JP7505230B2 - Defect prediction device - Google Patents

Defect prediction device Download PDF

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JP7505230B2
JP7505230B2 JP2020063829A JP2020063829A JP7505230B2 JP 7505230 B2 JP7505230 B2 JP 7505230B2 JP 2020063829 A JP2020063829 A JP 2020063829A JP 2020063829 A JP2020063829 A JP 2020063829A JP 7505230 B2 JP7505230 B2 JP 7505230B2
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JP2021159303A (en
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元就 中野
一樹 中山
宏史 近藤
雄介 今村
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Brother Industries Ltd
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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B51/00—Applications of needle-thread guards; Thread-break detectors
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B47/00—Needle-thread tensioning devices; Applications of tensometers
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B49/00—Take-up devices, e.g. levers, for the needle thread
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B55/00—Needle holders; Needle bars
    • D05B55/14—Needle-bar drives
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B69/00—Driving-gear; Control devices
    • D05B69/36—Devices for stopping drive when abnormal conditions occur, e.g. thread breakage

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Sewing Machines And Sewing (AREA)

Description

本発明は、不良予知装置に関する。 The present invention relates to a defect prediction device.

特許文献１は、ミシンが縫製する縫製対象物の縫い目の異常を検出する縫い目検査装置を開示する。縫い目検査装置は、上糸の張力を検出する張力センサを備え、張力センサの検出値から検出特徴量と参照特徴量とを算出する。検出特徴量は、上糸の張力の実際の特徴量を示す。参照特徴量は、縫製対象物の縫い目が正常である時の上糸の張力の特徴量を示す。縫い目検査装置は、縫製対象物の縫い目が正常である時、張力センサの検出値から算出した参照特徴量を参照特徴量記憶部に記憶する。縫い目検査装置は、張力センサの検出値から算出した検出特徴量と、参照特徴量記憶部に記憶の参照特徴量とを照合して、縫製対象物の縫い目の異常を判定する。 Patent Document 1 discloses a seam inspection device that detects abnormalities in the seams of a sewn object sewn by a sewing machine. The seam inspection device is equipped with a tension sensor that detects the tension of the upper thread, and calculates a detection feature and a reference feature from the detection value of the tension sensor. The detection feature indicates the actual feature of the tension of the upper thread. The reference feature indicates the feature of the tension of the upper thread when the seam of the sewn object is normal. When the seam of the sewn object is normal, the seam inspection device stores the reference feature calculated from the detection value of the tension sensor in a reference feature storage unit. The seam inspection device compares the detection feature calculated from the detection value of the tension sensor with the reference feature stored in the reference feature storage unit to determine abnormalities in the seam of the sewn object.

特開２０１９－２０１７４１号公報JP 2019-201741 A

上記縫い目検査装置は、縫い目の異常が発生したことを検出するので、縫い目の異常を未然に防ぐことができない。 The above seam inspection device only detects when an abnormality in a seam occurs, so it cannot prevent abnormalities in the seam.

本発明の目的は、縫製不良の発生を未然に防ぐことができる不良予知装置を提供することである。 The object of the present invention is to provide a defect prediction device that can prevent the occurrence of sewing defects.

請求項１の不良予知装置は、上糸を挿通した縫針が縫製中に上下動することに応じて周期的に変動する前記上糸に関する量である変量を取得する取得部と、前記取得部が取得する前記変量を記憶する記憶部と、前記記憶部が記憶する前記変量のうち特徴を示す量である特徴量の推移に基づき、ミシンによる縫製中の縫製不良の発生を予知する予知部とを備えることを特徴とする。不良予知装置は上糸に関する変量のうち特徴を示す特徴量の推移に基づき、縫製不良の発生を予知するので、縫製不良の発生を未然に防ぐことができる。 The defect prediction device of claim 1 is characterized by comprising an acquisition unit that acquires variables related to the upper thread that periodically fluctuate in response to the up and down movement of a sewing needle through which the upper thread is inserted during sewing, a storage unit that stores the variables acquired by the acquisition unit, and a prediction unit that predicts the occurrence of sewing defects during sewing by a sewing machine based on the transition of a characteristic quantity that is a quantity that indicates characteristics among the variables stored in the storage unit. Since the defect prediction device predicts the occurrence of sewing defects based on the transition of a characteristic quantity that indicates characteristics among the variables related to the upper thread, the occurrence of sewing defects can be prevented in advance.

請求項２の不良予知装置において、前記予知部は、前記縫針の上下動の一以上の周期を単位とした前記特徴量の推移に基づき、前記縫製不良の発生を予知する。不良予知装置は縫針の上下動の一以上の周期を単位とした特徴量の推移に依り予知するので、縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 2, the prediction unit predicts the occurrence of the sewing defect based on the transition of the feature amount in units of one or more periods of the up-and-down movement of the sewing needle. Since the defect prediction device predicts based on the transition of the feature amount in units of one or more periods of the up-and-down movement of the sewing needle, it is possible to improve the accuracy of preventing the occurrence of sewing defects.

請求項３の不良予知装置において、前記特徴量は、前記縫針の上下動の一周期の所定時機における前記変量に基づく量である。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 3, the characteristic amount is a quantity based on the variation at a predetermined time in one cycle of the up-and-down movement of the sewing needle. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of sewing defects.

請求項４の不良予知装置において、前記特徴量は、前記縫針の上下動の一周期又は前記縫針の上下動の一周期の所定時機における前記変量の大きさ、前記変量の大きさが所定の変量閾値に至った回数の少なくとも何れかである。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 4, the characteristic amount is at least one of the magnitude of the variation at a predetermined time during one cycle of the up-and-down movement of the sewing needle, or the number of times that the magnitude of the variation reaches a predetermined variation threshold. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of sewing defects.

請求項５の不良予知装置において、前記予知部は、前記特徴量の推移に基づき前記縫製不良の発生を予知する時、前記縫製不良が発生する可能性の度合を示す予知レベルを認識する。不良予知装置は縫製不良の発生を予知する時に予知レベルを認識するので、縫製不良が発生する可能性を複数段階で予知できる。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 5, when predicting the occurrence of the sewing defect based on the transition of the feature amount, the prediction unit recognizes a prediction level indicating the degree of possibility of the occurrence of the sewing defect. Since the defect prediction device recognizes the prediction level when predicting the occurrence of the sewing defect, it can predict the possibility of the occurrence of the sewing defect at multiple stages. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of the sewing defect.

請求項６の不良予知装置において、前記取得部は、前記上糸にかかる張力を取得する張力取得部、及び前記上糸の移動量を取得する移動量取得部の少なくとも何れかを備え、前記変量は、前記張力、前記移動量の少なくとも何れかである。不良予知装置は上糸にかかる張力、上糸の移動量の少なくとも何れかが変量であるので、容易に変量を取得できる。故に不良予知装置は縫製不良の発生を未然に防ぐことが容易になる。 In the defect prediction device of claim 6, the acquisition unit includes at least one of a tension acquisition unit that acquires the tension on the upper thread and a movement amount acquisition unit that acquires the movement amount of the upper thread, and the variable is at least one of the tension and the movement amount. Since at least one of the tension on the upper thread and the movement amount of the upper thread is a variable, the defect prediction device can easily acquire the variable. Therefore, the defect prediction device can easily prevent the occurrence of sewing defects.

請求項７の不良予知装置において、前記縫製不良は糸切れを含み、前記予知部は、前記特徴量の推移として、前記張力、前記移動量の少なくとも何れかにおける前記特徴量の前記単位あたりの推移に基づき糸切れの発生を予知する。不良予知装置は特徴量の単位あたりの推移に基づき糸切れの発生を予知するので、推移を比較し易い。故に不良予知装置は糸切れの発生を未然に防ぐことができる。 In the defect prediction device of claim 7, the sewing defect includes thread breakage, and the prediction unit predicts the occurrence of thread breakage based on the change in the characteristic amount per unit in at least one of the tension and the movement amount. Since the defect prediction device predicts the occurrence of thread breakage based on the change in the characteristic amount per unit, it is easy to compare the changes. Therefore, the defect prediction device can prevent the occurrence of thread breakage.

請求項８の不良予知装置において、前記縫製不良は目飛びを含み、前記予知部は、前記特徴量の推移として、前記張力、前記移動量の少なくとも何れかにおける前記特徴量の前記単位あたりの推移に基づき目飛びの発生を予知する。不良予知装置は特徴量の単位あたりの推移に基づき目飛びの発生を予知するので、推移を比較し易い。故に不良予知装置は目飛びを未然に防ぐことができる。 In the defect prediction device of claim 8, the sewing defect includes a skipped stitch, and the prediction unit predicts the occurrence of a skipped stitch based on the change in the characteristic amount per unit in at least one of the tension and the movement amount as the change in the characteristic amount. Since the defect prediction device predicts the occurrence of a skipped stitch based on the change in the characteristic amount per unit, it is easy to compare the changes. Therefore, the defect prediction device can prevent a skipped stitch before it occurs.

請求項９の不良予知装置において、前記縫製不良は締り不良を含み、前記予知部は、前記特徴量の推移として、前記張力、前記移動量の少なくとも何れかにおける前記特徴量の前記単位あたりの推移に基づき締り不良の発生を予知する。不良予知装置は特徴量の単位あたりの推移に基づき締り不良の発生を予知するので、推移を比較し易い。故に不良予知装置は締り不良を未然に防ぐことができる。 In the defect prediction device of claim 9, the sewing defect includes a tightening defect, and the prediction unit predicts the occurrence of a tightening defect based on the change in the characteristic amount per unit in at least one of the tension and the movement amount as the change in the characteristic amount. Since the defect prediction device predicts the occurrence of a tightening defect based on the change in the characteristic amount per unit, it is easy to compare the changes. Therefore, the defect prediction device can prevent a tightening defect before it occurs.

請求項１０の不良予知装置において、前記ミシンは、前記上糸を引き上げる天秤と、前記縫針に挿通した前記上糸のループを捕捉する釜とを備え、前記所定時機は、前記天秤が前記上糸を引上げる期間、前記釜が前記上糸のループを捕捉し前記上糸が前記釜を潜り抜ける期間の少なくとも何れかであって、前記予知部は、前記所定時機での前記張力の前記特徴量における前記単位あたりの推移が増加傾向にある時、前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が減少傾向にある時の少なくとも何れかの時、糸切れの発生を予知する。天秤が上糸を引上げる期間、釜が上糸のループを捕捉し上糸が釜を潜り抜ける期間での上糸にかかる張力、上糸の移動量の特徴量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。不良予知装置は特徴量の推移に基づき糸切れの発生を予知するので、糸切れを未然に防ぐ精度を向上できる。 In the defect prediction device of claim 10, the sewing machine includes a thread take-up lever that pulls up the upper thread and a hook that captures the loop of the upper thread inserted in the sewing needle, and the predetermined time is at least one of the period during which the thread take-up lever pulls up the upper thread and the hook captures the loop of the upper thread and the upper thread passes through the hook, and the prediction unit predicts the occurrence of thread breakage at least one of the periods when the change per unit in the characteristic amount of the tension at the predetermined time is on an increasing trend and when the change per unit in the characteristic amount of the movement amount at the predetermined time is on a decreasing trend. If the tension applied to the upper thread and the characteristic amount of the movement amount of the upper thread during the period during which the thread take-up lever pulls up the upper thread and the hook captures the loop of the upper thread and the upper thread passes through the hook change from the normal sewing time, it is likely to lead to the occurrence of sewing defects. The defect prediction device predicts the occurrence of yarn breakage based on the transition of feature values, improving the accuracy of preventing yarn breakage before it occurs.

