovation.
(6) After evaluating the innovative program sample, clearly define the project's improvement goals and technical requirements. Use the product data (sample) library, design database, institutional map, and relevant professional knowledge and experience to complete the detailed design plan. Verify the improved parts through physical production, which may require repeated revisions before reaching the optimal solution.
This is just a brief overview of the reverse engineering process. Innovative design is always about improvement and transformation. As long as we establish a strong concept of innovation, study diligently, explore boldly, and continuously accumulate experience, our innovation capabilities will surely improve. This will effectively promote breakthrough progress in China’s sewing machine industry and accelerate its rise as the world's largest sewing machine production power.
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