請求項１１の不良予知装置において、前記ミシンは、前記上糸を引き上げる天秤を備え、前記予知部は、前記天秤が前記上糸を引上げる期間での前記張力の前記特徴量における前記単位あたりの推移が減少傾向にある時、前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が減少傾向にある時の少なくとも何れかの時、目飛びの発生を予知する。天秤が上糸を引上げる期間の上糸にかかる張力の特徴量、及び縫針の上下動の周期の所定時機における上糸の移動量の特徴量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。不良予知装置は特徴量の推移に基づき、目飛びの発生を予知するので、目飛びを未然に防ぐ精度を向上できる。 In the defect prediction device of claim 11, the sewing machine is provided with a thread take-up that pulls up the upper thread, and the prediction unit predicts the occurrence of a skipped stitch at least when the change per unit in the characteristic amount of the tension during the period when the thread take-up is pulling up the upper thread is on a decreasing trend, or when the change per unit in the characteristic amount of the movement amount at the specified time is on a decreasing trend. If the characteristic amount of the tension applied to the upper thread during the period when the thread take-up is pulling up the upper thread and the characteristic amount of the movement amount of the upper thread at the specified time in the cycle of the up and down movement of the sewing needle change from normal sewing, it is likely to lead to the occurrence of a sewing defect. Since the defect prediction device predicts the occurrence of a skipped stitch based on the change in the characteristic amount, the accuracy of preventing skipped stitches can be improved.

請求項１２の不良予知装置において、前記ミシンは、前記縫針に挿通した前記上糸のループを捕捉する釜を更に備え、前記変量が前記張力を含む時、前記予知部は、前記天秤が前記上糸を引上げる期間での前記張力の前記特徴量における前記単位あたりの推移が減少傾向にある時、及び前記所定時機として前記釜が前記上糸のループを捕捉し前記上糸が前記釜を潜り抜ける期間での前記張力の前記特徴量における前記単位あたりの推移が増加傾向にある時、目飛びの発生を予知する。釜が上糸のループを捕捉し上糸が釜を潜り抜ける期間の上糸にかかる張力の特徴量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。不良予知装置は特徴量の推移に基づき、目飛びの発生を予知するので、目飛びを未然に防ぐ精度を向上できる。 In the defect prediction device of claim 12, the sewing machine further includes a hook that captures the loop of the upper thread inserted in the sewing needle, and when the variable includes the tension, the prediction unit predicts the occurrence of a skipped stitch when the change per unit in the characteristic amount of the tension during the period when the thread take-up lever pulls up the upper thread is on a decreasing trend, and when the change per unit in the characteristic amount of the tension during the period when the hook captures the loop of the upper thread and the upper thread passes through the hook at the specified time is on an increasing trend. If the characteristic amount of the tension applied to the upper thread during the period when the hook captures the loop of the upper thread and the upper thread passes through the hook changes from the time of normal sewing, it is likely to lead to the occurrence of a sewing defect. The defect prediction device predicts the occurrence of a skipped stitch based on the change in the characteristic amount, and therefore the accuracy of preventing a skipped stitch can be improved.

請求項１３の不良予知装置において、前記ミシンは、前記上糸を引き上げる天秤を備え、前記所定時機は、前記天秤が前記上糸を引上げる期間であって、前記予知部は、前記所定時機での前記張力の前記特徴量における前記単位あたりの推移が増加傾向にある時、前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が増加傾向にある時の少なくとも何れかである時、締り不良の発生を予知する。天秤が上糸を引上げる期間での上糸にかかる張力、上糸の移動量の特徴量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。不良予知装置は特徴量の推移に基づき締り不良の発生を予知するので、締り不良を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 13, the sewing machine is equipped with a thread take-up that pulls up the upper thread, the predetermined time is a period during which the thread take-up pulls up the upper thread, and the prediction unit predicts the occurrence of a tightening defect when at least one of the following occurs: the change per unit in the characteristic amount of the tension at the predetermined time is on the rise, and the change per unit in the characteristic amount of the movement amount at the predetermined time is on the rise. If the tension on the upper thread and the characteristic amount of the movement amount of the upper thread during the period when the thread take-up pulls up the upper thread change from normal sewing, this is likely to lead to the occurrence of a sewing defect. Since the defect prediction device predicts the occurrence of a tightening defect based on the change in the characteristic amount, the accuracy of preventing a tightening defect can be improved.

請求項１４の不良予知装置において、前記ミシンは、縫製中に駆動して布を縫製する駆動部を備え、前記不良予知装置は、前記予知部が前記縫製不良の発生を予知した時、前記駆動部を制御して前記縫製不良の発生を回避する回避制御を実行する回避制御部を更に備える。不良予知装置は縫製不良の発生を予知する時、回避制御部の回避制御に依り縫製不良の発生を回避するので、縫製不良の発生を未然に防ぐことができる。 In the defect prediction device of claim 14, the sewing machine includes a drive unit that drives during sewing to sew the cloth, and the defect prediction device further includes an avoidance control unit that controls the drive unit to execute avoidance control to avoid the occurrence of the sewing defect when the prediction unit predicts the occurrence of the sewing defect. When the defect prediction device predicts the occurrence of the sewing defect, it avoids the occurrence of the sewing defect through the avoidance control of the avoidance control unit, so that the occurrence of the sewing defect can be prevented in advance.

請求項１５の不良予知装置において、前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部を含み、前記回避制御部は、前記回避制御として前記針棒駆動部の駆動速度を低下する。回避制御として針棒駆動部の駆動速度を低下することで、特徴量の単位あたりの変動が小さくなる。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 15, the drive unit of the sewing machine includes a needle bar drive unit that moves the needle bar to which the sewing needle is attached up and down, and the avoidance control unit reduces the drive speed of the needle bar drive unit as the avoidance control. By reducing the drive speed of the needle bar drive unit as the avoidance control, the fluctuation per unit of the feature is reduced. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of sewing defects.

請求項１６の不良予知装置において、前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部と、前記上糸に張力を付与する糸調子機構とを含み、前記回避制御部は、前記回避制御に依り、前記縫針の上下動の一周期における、前記糸調子機構が付与する張力を制御する。不良予知装置は縫針の上下動に依り周期的に変動する、上糸にかかる張力を制御でき、特徴量の単位あたりの変動が小さくなる。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 16, the drive unit of the sewing machine includes a needle bar drive unit that moves the needle bar to which the sewing needle is attached up and down, and a thread tensioning mechanism that applies tension to the upper thread, and the avoidance control unit controls the tension applied by the thread tensioning mechanism in one cycle of the up and down movement of the sewing needle through the avoidance control. The defect prediction device can control the tension applied to the upper thread, which varies periodically due to the up and down movement of the sewing needle, and the variation per unit of the characteristic amount is reduced. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of sewing defects.

請求項１７の不良予知装置において、前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部と、前記上糸に張力を付与し且つ前記上糸の移動量を回転駆動で調整する糸調子機構とを含み、前記回避制御部は、前記回避制御に依り、前記縫針の上下動の一周期における、前記糸調子機構が付与する張力、前記移動量の変動の少なくとも何れかを制御する。不良予知装置は縫針の上下動に依り周期的に変動する、上糸にかかる張力、上糸の移動量の変動を制御できるので、特徴量の単位あたりの変動が小さくなる。故に不良予知装置は縫製不良の発生を未然に防ぐ精度を向上できる。 In the defect prediction device of claim 17, the drive unit of the sewing machine includes a needle bar drive unit that moves the needle bar to which the sewing needle is attached up and down, and a thread tensioning mechanism that applies tension to the upper thread and adjusts the amount of movement of the upper thread by rotary drive, and the avoidance control unit controls at least one of the tension applied by the thread tensioning mechanism and the fluctuation in the amount of movement in one cycle of the up and down movement of the sewing needle through the avoidance control. Since the defect prediction device can control the tension on the upper thread and the fluctuation in the amount of movement of the upper thread, which fluctuate periodically due to the up and down movement of the sewing needle, the fluctuation per unit of the characteristic amount is reduced. Therefore, the defect prediction device can improve the accuracy of preventing the occurrence of sewing defects.

請求項１８の不良予知装置は、前記回避制御部が回避制御を実行後、前記予知部が前記縫製不良の発生を予知する時、前記駆動部を停止する予知停止部を更に備える。不良予知装置は回避制御を実行後でも、予知部が縫製不良の発生を予知する時、駆動部を停止することで縫製を中止する。故に不良予知装置は回避できない縫製不良の発生を予知した時に、縫製不良の発生を未然に防ぐことができる。 The defect prediction device of claim 18 further includes a prediction stop unit that stops the drive unit when the prediction unit predicts the occurrence of the sewing defect after the avoidance control unit executes the avoidance control. Even after the avoidance control is executed, when the prediction unit predicts the occurrence of a sewing defect, the defect prediction device stops sewing by stopping the drive unit. Therefore, when the defect prediction device predicts the occurrence of an unavoidable sewing defect, it can prevent the occurrence of the sewing defect.

請求項１９の不良予知装置において、前記ミシンは、縫製中に駆動して布を縫製する駆動部を備え、前記不良予知装置は、前記予知部が前記糸切れの発生を予知した時、前記駆動部を停止する糸切れ予知停止部を更に備える。不良予知装置は糸切れの発生を予知した時、駆動部を停止することで縫製を中止するので、糸切れの発生を未然に防ぐことができる。 In the defect prediction device of claim 19, the sewing machine includes a drive unit that drives during sewing to sew the cloth, and the defect prediction device further includes a thread breakage prediction stop unit that stops the drive unit when the prediction unit predicts the occurrence of thread breakage. When the defect prediction device predicts the occurrence of thread breakage, it stops sewing by stopping the drive unit, thereby preventing thread breakage from occurring.

請求項２０の不良予知装置は、前記予知部が前記縫製不良の発生を予知した時、前記縫製不良の発生を予知したことを報知する報知部を更に備える。不良予知装置は縫製不良の発生を予知した時、報知部に依り縫製不良の発生を予知したことを報知するので、作業者が縫製不良の発生を予知したことを把握できる。 The defect prediction device of claim 20 further includes a notification unit that notifies the operator of the prediction of the occurrence of the sewing defect when the prediction unit predicts the occurrence of the sewing defect. When the defect prediction device predicts the occurrence of the sewing defect, the notification unit notifies the operator of the prediction of the occurrence of the sewing defect, so that the operator can understand that the occurrence of the sewing defect has been predicted.

請求項２１の不良予知装置は、前記予知部が認識した前記予知レベルを報知する予知レベル報知部を更に備える。不良予知装置は縫製不良の発生を予知した時、予知レベル報知部に依り予知レベルを報知するので、縫製不良が発生する可能性の度合を作業者が把握できる。 The defect prediction device of claim 21 further includes a prediction level notification unit that notifies the prediction level recognized by the prediction unit. When the defect prediction device predicts the occurrence of a sewing defect, the prediction level is notified by the prediction level notification unit, so that the operator can grasp the degree of possibility of the occurrence of a sewing defect.

請求項２２の不良予知装置は、前記回避制御部が前記回避制御を実行時、前記回避制御の実行を報知する回避報知部を更に備える。不良予知装置は回避制御を実行する時、回避報知部に依り回避制御を実行することを報知するので、縫製不良の発生を予知した時に縫製不良の発生を回避することを、作業者が把握できる。 The defect prediction device of claim 22 further includes an avoidance notification unit that notifies the avoidance control when the avoidance control unit executes the avoidance control. When the defect prediction device executes the avoidance control, the avoidance notification unit notifies the operator that the avoidance control will be executed, so that the operator can know that the occurrence of a sewing defect is to be avoided when the occurrence of a sewing defect is predicted.

請求項２３の不良予知装置は、前記予知停止部が前記駆動部を停止時、前記駆動部の停止を報知する停止報知部を更に備える。不良予知装置は回避制御を実行しても縫製不良の発生を予知して駆動部を停止した時、停止報知部に依り駆動部の停止を報知する。故に不良予知装置は回避できない縫製不良の発生の予知により縫製を停止したことを、作業者が把握できる。 The defect prediction device of claim 23 further includes a stop notification unit that notifies the driver of the stop when the prediction stop unit stops the driver. When the defect prediction device predicts the occurrence of a sewing defect even when the avoidance control is executed and stops the driver, the stop notification unit notifies the driver of the stop. Therefore, the operator can know that the defect prediction device has stopped sewing due to the prediction of the occurrence of an unavoidable sewing defect.

ミシン１の斜視図。FIG. 頭部５の部分拡大図。FIG. 張力検出機構１８の斜視図。FIG. ミシン１の電気ブロック図。Electrical block diagram of sewing machine 1. 釜４９が上糸６６を捕捉する流れを示す概念図。6 is a conceptual diagram showing a process in which the shuttle 49 captures the upper thread 66. 一針分の縫製期間における変動張力を示す図表。1 is a diagram showing the fluctuating tension during one stitch sewing period. 糸切れ発生前の変動張力を示す図表。Graph showing fluctuating tension before yarn breakage occurs. 目飛び発生前の変動張力を示す図表。A diagram showing the fluctuating tension before skipping occurs. 締り不良発生前の変動張力を示す図表。A chart showing fluctuating tension before tightness failure occurs. 一針分の縫製期間における変動移動量を示す図表。13 is a diagram showing the amount of fluctuation movement during one stitch sewing period. 予知単位での第一張力の変動を示す図表。A diagram showing the variation of first tension in prognostic units. 第一縫製処理の流れ図。1 is a flow chart of the first sewing process. 図１２に続く第一縫製処理の流れ図。13 is a flowchart of the first sewing process following FIG. 12 . 第一特徴量処理の流れ図。11 is a flow diagram of a first feature amount process. 第一糸切れ予知処理の流れ図。11 is a flowchart showing a first yarn breakage prediction process. 糸切れ回避処理の流れ図。1 is a flow chart of a process for preventing thread breakage. 第一目飛び予知処理の流れ図。11 is a flowchart of a first stitch skip prediction process. 目飛び回避処理の流れ図。11 is a flow diagram of a process for avoiding skipped stitches. 第一締り不良予知処理の流れ図。11 is a flow chart of the first tightening defect prediction process. 締り不良回避処理の流れ図。13 is a flow chart of a process for avoiding poor tightening. 予知停止処理の流れ図。13 is a flow diagram of a prediction stop process. 第二縫製処理の流れ図の一部。Part of a flow chart of the second sewing process. 第二特徴量処理の流れ図。11 is a flowchart of a second feature amount process. 第二糸切れ予知処理の流れ図。11 is a flowchart showing a second yarn breakage prediction process.

図面を参照し、本発明の一実施形態のミシン１を説明する。以下説明は、図中に矢印で示す左右、前後、上下を使用する。 A sewing machine 1 according to one embodiment of the present invention will be described with reference to the drawings. In the following description, the left/right, front/back, and top/bottom directions will be used as indicated by arrows in the drawings.

図１～図３を参照し、ミシン１の構造を説明する。図１の如く、ミシン１はベッド部２、脚柱部３、アーム部４を備える。ベッド部２は上面に針板７を備える。針板７は略中央に針穴８と送り歯穴１４を備える。送り歯穴１４は、針穴８の左方、後方、右方、前方の夫々にある。 The structure of the sewing machine 1 will be described with reference to Figures 1 to 3. As shown in Figure 1, the sewing machine 1 comprises a bed 2, a pillar 3, and an arm 4. The bed 2 has a needle plate 7 on its upper surface. The needle plate 7 has a needle hole 8 and a feed dog hole 14 approximately in the center. The feed dog holes 14 are located to the left, rear, right, and front of the needle hole 8.

脚柱部３はベッド部２右端から上方に延びる。アーム部４は脚柱部３上端から左方に延び、ベッド部２と対向する。アーム部４前面は左右方向略中央部に入力部２４と表示部２５を備える。入力部２４は上下方向に並ぶ三つのボタンである。表示部２５は各種情報を表示する。作業者は表示部２５を見ながら入力部２４を操作して各種指示を入力する。アーム部４は上面左側に上方に突出する糸立棒２０を備える。糸立棒２０は糸駒から繰り出した上糸６６（図２参照）を挿通する。上糸６６は複数の糸を撚り合わせてある。 The pillar 3 extends upward from the right end of the bed 2. The arm 4 extends leftward from the top end of the pillar 3 and faces the bed 2. The front of the arm 4 is equipped with an input unit 24 and a display unit 25, located approximately in the center in the left-right direction. The input unit 24 is made up of three buttons lined up in the vertical direction. The display unit 25 displays various information. The operator operates the input unit 24 while looking at the display unit 25 to input various instructions. The arm 4 is equipped with a spool pin 20 that protrudes upward from the left side of the top surface. The spool pin 20 passes through the upper thread 66 (see Figure 2) that is unwound from a spool. The upper thread 66 is made of multiple threads twisted together.

アーム部４は内部に上軸１５と主モータ２７（図４参照）を備える。上軸１５は左右方向に延び、上軸プーリを介して主モータ２７の出力軸に連結する。上軸プーリは上軸１５右端部に固定する。上軸１５は主モータ２７の動力で回動する。アーム部４左端部は頭部５を備える。頭部５はアーム部４から下方に突出し、針板７に上方から対向する。頭部５は針棒１１を上下動可能に支持する。針棒１１下端部は頭部５から下方に突出する。針棒１１は上下動機構を介して上軸１５に連結する。針棒１１は上軸１５の回動に伴い上下動する。針棒１１は下端に縫針１０を装着する。縫針１０は目孔１０Ａ（図５参照）に挿通した上糸６６を保持する。縫針１０は針棒１１と共に上下動する。縫針１０は針穴８を通過できる。縫針１０の可動範囲上端は上死点であり、下端は下死点である。 The arm portion 4 has an upper shaft 15 and a main motor 27 (see FIG. 4) inside. The upper shaft 15 extends in the left-right direction and is connected to the output shaft of the main motor 27 via an upper shaft pulley. The upper shaft pulley is fixed to the right end of the upper shaft 15. The upper shaft 15 rotates by the power of the main motor 27. The left end of the arm portion 4 has a head 5. The head 5 protrudes downward from the arm portion 4 and faces the needle plate 7 from above. The head 5 supports the needle bar 11 so that it can move up and down. The lower end of the needle bar 11 protrudes downward from the head 5. The needle bar 11 is connected to the upper shaft 15 via a vertical movement mechanism. The needle bar 11 moves up and down as the upper shaft 15 rotates. The sewing needle 10 is attached to the lower end of the needle bar 11. The sewing needle 10 holds the upper thread 66 inserted through the eye 10A (see FIG. 5). The sewing needle 10 moves up and down together with the needle bar 11. The sewing needle 10 can pass through the needle hole 8. The upper end of the movable range of the sewing needle 10 is the top dead point, and the lower end is the bottom dead point.

ベッド部２は内部に釜４９（図５参照）、糸切機構１７（図４参照）、送り機構を備える。釜４９は針板７下方に設け、下糸６７（図５参照）を巻いたボビンを収容する。釜４９は剣先４６（図５参照）を備える。釜４９は主モータ２７の動力で回動し、縫針１０に挿通する上糸６６を剣先４６で捕捉して、下糸６７と絡める。 The bed section 2 is equipped with a shuttle 49 (see Figure 5), a thread cutting mechanism 17 (see Figure 4), and a feed mechanism inside. The shuttle 49 is provided below the needle plate 7, and houses a bobbin wound with a lower thread 67 (see Figure 5). The shuttle 49 has a point 46 (see Figure 5). The shuttle 49 rotates with the power of the main motor 27, and the point 46 captures the upper thread 66 inserted into the sewing needle 10, and entangles it with the lower thread 67.

糸切機構１７は固定刃、可動刃、ソレノイド１７Ａ（図４参照）を備える。可動刃はソレノイド１７Ａに連結する。ソレノイド１７Ａの駆動に依り、可動刃は固定刃に対して移動する。糸切機構１７は可動刃と固定刃の協働で上糸６６と下糸６７を切断する。 The thread cutting mechanism 17 includes a fixed blade, a movable blade, and a solenoid 17A (see FIG. 4). The movable blade is connected to the solenoid 17A. When the solenoid 17A is driven, the movable blade moves relative to the fixed blade. The thread cutting mechanism 17 cuts the upper thread 66 and the lower thread 67 through the cooperation of the movable blade and the fixed blade.

送り機構は送り歯１３、送りモータ２８（図４参照）を備える。送り歯１３は針板７下方に設ける。送り歯１３は送りモータ２８の動力で前後方向に移動し、主モータ２７の動力で上下方向に移動する。該時、送り歯１３は送り歯穴１４にて出没する。送り歯１３は送り歯穴１４から上方に出た状態で前後方向に移動することで、布６９を送る。 The feed mechanism includes a feed dog 13 and a feed motor 28 (see Figure 4). The feed dog 13 is provided below the needle plate 7. The feed dog 13 moves in the front-rear direction by the power of the feed motor 28, and moves in the up-down direction by the power of the main motor 27. At that time, the feed dog 13 appears and disappears in the feed dog hole 14. The feed dog 13 moves in the front-rear direction while protruding upward from the feed dog hole 14, thereby feeding the fabric 69.

図２の如く、頭部５は糸駒から縫針１０へと至る上糸６６の供給経路の上流側から順に、副糸調子器２６、主糸調子器２２、糸案内２１、張力検出機構１８、天秤２３、案内鉤２９を備える。 As shown in FIG. 2, the head 5 is equipped with, in order from the upstream side of the supply path of the upper thread 66 from the thread spool to the sewing needle 10, a sub-thread tensioner 26, a main thread tensioner 22, a thread guide 21, a tension detection mechanism 18, a thread take-up lever 23, and a guide hook 29.

副糸調子器２６は頭部５前面の右上部に設ける。主糸調子器２２は副糸調子器２６下方に設ける。副糸調子器２６と主糸調子器２２夫々は上糸６６に張力を付与する。副糸調子器２６は糸切機構１７による上糸６６と下糸６７の切断時に必要な張力を上糸６６に付与する。主糸調子器２２は糸調子モータ１６（図４参照）を備え、糸調子モータ１６の駆動に依り上糸６６に張力を付与する。主糸調子器２２はミシン１の縫製に伴って上糸６６に作用する張力（以下、上糸張力という。）、上糸６６を供給経路の下流側に送る量（以下、上糸移動量という。）を適正化する。糸案内２１は主糸調子器２２左方に設ける。糸案内２１は主糸調子器２２を経由した上糸６６を張力検出機構１８と天秤２３に向けて折り返して案内する。 The sub-thread tensioner 26 is provided at the upper right part of the front of the head 5. The main thread tensioner 22 is provided below the sub-thread tensioner 26. The sub-thread tensioner 26 and the main thread tensioner 22 each apply tension to the upper thread 66. The sub-thread tensioner 26 applies the tension required for cutting the upper thread 66 and the lower thread 67 by the thread cutting mechanism 17. The main thread tensioner 22 is equipped with a thread tension motor 16 (see FIG. 4), and applies tension to the upper thread 66 by driving the thread tension motor 16. The main thread tensioner 22 optimizes the tension acting on the upper thread 66 (hereinafter referred to as upper thread tension) and the amount of upper thread 66 fed downstream of the supply path (hereinafter referred to as upper thread movement amount) as the sewing machine 1 sews. The thread guide 21 is provided to the left of the main thread tensioner 22. The thread guide 21 guides the upper thread 66 that has passed through the main thread tensioner 22 back toward the tension detection mechanism 18 and the thread take-up lever 23.

張力検出機構１８は頭部５前面から後方に凹む凹部５Ａに設ける。張力検出機構１８は副糸調子器２６と主糸調子器２２の間の上下位置に在る。張力検出機構１８は上糸張力を検出できる。張力検出機構１８の説明は後述する。天秤２３は副糸調子器２６左方に設ける。天秤２３は上糸６６を挿通する挿通孔２３Ａを有する。天秤２３は主モータ２７の駆動に伴って上下動する。案内鉤２９は張力検出機構１８左方に設ける。案内鉤２９は、天秤２３の挿通孔２３Ａを通った上糸６６を針棒１１に向けて案内する。 The tension detection mechanism 18 is provided in a recess 5A recessed rearward from the front surface of the head 5. The tension detection mechanism 18 is located vertically between the auxiliary thread tensioner 26 and the main thread tensioner 22. The tension detection mechanism 18 can detect the upper thread tension. The tension detection mechanism 18 will be described later. The thread take-up lever 23 is provided to the left of the auxiliary thread tensioner 26. The thread take-up lever 23 has an insertion hole 23A through which the upper thread 66 passes. The thread take-up lever 23 moves up and down as the main motor 27 is driven. The guide hook 29 is provided to the left of the tension detection mechanism 18. The guide hook 29 guides the upper thread 66 that has passed through the insertion hole 23A of the thread take-up lever 23 toward the needle bar 11.

図３の如く、張力検出機構１８は取付台５１、保持部５２、磁気センサ５３、板５４、案内部材５５、磁石５６を備える。取付台５１は取付部５７と台座部５９を備える。取付部５７と台座部５９は互いに一体的に形成する。取付部５７は、螺子を挿通する長孔５８を備える。長孔５８に挿通した螺子は凹部５Ａに設けた螺子穴に締結する。台座部５９は取付台５１左側にある。台座部５９は左突部６０と右突部６１を備える。左突部６０と右突部６１夫々は前後方向に延びる直方体状である。 As shown in FIG. 3, the tension detection mechanism 18 includes a mounting base 51, a holding portion 52, a magnetic sensor 53, a plate 54, a guide member 55, and a magnet 56. The mounting base 51 includes a mounting portion 57 and a base portion 59. The mounting portion 57 and the base portion 59 are formed integrally with each other. The mounting portion 57 includes an elongated hole 58 through which a screw is inserted. The screw inserted into the elongated hole 58 is fastened to a screw hole provided in the recess 5A. The base portion 59 is located on the left side of the mounting base 51. The base portion 59 includes a left protrusion 60 and a right protrusion 61. The left protrusion 60 and the right protrusion 61 are each a rectangular parallelepiped extending in the front-to-rear direction.

保持部５２は略直方体状に形成し、左突部６０と右突部６１の間で台座部５９に取付ける。保持部５２は非磁性体である。磁気センサ５３は保持部５２前面にて保持する。磁気センサ５３はホール素子である。磁気センサ５３は左突部６０と右突部６１夫々の前端よりも後側に在る。 The holding portion 52 is formed in a roughly rectangular parallelepiped shape and is attached to the base portion 59 between the left protrusion 60 and the right protrusion 61. The holding portion 52 is made of a non-magnetic material. The magnetic sensor 53 is held by the front surface of the holding portion 52. The magnetic sensor 53 is a Hall element. The magnetic sensor 53 is located rearward of the front ends of the left protrusion 60 and the right protrusion 61.

板５４は前後方向に厚みを有する板状であり、左突部６０と右突部６１に架け渡す。案内部材５５は左突部６０と右突部６１に取付ける。案内部材５５は左突部６０との間に板５４の左端部を挟込み、且つ右突部６１との間に板５４の右端部を挟込む。板５４の左右方向中央部は保持部５２前面との間に隙間を有する。故に板５４は左右方向の両端部を支点として、前後方向に撓む。 The plate 54 is a plate with a thickness in the front-rear direction, and spans the left protrusion 60 and the right protrusion 61. The guide member 55 is attached to the left protrusion 60 and the right protrusion 61. The guide member 55 sandwiches the left end of the plate 54 between itself and the left protrusion 60, and the right end of the plate 54 between itself and the right protrusion 61. There is a gap between the left-right center of the plate 54 and the front of the retaining portion 52. Therefore, the plate 54 bends in the front-rear direction, with both left-right ends as fulcrums.

磁石５６は前後方向に延びる円柱状に形成する。磁石５６は板５４の左右方向中央部の後面に固定する。板５４が前後方向に撓むと、磁石５６は前後に移動し、磁気センサ５３との距離が変化する。磁気センサ５３は磁石５６からの磁束密度の変化を検出し、磁束密度に応じた電圧を出力する。 The magnet 56 is formed into a cylindrical shape extending in the front-rear direction. The magnet 56 is fixed to the rear surface of the plate 54 in the center in the left-right direction. When the plate 54 bends in the front-rear direction, the magnet 56 moves forward or backward, changing the distance from the magnetic sensor 53. The magnetic sensor 53 detects the change in the magnetic flux density from the magnet 56 and outputs a voltage according to the magnetic flux density.

案内部材５５は上案内溝６３と下案内溝６５を備える。上案内溝６３と下案内溝６５は板５４を間にして上下方向に並ぶ。上案内溝６３と下案内溝６５は上下方向に開口し、鉤状に形成する。上案内溝６３は上保持孔６２を備え、下案内溝６５は下保持孔６４を備える。上保持孔６２と下保持孔６４は上下方向に開口する貫通孔である。上糸６６は上保持孔６２と下保持孔６４夫々を挿通する。上保持孔６２と下保持孔６４の間にある上糸６６は前方から板５４に接触する。上糸張力が増大する程、上糸６６は板５４を後方に付勢する。磁気センサ５３は上糸張力に依り前後方向に撓む板５４の前後位置に応じた電圧を出力する。ミシン１は磁気センサ５３の出力電圧に依り上糸張力を取得できる。 The guide member 55 has an upper guide groove 63 and a lower guide groove 65. The upper guide groove 63 and the lower guide groove 65 are arranged vertically with the plate 54 between them. The upper guide groove 63 and the lower guide groove 65 open vertically and are formed in a hook shape. The upper guide groove 63 has an upper holding hole 62, and the lower guide groove 65 has a lower holding hole 64. The upper holding hole 62 and the lower holding hole 64 are through holes that open vertically. The upper thread 66 passes through the upper holding hole 62 and the lower holding hole 64, respectively. The upper thread 66 between the upper holding hole 62 and the lower holding hole 64 contacts the plate 54 from the front. As the upper thread tension increases, the upper thread 66 urges the plate 54 backward. The magnetic sensor 53 outputs a voltage corresponding to the front-rear position of the plate 54, which is bent in the front-rear direction due to the upper thread tension. The sewing machine 1 can obtain the upper thread tension from the output voltage of the magnetic sensor 53.

図２の如く、頭部５は更に頭部アンプ７０を備える。頭部アンプ７０は頭部５後部の上面に設ける。頭部アンプ７０上部は前面に右方から順に糸切れＬＥＤ７１、目飛びＬＥＤ７２、締り不良ＬＥＤ７３を設ける。糸切れＬＥＤ７１、目飛びＬＥＤ７２、及び締り不良ＬＥＤ７３夫々は発光可能なフルカラーＬＥＤである。糸切れＬＥＤ７１はミシン１が糸切れの発生を予知した時発光する。目飛びＬＥＤ７２はミシン１が目飛びの発生を予知した時発光する。締り不良ＬＥＤ７３はミシン１が締り不良の発生を予知した時発光する。糸切れ、目飛び、締り不良夫々は縫製不良の一種である。縫製不良の詳細は後述する。 As shown in FIG. 2, the head 5 further includes a head amplifier 70. The head amplifier 70 is provided on the upper surface of the rear part of the head 5. On the front of the upper part of the head amplifier 70, a thread breakage LED 71, a skipped stitch LED 72, and a tightness failure LED 73 are provided in this order from the right. The thread breakage LED 71, the skipped stitch LED 72, and the tightness failure LED 73 are each full-color LEDs that can emit light. The thread breakage LED 71 emits light when the sewing machine 1 predicts the occurrence of a thread breakage. The skipped stitch LED 72 emits light when the sewing machine 1 predicts the occurrence of a skipped stitch. The tightness failure LED 73 emits light when the sewing machine 1 predicts the occurrence of a tightness failure. A thread breakage, a skipped stitch, and a tightness failure are each a type of sewing failure. The sewing failures will be described in detail later.

図４を参照し、ミシン１の電気的構成を説明する。ミシン１の制御装置９０はＣＰＵ９１、ＲＯＭ９２、ＲＡＭ９３、記憶装置９４、Ｉ／Ｏインタフェース（以下、Ｉ／Ｏという。）９５、駆動回路８１～８６を備える。ＣＰＵ９１はＲＯＭ９２、ＲＡＭ９３、記憶装置９４、Ｉ／Ｏ９５夫々に接続する。ＣＰＵ９１はミシン１の制御を司る。ＣＰＵ９１は各種プログラムに従って、後述の第一縫製処理（図１２参照）等の処理、各種演算を実行する。ＲＯＭ９２は各種プログラム、各種初期設定パラメータ、後述の検出閾値等を記憶する。ＲＡＭ９３はＣＰＵ９１の演算結果、カウンタ等を一時的に記憶する。記憶装置９４は作業者が入力した各種設定情報等を記憶する。 The electrical configuration of the sewing machine 1 will be described with reference to FIG. 4. The control device 90 of the sewing machine 1 includes a CPU 91, a ROM 92, a RAM 93, a storage device 94, an I/O interface (hereinafter referred to as I/O) 95, and drive circuits 81 to 86. The CPU 91 is connected to the ROM 92, the RAM 93, the storage device 94, and the I/O 95. The CPU 91 controls the sewing machine 1. The CPU 91 executes processes such as the first sewing process (see FIG. 12) described below and various calculations according to various programs. The ROM 92 stores various programs, various initial setting parameters, detection thresholds described below, etc. The RAM 93 temporarily stores the calculation results of the CPU 91, counters, etc. The storage device 94 stores various setting information input by the operator, etc.

Ｉ／Ｏ９５は駆動回路８１～８６、スピーカ３９、入力部２４、ペダル３８、磁気センサ５３夫々に接続する。駆動回路８１は主モータ２７に接続する。主モータ２７はエンコーダ２７Ａを備える。エンコーダ２７Ａは主モータ２７の出力軸の回動位置を検出する。即ち、エンコーダ２７Ａの検出結果は上軸１５の回転角位相である上軸角を示す。エンコーダ２７Ａは検出結果をＩ／Ｏ９５を介してＣＰＵ９１に送信する。駆動回路８２は送りモータ２８に接続する。 The I/O 95 is connected to each of the drive circuits 81-86, the speaker 39, the input unit 24, the pedal 38, and the magnetic sensor 53. The drive circuit 81 is connected to the main motor 27. The main motor 27 is equipped with an encoder 27A. The encoder 27A detects the rotational position of the output shaft of the main motor 27. In other words, the detection result of the encoder 27A indicates the upper shaft angle, which is the rotational angle phase of the upper shaft 15. The encoder 27A transmits the detection result to the CPU 91 via the I/O 95. The drive circuit 82 is connected to the feed motor 28.

駆動回路８３は糸調子モータ１６に接続する。糸調子モータ１６はエンコーダ１６Ａを備える。エンコーダ１６Ａは糸調子モータ１６の出力軸の回動位置を検出する。エンコーダ１６Ａは検出結果をＩ／Ｏ９５を介してＣＰＵ９１に送信する。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づき、上糸移動量を取得する。以下、主モータ２７、送りモータ２８、糸調子モータ１６を、駆動部と総称する。ＣＰＵ９１は駆動回路８１～８３を介して駆動部を制御する。 The drive circuit 83 is connected to the thread tension motor 16. The thread tension motor 16 is equipped with an encoder 16A. The encoder 16A detects the rotational position of the output shaft of the thread tension motor 16. The encoder 16A transmits the detection result to the CPU 91 via the I/O 95. The CPU 91 obtains the upper thread movement amount based on the detection result of the encoder 16A. Hereinafter, the main motor 27, the feed motor 28, and the thread tension motor 16 are collectively referred to as the drive unit. The CPU 91 controls the drive unit via the drive circuits 81 to 83.

駆動回路８４は糸切機構１７に接続する。ＣＰＵ９１は駆動回路８４を介して糸切機構１７のソレノイド１７Ａを制御する。駆動回路８５は表示部２５に接続する。ＣＰＵ９１は駆動回路８５を介して表示部２５を制御する。駆動回路８６は頭部アンプ７０に接続する。ＣＰＵ９１は駆動回路８６を介して糸切れＬＥＤ７１、目飛びＬＥＤ７２、及び締り不良ＬＥＤ７３夫々を制御する。 The drive circuit 84 is connected to the thread cutting mechanism 17. The CPU 91 controls the solenoid 17A of the thread cutting mechanism 17 via the drive circuit 84. The drive circuit 85 is connected to the display unit 25. The CPU 91 controls the display unit 25 via the drive circuit 85. The drive circuit 86 is connected to the head amplifier 70. The CPU 91 controls the thread breakage LED 71, the skipped stitch LED 72, and the tightness failure LED 73 via the drive circuit 86.

スピーカ３９はＣＰＵ９１の制御に基づき各種音を出力する。入力部２４は作業者が入力する各種指示をＣＰＵ９１に出力する。ペダル３８は作業者のペダル３８の操作に依る操作方向と操作量夫々の検出結果をＣＰＵ９１に出力する。磁気センサ５３は上糸張力を示す出力電圧をＣＰＵ９１に出力する。 The speaker 39 outputs various sounds under the control of the CPU 91. The input unit 24 outputs various instructions input by the operator to the CPU 91. The pedal 38 outputs the detection results of the operation direction and operation amount of the pedal 38 operated by the operator to the CPU 91. The magnetic sensor 53 outputs an output voltage indicating the upper thread tension to the CPU 91.

図１、図５を参照し、ミシン１の動作概要を説明する。作業者は針板７に布６９を載置する。作業者がペダル３８を所定方向に操作することで、主モータ２７は駆動する。主モータ２７の駆動に依り、上軸１５は回動して針棒１１と天秤２３を上下動する。釜４９は上軸１５の回動に同期して回動する。 The operation of the sewing machine 1 will be described with reference to Figures 1 and 5. The operator places the fabric 69 on the needle plate 7. The operator operates the pedal 38 in a specified direction, which drives the main motor 27. Driven by the main motor 27, the upper shaft 15 rotates, moving the needle bar 11 and the thread take-up lever 23 up and down. The shuttle 49 rotates in synchronization with the rotation of the upper shaft 15.

針棒１１と共に下降する縫針１０は、布６９を貫通して針穴８を通過する。針穴８下方まで下降した目孔１０Ａ近傍の上糸６６は環状になる（図５（ａ）参照）。釜４９が正面視時計回りに回動することで、剣先４６は環状の上糸６６を捕捉する（図５（ｂ）参照）。縫針１０が布６９上方に向けて上昇し、釜４９が正面視時計回りに更に回動する。剣先４６は環状の上糸６６を回動方向に引き込み、環状の上糸６６は拡径する。 The sewing needle 10 descends together with the needle bar 11, penetrating the fabric 69 and passing through the needle eye 8. The upper thread 66 near the eye 10A that has descended below the needle eye 8 becomes circular (see FIG. 5(a)). As the shuttle 49 rotates clockwise as viewed from the front, the point 46 captures the circular upper thread 66 (see FIG. 5(b)). The sewing needle 10 rises above the fabric 69, and the shuttle 49 rotates further clockwise as viewed from the front. The point 46 pulls in the circular upper thread 66 in the direction of rotation, and the circular upper thread 66 expands in diameter.

環状になった上糸６６が釜４９を潜り抜けると（図５（ｃ）参照）、上糸６６は下糸６７に絡まる。以下、剣先４６が環状の上糸６６を捕捉し釜４９が環状になった上糸６６を潜り抜ける迄の期間を釜捕捉期間という。釜４９の回動方向は、正面視反時計回りに切替わる。該時、天秤２３は下糸６７に絡んだ上糸６６を引上げる（図５（ｄ）参照）。以下、天秤２３が上糸６６を引上げる期間を天秤引上期間という。環状の上糸６６が縮径し、ミシン１は一針分の縫製を完了する。本実施形態では上軸１５が一回転する度に、ミシン１は一針分の縫製を実行する。ミシン１は上記動作を繰返すことで布６９に複数の縫目６８を形成する。 When the looped upper thread 66 passes through the shuttle 49 (see FIG. 5(c)), the upper thread 66 becomes entangled with the bobbin thread 67. Hereinafter, the period from when the point 46 captures the looped upper thread 66 until the shuttle 49 passes through the looped upper thread 66 is referred to as the shuttle capture period. The rotation direction of the shuttle 49 is switched to counterclockwise when viewed from the front. At that time, the thread take-up lever 23 pulls up the upper thread 66 entangled with the bobbin thread 67 (see FIG. 5(d)). Hereinafter, the period during which the thread take-up lever 23 pulls up the upper thread 66 is referred to as the thread take-up period. The looped upper thread 66 shrinks in diameter, and the sewing machine 1 completes sewing one stitch. In this embodiment, the sewing machine 1 performs sewing one stitch each time the upper shaft 15 rotates once. The sewing machine 1 repeats the above operations to form multiple stitches 68 on the fabric 69.

ミシン１の縫製不良を説明する。縫製不良は縫製動作中に正常な縫目６８が形成できなかったことを示す。縫製不良は糸切れ、目飛び、締り不良を含む。糸切れは縫製中に上糸６６が切れる不良であり、布６９に縫目６８が形成できない不良である。目飛びは縫製中における釜４９に依る上糸６６の捕捉の失敗であり、上糸６６と下糸６７が絡まずに布６９に正常な縫目６８が形成できない不良である。締り不良は天秤２３が上糸６６を引き上げた時に布６９に縫目６８を形成する上糸６６と下糸６７のバランス不良である。例えば、上糸６６が下糸６７に強固に絡まり過ぎると、天秤２３が上糸６６を引上げる時に引上げきれずに上糸６６と下糸６７の絡む位置が適正な位置からずれる。 The sewing defects of the sewing machine 1 are explained below. A sewing defect indicates that a normal stitch 68 could not be formed during the sewing operation. The sewing defects include thread breakage, skipped stitches, and poor tightening. A thread breakage is a defect in which the upper thread 66 breaks during sewing, and a stitch 68 cannot be formed on the fabric 69. A skipped stitch is a defect in which the shuttle 49 fails to capture the upper thread 66 during sewing, and the upper thread 66 and the lower thread 67 do not become entangled, and a normal stitch 68 cannot be formed on the fabric 69. A poor tightening is a poor balance between the upper thread 66 and the lower thread 67 that form the stitch 68 on the fabric 69 when the thread take-up 23 pulls up the upper thread 66. For example, if the upper thread 66 is too tightly entangled with the lower thread 67, the thread take-up 23 cannot pull up the upper thread 66 completely when it pulls it up, and the position where the upper thread 66 and the lower thread 67 are entangled is shifted from the correct position.

図６～図１０を参照し、縫製不良の発生に至る迄の上糸張力、上糸移動量の変化について説明する。ＣＰＵ９１は磁気センサ５３の検出結果に依る上糸張力、エンコーダ１６Ａの検出結果に依る上糸移動量、エンコーダ２７Ａの検出結果に依る上軸角夫々を取得する。図６、図１０（ａ）の如く、縫製時、上糸張力、上糸移動量は上軸角に応じて縫製期間を単位周期として周期的に変動する。縫製期間はミシン１の一針分の縫製を行う期間である。以下、周期的に変動する上糸張力を変動張力、周期的に変動する上糸移動量を変動移動量と夫々称す。 Referring to Figures 6 to 10, the changes in upper thread tension and upper thread movement amount until a sewing defect occurs will be described. The CPU 91 obtains the upper thread tension based on the detection result of the magnetic sensor 53, the upper thread movement amount based on the detection result of the encoder 16A, and the upper shaft angle based on the detection result of the encoder 27A. As shown in Figures 6 and 10(a), during sewing, the upper thread tension and upper thread movement amount vary periodically according to the upper shaft angle, with the sewing period being the unit period. The sewing period is the period during which one stitch is sewn by the sewing machine 1. Hereinafter, the periodically varying upper thread tension will be referred to as the variable tension, and the periodically varying upper thread movement amount will be referred to as the variable movement amount.

縫針１０の上死点を基準（上軸角０°）とした一針分（一周期分）の縫製期間では、天秤引上期間、釜捕捉期間が順に生じる。天秤引上期間の上軸角Ｈ１（約７０°）において、縫製期間における変動張力の一回目のピークが生じる。釜捕捉期間の上軸角Ｈ２（約３３０°）において、縫製期間における変動張力の二回目のピークが生じる。ＣＰＵ９１は天秤引上期間、釜捕捉期間をエンコーダ２７Ａの検出結果に依る上軸角から判断する。 During a sewing period of one stitch (one cycle) with the top dead center of the sewing needle 10 as the reference (upper shaft angle 0°), a thread take-up period and a shuttle capture period occur in that order. The first peak of the fluctuating tension during the sewing period occurs at upper shaft angle H1 (approximately 70°) during the thread take-up period. The second peak of the fluctuating tension during the sewing period occurs at upper shaft angle H2 (approximately 330°) during the shuttle capture period. The CPU 91 determines the thread take-up period and shuttle capture period from the upper shaft angle based on the detection results of the encoder 27A.

糸切れの発生に至る迄の変動張力、変動移動量の変化を説明する。糸切れが発生する前、縫製中の上糸６６の撚りが解ける撚り戻りが生じる。上糸６６の撚り戻りは縫製中に上糸６６と共に移動する撚り移動を生じる。撚り移動が生じると、上糸６６の撚りが蓄積し、天秤２３等、上糸６６が屈曲する位置で円滑に移動できず、屈曲抵抗が大きくなる。故に図７の如く、天秤引上期間の上糸張力の最大値（以下、第一張力という。）、釜捕捉期間の上糸張力の最大値（以下、第二張力という。）は夫々正常時より大きくなる。第一張力、第二張力が極限に迄大きくなる時、糸切れが発生する。 The following explains the changes in fluctuating tension and fluctuating movement leading up to thread breakage. Before thread breakage occurs, the upper thread 66 untwists during sewing, causing a twist movement that moves with the upper thread 66 during sewing. When twist movement occurs, the twist in the upper thread 66 accumulates, and the upper thread 66 cannot move smoothly at positions where it bends, such as the thread take-up lever 23, and the bending resistance increases. Therefore, as shown in FIG. 7, the maximum upper thread tension during the thread take-up lever lift period (hereinafter referred to as the first tension) and the maximum upper thread tension during the hook capture period (hereinafter referred to as the second tension) are both greater than normal. When the first tension and second tension reach their limits, thread breakage occurs.

撚り移動が生じて上糸６６の撚りが蓄積する時、増加する上糸張力に依り、上糸６６が伸長する。該時、上糸６６が伸長した分、縫針１０に供給される上糸移動量が低下する。故に図１０（ｂ）の如く、上軸角Ｈ１の上糸移動量（以下、第一移動量という。）、上軸角Ｈ２の上糸移動量（以下、第二移動量という。）夫々は正常時より小さくなる。 When twist shift occurs and the twist of the upper thread 66 accumulates, the upper thread 66 stretches due to the increasing upper thread tension. At that time, the amount of upper thread movement supplied to the sewing needle 10 decreases by the amount of the upper thread 66 stretched. Therefore, as shown in Figure 10(b), the upper thread movement amount for upper shaft angle H1 (hereinafter referred to as the first movement amount) and the upper thread movement amount for upper shaft angle H2 (hereinafter referred to as the second movement amount) are each smaller than normal.

目飛びの発生に至る迄の変動張力、変動移動量の変化を説明する。上糸６６が屈曲する位置に蓄積した上糸６６の撚り戻りが移動する時がある。該時、上糸６６の撚り戻りは針穴８を通過し難い。該時、針穴８上方には上糸６６が溜まり、上糸移動量が低下する。故に図１０（ｃ）の如く、縫針１０の上死点（上軸角３６０°）での上糸移動量（以下、第三移動量という。）は正常時より小さくなる。上糸６６の撚り戻り箇所が針穴８を通過し難いので、針穴８下方の環状の上糸６６は正常時の時ほど拡径しない。該時、釜４９は上糸６６を捕捉できず、目飛びが発生する。 The following explains the changes in fluctuating tension and fluctuating movement amount until a skip occurs. The upper thread 66 that has accumulated at the position where it bends may move. At that time, the upper thread 66 has difficulty passing through the needle hole 8. At that time, the upper thread 66 accumulates above the needle hole 8, and the upper thread movement amount decreases. Therefore, as shown in FIG. 10(c), the upper thread movement amount (hereinafter referred to as the third movement amount) at the top dead center (upper shaft angle 360°) of the sewing needle 10 becomes smaller than normal. Because the upper thread 66 has difficulty passing through the needle hole 8 at the point where it has been untwisted, the annular upper thread 66 below the needle hole 8 does not expand as much as it does under normal circumstances. At that time, the shuttle 49 cannot capture the upper thread 66, and a skip occurs.

撚り移動が生じる時、上糸６６の撚り戻り箇所は針穴８を通過し難いので、釜４９が針穴８下方の上糸６６を引き込む張力が大きくなり、天秤２３が針穴８上方の上糸６６を引上げる張力が小さくなる。故に図８の如く、第一張力は正常時より小さくなり、第二張力は正常時より大きくなる。 When twist shift occurs, the untwisted portion of the upper thread 66 has difficulty passing through the needle hole 8, so the tension with which the shuttle 49 pulls in the upper thread 66 below the needle hole 8 increases, and the tension with which the thread take-up 23 pulls up the upper thread 66 above the needle hole 8 decreases. Therefore, as shown in Figure 8, the first tension is smaller than normal, and the second tension is larger than normal.

締り不良の発生に至る迄の変動張力、変動移動量の変化を説明する。上糸６６の撚り戻りは上糸６６が屈曲する位置で蓄積し、螺旋状に捩じれる。捩じれた上糸６６が移動し、釜４９が捩じれた上糸６６を捕捉する時がある。捩じれた上糸６６が釜４９を潜り抜ける時、捩じれた上糸６６は捩じれに依る力で下糸６７を軸に旋回し、下糸６７に絡まる。天秤２３は下糸６７に絡まる上糸６６を引上げる。故に図９の如く、第一張力は正常時より大きくなる。該時、上糸６６は正常時より大きく移動する。故に図１０（ｄ）の如く、第一移動量は正常時より大きくなる。第一移動量が正常時より大きいと、天秤２３が上糸６６を引上げる時に引上げきれずに上糸６６と下糸６７のバランス不良が生じ、締り不良が発生する。 The following explains the changes in the fluctuating tension and fluctuating movement amount until poor tightening occurs. The untwisting of the upper thread 66 accumulates at the position where the upper thread 66 bends, and it becomes twisted in a spiral. The twisted upper thread 66 moves, and the shuttle 49 sometimes catches the twisted upper thread 66. When the twisted upper thread 66 passes through the shuttle 49, the force caused by the torsion causes the twisted upper thread 66 to rotate around the lower thread 67 as an axis, and the twisted upper thread 66 becomes entangled with the lower thread 67. The take-up lever 23 pulls up the upper thread 66 entangled with the lower thread 67. Therefore, as shown in Figure 9, the first tension becomes greater than normal. At that time, the upper thread 66 moves a greater distance than normal. Therefore, as shown in Figure 10(d), the first movement amount becomes greater than normal. If the first movement amount is larger than normal, the thread take-up 23 will not be able to fully pull up the upper thread 66, causing an imbalance between the upper thread 66 and the lower thread 67, resulting in poor tightening.

縫製時に縫製不良が発生する前、第一張力、第二張力、第一移動量、第二移動量、第三移動量は正常時から変動する。縫製不良が発生する前に変動し、縫製不良の発生の特徴を示す量を特徴量という。第一張力、第二張力、第一移動量、第二移動量、第三移動量夫々は特徴量の一例である。 Before a sewing defect occurs during sewing, the first tension, second tension, first movement amount, second movement amount, and third movement amount fluctuate from normal. Amounts that fluctuate before a sewing defect occurs and indicate the characteristics of the occurrence of a sewing defect are called characteristic amounts. The first tension, second tension, first movement amount, second movement amount, and third movement amount are each an example of a characteristic amount.

ミシン１は予知単位における特徴量の推移に基づき縫製不良の発生を予知する。予知単位は一周期以上の縫製期間である。ミシン１は予知単位における特徴量を夫々取得する。ミシン１は取得順に特徴量をＲＡＭ９３に記憶する。図１１の如く、一針分の縫製期間を予知単位とした時、ＲＡＭ９３に記憶の第一張力は取得順に変動する。特徴量が予知単位五回分で連続して増加する時、特徴量の推移が増加傾向にあるという。特徴量が予知単位五回分で連続して減少する時、特徴量の推移が減少傾向にあるという。 The sewing machine 1 predicts the occurrence of sewing defects based on the transition of the feature value in a prediction unit. A prediction unit is a sewing period of one cycle or more. The sewing machine 1 acquires each feature value in the prediction unit. The sewing machine 1 stores the feature values in the RAM 93 in the order of acquisition. As shown in FIG. 11, when the sewing period of one stitch is taken as a prediction unit, the first tension stored in the RAM 93 varies in the order of acquisition. When the feature value increases for five consecutive prediction units, it is said that the transition of the feature value is on an increasing trend. When the feature value decreases for five consecutive prediction units, it is said that the transition of the feature value is on a decreasing trend.

ミシン１は縫製不良の発生を予知した時、縫製不良の発生を予知したことを頭部アンプ７０に依り報知する。ミシン１は糸切れの発生を予知した時、糸切れＬＥＤ７１を発光することで報知する。ミシン１は目飛びの発生を予知した時、目飛びＬＥＤ７２を発光することで報知する。ミシン１は締り不良の発生を予知した時、締り不良ＬＥＤ７３を発光することで報知する。ミシン１は縫製不良の発生を所定回数連続して予知した時、ミシン１は糸切れＬＥＤ７１、目飛びＬＥＤ７２、締り不良ＬＥＤ７３が発光する色を変更する。 When the sewing machine 1 predicts the occurrence of a sewing defect, it notifies the user through the head amplifier 70. When the sewing machine 1 predicts the occurrence of a thread break, it notifies the user by illuminating the thread break LED 71. When the sewing machine 1 predicts the occurrence of a skipped stitch, it notifies the user by illuminating the skipped stitch LED 72. When the sewing machine 1 predicts the occurrence of a tightness defect, it notifies the user by illuminating the tightness defect LED 73. When the sewing machine 1 predicts the occurrence of a sewing defect a predetermined number of times in succession, it changes the colors of the light emitted by the thread break LED 71, the skipped stitch LED 72 and the tightness defect LED 73.

ミシン１は縫製不良の発生を予知した時、縫製不良の発生を回避する回避制御を実行する。ミシン１は回避制御を実行することで主モータ２７の回転速度を減速し、主糸調子器２２が付与する上糸張力の大きさを小さくする。該時、ミシン１はスピーカ３９から音を出力することで回避制御の実行を報知する。 When the sewing machine 1 predicts the occurrence of a sewing defect, it executes avoidance control to prevent the occurrence of the sewing defect. By executing the avoidance control, the sewing machine 1 reduces the rotation speed of the main motor 27 and reduces the magnitude of the upper thread tension applied by the main thread tensioner 22. At that time, the sewing machine 1 notifies the user that the avoidance control is being executed by outputting a sound from the speaker 39.

ミシン１は回避制御を実行した後、繰返し縫製不良の発生を予知する時、駆動部を停止して縫製を停止する。該時、ミシン１は糸切れＬＥＤ７１、目飛びＬＥＤ７２、締り不良ＬＥＤ７３が発光する色を縫製不良の発生を予知した時と異なる色に変更し、スピーカ３９から音を出力することで縫製の停止を報知する。 After executing the avoidance control, when the sewing machine 1 predicts the occurrence of repeated sewing defects, it stops the drive unit and stops sewing. At that time, the sewing machine 1 changes the colors of the thread breakage LED 71, skipped stitch LED 72, and tightness failure LED 73 to colors different from when it predicted the occurrence of sewing defects, and outputs a sound from the speaker 39 to notify the stop of sewing.

図１２～図２１を参照し、ミシン１の第一縫製処理を説明する。作業者がミシン１の電源をＯＮした時、ＣＰＵ９１はＲＯＭ９２からプログラムを読み出して第一縫製処理を開始する。 The first sewing process of the sewing machine 1 will be described with reference to Figures 12 to 21. When the operator turns on the power of the sewing machine 1, the CPU 91 reads a program from the ROM 92 and starts the first sewing process.

第一縫製処理において、ＣＰＵ９１は一針分の縫製期間を予知単位として、縫製不良の発生を予知する。第一張力、第二張力、第一移動量、第二移動量、第三移動量は第一縫製処理における特徴量である。第一縫製処理において、ＣＰＵ９１は第一張力、第二張力が増加傾向にある時、又は第一移動量、第二移動量が減少傾向にある時、糸切れの発生を予知する。ＣＰＵ９１は第一張力が減少傾向にあり且つ第二張力が増加傾向にある時、又は第三移動量が減少傾向にある時、目飛びの発生を予知する。ＣＰＵ９１は第一張力が増加傾向にある時、又は第一移動量が増加傾向にある時、締り不良の発生を予知する。 In the first sewing process, the CPU 91 predicts the occurrence of poor sewing using the sewing period of one stitch as a prediction unit. The first tension, second tension, first movement amount, second movement amount, and third movement amount are characteristic amounts in the first sewing process. In the first sewing process, the CPU 91 predicts the occurrence of thread breakage when the first tension and second tension are on an increasing trend, or when the first movement amount and the second movement amount are on a decreasing trend. The CPU 91 predicts the occurrence of skipped stitches when the first tension is on a decreasing trend and the second tension is on an increasing trend, or when the third movement amount is on a decreasing trend. The CPU 91 predicts the occurrence of poor tightening when the first tension is on an increasing trend, or when the first movement amount is on an increasing trend.

ＣＰＵ９１が第一縫製処理で使用するフラグ、カウンタを説明する。ＲＡＭ９３は糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグ等を記憶する。糸切れ予知停止フラグはＣＰＵ９１が繰返し糸切れの発生を予知して縫製を停止する時、値を１に設定する。目飛び予知停止フラグはＣＰＵ９１が繰返し目飛びの発生を予知して縫製を停止する時、値を１に設定する。締り不良予知停止フラグはＣＰＵ９１が繰返し締り不良の発生を予知して縫製を停止する時、値を１に設定する。第一縫製処理の開始時、糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグは何れも０である。 The flags and counters used by the CPU 91 in the first sewing process are explained below. The RAM 93 stores a thread breakage prediction stop flag, a stitch skip prediction stop flag, a tightness failure prediction stop flag, etc. The thread breakage prediction stop flag is set to a value of 1 when the CPU 91 predicts repeated occurrences of thread breakage and stops sewing. The stitch skip prediction stop flag is set to a value of 1 when the CPU 91 predicts repeated occurrences of stitch skips and stops sewing. The tightness failure prediction stop flag is set to a value of 1 when the CPU 91 predicts repeated occurrences of tightness failure and stops sewing. At the start of the first sewing process, the thread breakage prediction stop flag, stitch skip prediction stop flag and tightness failure prediction stop flag are all 0.

ＲＡＭ９３は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷ、針落ち数Ｎ、累積針落ち数Ｌ等を記憶する。糸切れ予知カウンタＵはＣＰＵ９１が糸切れの発生を予知した時、値に１を加算する。目飛び予知カウンタＶはＣＰＵ９１が目飛びの発生を予知した時、値に１を加算する。締り不良予知カウンタＷはＣＰＵ９１が締り不良の発生を予知した時、値に１を加算する。 The RAM 93 stores a thread breakage prediction counter U, a stitch skip prediction counter V, a tightness failure prediction counter W, the number of needle points N, the cumulative number of needle points L, etc. The thread breakage prediction counter U adds 1 to its value when the CPU 91 predicts the occurrence of a thread breakage. The stitch skip prediction counter V adds 1 to its value when the CPU 91 predicts the occurrence of a stitch skip. The tightness failure prediction counter W adds 1 to its value when the CPU 91 predicts the occurrence of a tightness failure.

ＣＰＵ９１は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷの値が大きい程、縫製不良の発生する可能性が高いと判断する。ＣＰＵ９１が糸切れの発生を連続して予知し、糸切れ予知カウンタＵが糸切れ予知停止数Ｘに到達した時、ＣＰＵ９１は縫製を停止する。ＣＰＵ９１が目飛びの発生を連続して予知し、目飛び予知カウンタＶが目飛び予知停止数Ｙに到達した時、ＣＰＵ９１は縫製を停止する。ＣＰＵ９１が締り不良の発生を連続して予知し、締り不良予知カウンタＷが締り不良予知停止数Ｚに到達した時、ＣＰＵ９１は縫製を停止する。 The CPU 91 determines that the greater the values of the thread breakage prediction counter U, stitch skip prediction counter V, and tightness failure prediction counter W, the greater the possibility of a sewing failure occurring. When the CPU 91 continuously predicts thread breakage and the thread breakage prediction counter U reaches the thread breakage prediction stop number X, the CPU 91 stops sewing. When the CPU 91 continuously predicts stitch skipping and the stitch skip prediction counter V reaches the stitch skip prediction stop number Y, the CPU 91 stops sewing. When the CPU 91 continuously predicts tightness failure and the tightness failure prediction counter W reaches the tightness failure prediction stop number Z, the CPU 91 stops sewing.

針落ち数Ｎは縫製を開始してから停止する迄に針棒１１が上下動した回数であり、一針分の縫製を繰返した回数である。累積針落ち数Ｌはミシン１の電源をＯＮしてから電源をＯＦＦする迄に針棒１１が上下動した累積回数である。第一縫製処理の開始時、糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷ、針落ち数Ｎ、累積針落ち数Ｌの値は何れも０である。 The number of needle points N is the number of times the needle bar 11 moves up and down from the start of sewing to the stop of sewing, and is the number of times sewing one stitch is repeated. The cumulative number of needle points L is the cumulative number of times the needle bar 11 moves up and down from the time the power to the sewing machine 1 is turned on to the time it is turned off. At the start of the first sewing process, the values of the thread breakage prediction counter U, the skipped stitch prediction counter V, the tightness failure prediction counter W, the number of needle points N, and the cumulative number of needle points L are all 0.

図１２の如く、ＣＰＵ９１は初期化処理を実行する（Ｓ１）。ＣＰＵ９１はＲＡＭ９３に記憶の糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグ夫々を０に設定する。ＣＰＵ９１は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷ、針落ち数Ｎの値を０にする。ＣＰＵ９１は後述の糸切れ予知停止報知、目飛び予知停止報知、締り不良予知停止報知の何れかを報知中である時、報知を終了する。 As shown in FIG. 12, the CPU 91 executes an initialization process (S1). The CPU 91 sets the thread breakage prediction stop flag, stitch skip prediction stop flag, and tightness failure prediction stop flag stored in the RAM 93 to 0. The CPU 91 sets the values of the thread breakage prediction counter U, stitch skip prediction counter V, tightness failure prediction counter W, and number of needle drops N to 0. When the CPU 91 is issuing a thread breakage prediction stop notification, stitch skip prediction stop notification, or tightness failure prediction stop notification, which will be described later, it ends the notification.

ＣＰＵ９１は入力部２４からＸ設定指示信号を受信したか否かを判断する（Ｓ４）。作業者は糸切れ予知停止数Ｘを設定する時、入力部２４を操作する。該時、入力部２４はＸ設定指示信号をＣＰＵ９１に出力する。ＣＰＵ９１は入力部２４からＸ設定指示信号を受信しないと判断した時（Ｓ４：ＮＯ）、処理をＳ６に移行する。ＣＰＵ９１は入力部２４からＸ設定指示信号を受信したと判断した時（Ｓ４：ＹＥＳ）、糸切れ予知停止数Ｘを設定して（Ｓ５）、処理をＳ６に移行する。 The CPU 91 judges whether or not it has received an X setting instruction signal from the input unit 24 (S4). When the operator sets the yarn breakage prediction stop number X, the input unit 24 operates the input unit 24. At that time, the input unit 24 outputs an X setting instruction signal to the CPU 91. When the CPU 91 judges that it has not received an X setting instruction signal from the input unit 24 (S4: NO), it shifts the process to S6. When the CPU 91 judges that it has received an X setting instruction signal from the input unit 24 (S4: YES), it sets the yarn breakage prediction stop number X (S5) and shifts the process to S6.

ＣＰＵ９１は入力部２４からＹ設定指示信号を受信したか否かを判断する（Ｓ６）。作業者は目飛び予知停止数Ｙを設定する時、入力部２４を操作する。該時、入力部２４はＹ設定指示信号をＣＰＵ９１に出力する。ＣＰＵ９１は入力部２４からＹ設定指示信号を受信しないと判断した時（Ｓ６：ＮＯ）、処理をＳ８に移行する。ＣＰＵ９１は入力部２４からＹ設定指示信号を受信したと判断した時（Ｓ６：ＹＥＳ）、目飛び予知停止数Ｙを設定して（Ｓ７）、処理をＳ８に移行する。 The CPU 91 determines whether or not it has received a Y setting instruction signal from the input unit 24 (S6). When setting the stitch skip prediction stop number Y, the worker operates the input unit 24. At that time, the input unit 24 outputs a Y setting instruction signal to the CPU 91. When the CPU 91 determines that it has not received a Y setting instruction signal from the input unit 24 (S6: NO), it shifts the process to S8. When the CPU 91 determines that it has received a Y setting instruction signal from the input unit 24 (S6: YES), it sets the stitch skip prediction stop number Y (S7) and shifts the process to S8.

ＣＰＵ９１は入力部２４からＺ設定指示信号を受信したか否かを判断する（Ｓ８）。作業者は締り不良予知停止数Ｚを設定する時、入力部２４を操作する。該時、入力部２４はＺ設定指示信号をＣＰＵ９１に出力する。ＣＰＵ９１は入力部２４からＺ設定指示信号を受信しないと判断した時（Ｓ８：ＮＯ）、処理をＳ１１に移行する。ＣＰＵ９１は入力部２４からＺ設定指示信号を受信したと判断した時（Ｓ８：ＹＥＳ）、締り不良予知停止数Ｚを設定して（Ｓ９）、処理をＳ１１に移行する。 The CPU 91 determines whether or not it has received a Z setting instruction signal from the input unit 24 (S8). When setting the tightening failure prediction stop number Z, the operator operates the input unit 24. At that time, the input unit 24 outputs a Z setting instruction signal to the CPU 91. When the CPU 91 determines that it has not received a Z setting instruction signal from the input unit 24 (S8: NO), it transitions to S11. When the CPU 91 determines that it has received a Z setting instruction signal from the input unit 24 (S8: YES), it sets the tightening failure prediction stop number Z (S9) and transitions to S11.

ＣＰＵ９１はペダル３８の検出結果に基づき縫製を開始するか否かを判断する（Ｓ１１）。作業者がペダル３８を所定方向に操作しない時、ペダル３８はＯＦＦ信号を出力する。ペダル３８からＯＦＦ信号を受信した時、ＣＰＵ９１は縫製を開始しないと判断し（Ｓ１１：ＮＯ）、処理をＳ４に戻す。作業者は針板７に布６９を載置する。布６９の載置後、作業者がペダル３８を所定方向に操作した時、ペダル３８はＯＮ信号を出力する。ペダル３８からＯＮ信号を受信した時、ＣＰＵ９１は縫製動作を開始すると判断し（Ｓ１１：ＹＥＳ）、駆動部の駆動を開始して（Ｓ１３）、布６９の縫製を開始する。ＣＰＵ９１は処理をＳ２１（図１３参照）に移行する。 The CPU 91 determines whether or not to start sewing based on the detection result of the pedal 38 (S11). When the operator does not operate the pedal 38 in the specified direction, the pedal 38 outputs an OFF signal. When the CPU 91 receives the OFF signal from the pedal 38, it determines not to start sewing (S11: NO) and returns the process to S4. The operator places the fabric 69 on the needle plate 7. After placing the fabric 69, when the operator operates the pedal 38 in the specified direction, the pedal 38 outputs an ON signal. When the CPU 91 receives the ON signal from the pedal 38, it determines to start sewing operation (S11: YES), starts driving the drive unit (S13), and starts sewing the fabric 69. The CPU 91 shifts the process to S21 (see FIG. 13).

図１３の如く、ＣＰＵ９１は第一特徴量処理を実行する（Ｓ２１）。第一特徴量処理は第一縫製処理における特徴量を取得する為の処理である。 As shown in FIG. 13, the CPU 91 executes a first characteristic amount process (S21). The first characteristic amount process is a process for acquiring a characteristic amount in the first sewing process.

図１４を参照し、第一特徴量処理を説明する。ＣＰＵ９１はエンコーダ２７Ａの検出結果、磁気センサ５３の検出結果、エンコーダ１６Ａの検出結果から変動張力、変動移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５１）。ＣＰＵ９１は取得した上軸角が天秤引上期間内であるか否かを判断する（Ｓ５２）。上軸角が天秤引上期間内でない時（Ｓ５２：ＮＯ）、ＣＰＵ９１は処理をＳ５５に移行する。上軸角が天秤引上期間内である時（Ｓ５２：ＹＥＳ）、ＣＰＵ９１は磁気センサ５３の検出結果に基づいて第一張力を取得し、ＲＡＭ９３に記憶する（Ｓ５３）。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第一移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５４）。ＣＰＵ９１は処理をＳ５５に移行する。 The first feature amount processing will be described with reference to FIG. 14. The CPU 91 acquires the variable tension and variable movement amount from the detection results of the encoder 27A, the detection results of the magnetic sensor 53, and the detection results of the encoder 16A, and stores them in the RAM 93 (S51). The CPU 91 determines whether the acquired upper shaft angle is within the balance pull-up period (S52). If the upper shaft angle is not within the balance pull-up period (S52: NO), the CPU 91 shifts the processing to S55. If the upper shaft angle is within the balance pull-up period (S52: YES), the CPU 91 acquires the first tension based on the detection results of the magnetic sensor 53, and stores it in the RAM 93 (S53). The CPU 91 acquires the first movement amount based on the detection results of the encoder 16A, and stores it in the RAM 93 (S54). The CPU 91 shifts the processing to S55.

ＣＰＵ９１は上軸角が釜捕捉期間内であるか否かを判断する（Ｓ５５）。上軸角が釜捕捉期間内でない時（Ｓ５５：ＮＯ）、ＣＰＵ９１は処理をＳ５８に移行する。上軸角が釜捕捉期間内である時（Ｓ５５：ＹＥＳ）、ＣＰＵ９１は磁気センサ５３の検出結果に基づいて第二張力を取得し、ＲＡＭ９３に記憶する（Ｓ５６）。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第二移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５７）。ＣＰＵ９１は処理をＳ５８に移行する。 The CPU 91 determines whether the upper shaft angle is within the shuttle capture period (S55). When the upper shaft angle is not within the shuttle capture period (S55: NO), the CPU 91 transitions to S58. When the upper shaft angle is within the shuttle capture period (S55: YES), the CPU 91 obtains the second tension based on the detection result of the magnetic sensor 53 and stores it in the RAM 93 (S56). The CPU 91 obtains the second movement amount based on the detection result of the encoder 16A and stores it in the RAM 93 (S57). The CPU 91 transitions to S58.

ＣＰＵ９１は縫針１０が上死点に在るか否かを判断する（Ｓ５８）。上軸角が３６０°でなく、縫針１０が上死点にない時（Ｓ５８：ＮＯ）、ＣＰＵ９１は処理を第一縫製処理（図１３参照）に戻す。上軸角が３６０°であり、縫針１０が上死点に在る時（Ｓ５８：ＹＥＳ）、ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第三移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５９）。ＣＰＵ９１は上糸移動量の大きさを０にして（Ｓ６０）、処理を第一縫製処理に戻す。 The CPU 91 determines whether the sewing needle 10 is at the top dead point (S58). When the upper shaft angle is not 360° and the sewing needle 10 is not at the top dead point (S58: NO), the CPU 91 returns the process to the first sewing process (see FIG. 13). When the upper shaft angle is 360° and the sewing needle 10 is at the top dead point (S58: YES), the CPU 91 obtains the third movement amount based on the detection result of the encoder 16A and stores it in the RAM 93 (S59). The CPU 91 sets the magnitude of the upper thread movement amount to 0 (S60) and returns the process to the first sewing process.

図１３の如く、第一特徴量処理（Ｓ２１）の実行後、ＣＰＵ９１は縫針１０が上死点に在るか否かを判断する（Ｓ２２）。Ｓ２２はＳ５８（図１４参照）と同様の処理である。縫針１０が上死点にない時（Ｓ２２：ＮＯ）、ＣＰＵ９１はペダル３８の検出結果に基づき縫製を終了するか否かを判断する（Ｓ２３）。ペダル３８からＯＮ信号を受信した時、ＣＰＵ９１は縫製を終了しないと判断し（Ｓ２３：ＮＯ）、処理をＳ２１に戻す。 As shown in FIG. 13, after executing the first characteristic amount process (S21), the CPU 91 determines whether or not the sewing needle 10 is at the top dead center (S22). S22 is the same process as S58 (see FIG. 14). When the sewing needle 10 is not at the top dead center (S22: NO), the CPU 91 determines whether or not to end sewing based on the detection result of the pedal 38 (S23). When an ON signal is received from the pedal 38, the CPU 91 determines not to end sewing (S23: NO) and returns the process to S21.

ＣＰＵ９１はＳ２１～Ｓ２３を繰返し実行する。縫針１０が上死点に在る時（Ｓ２２：ＹＥＳ）、ＣＰＵ９１は針落ち数Ｎ、累積針落ち数Ｌの値に１を加算する（Ｓ３１）。ＣＰＵ９１は針落ち数Ｎが５以上であるか否かを判断する（Ｓ３３）。針落ち数Ｎが５未満である時（Ｓ３３：ＮＯ）、ＣＰＵ９１は縫製不良の発生を予知できないとして、処理をＳ２３に移行する。針落ち数Ｎが５以上である時（Ｓ３３：ＹＥＳ）、ＣＰＵ９１はＲＡＭ９３に記憶した夫々の特徴量の内、記憶した順が新しい五つを取得する（Ｓ３４）。ＣＰＵ９１は第一糸切れ予知処理（Ｓ３５）、第一目飛び予知処理（Ｓ３６）、第一締り不良予知処理（Ｓ３７）を実行し、処理をＳ３８に移行する。 The CPU 91 repeatedly executes S21 to S23. When the sewing needle 10 is at the top dead point (S22: YES), the CPU 91 adds 1 to the number of needles N and the cumulative number of needles L (S31). The CPU 91 determines whether the number of needles N is 5 or more (S33). When the number of needles N is less than 5 (S33: NO), the CPU 91 determines that the occurrence of a sewing defect cannot be predicted and shifts the process to S23. When the number of needles N is 5 or more (S33: YES), the CPU 91 acquires the five most recent feature amounts stored in the RAM 93 (S34). The CPU 91 executes a first thread breakage prediction process (S35), a first skipped stitch prediction process (S36), and a first tightening defect prediction process (S37), and shifts the process to S38.

図１５を参照し、第一糸切れ予知処理を説明する。第一糸切れ予知処理は糸切れの発生を予知する為の処理である。ＣＰＵ９１はＳ３４（図１３参照）で取得した五つの第一張力に基づいて、第一張力が増加傾向にあるか否かを判断する（Ｓ６１）。第一張力が増加傾向にない時（Ｓ６１：ＮＯ）、ＣＰＵ９１は処理をＳ６３に移行する。第一張力が増加傾向にある時（Ｓ６１：ＹＥＳ）、ＣＰＵ９１はＳ３４で取得した五つの第二張力に基づいて、第二張力が増加傾向にあるか否かを判断する（Ｓ６２）。第二張力が増加傾向にない時（Ｓ６２：ＮＯ）、ＣＰＵ９１は処理をＳ６３に移行する。第二張力が増加傾向にある時（Ｓ６２：ＹＥＳ）、ＣＰＵ９１は処理をＳ７１に移行する。 The first thread breakage prediction process will be described with reference to FIG. 15. The first thread breakage prediction process is a process for predicting the occurrence of thread breakage. The CPU 91 determines whether the first tension is on an increasing trend (S61) based on the five first tensions acquired in S34 (see FIG. 13). If the first tension is not on an increasing trend (S61: NO), the CPU 91 shifts the process to S63. If the first tension is on an increasing trend (S61: YES), the CPU 91 determines whether the second tension is on an increasing trend (S62) based on the five second tensions acquired in S34. If the second tension is not on an increasing trend (S62: NO), the CPU 91 shifts the process to S63. If the second tension is on an increasing trend (S62: YES), the CPU 91 shifts the process to S71.

ＣＰＵ９１はＳ３４で取得した五つの第一移動量に基づいて、第一移動量が減少傾向にあるか否かを判断する（Ｓ６３）。第一移動量が減少傾向にない時（Ｓ６３：ＮＯ）、ＣＰＵ９１は処理をＳ８１に移行する。第一移動量が減少傾向にある時（Ｓ６３：ＹＥＳ）、ＣＰＵ９１はＳ３４で取得した五つの第二移動量に基づいて、第二移動量が減少傾向にあるか否かを判断する（Ｓ６４）。第二移動量が減少傾向にない時（Ｓ６４：ＮＯ）、ＣＰＵ９１は処理をＳ８１に移行する。第二移動量が減少傾向にある時（Ｓ６４：ＹＥＳ）、ＣＰＵ９１は処理をＳ７１に移行する。 The CPU 91 determines whether the first movement amount is on a decreasing trend based on the five first movement amounts obtained in S34 (S63). When the first movement amount is not on a decreasing trend (S63: NO), the CPU 91 transitions the process to S81. When the first movement amount is on a decreasing trend (S63: YES), the CPU 91 determines whether the second movement amount is on a decreasing trend based on the five second movement amounts obtained in S34 (S64). When the second movement amount is not on a decreasing trend (S64: NO), the CPU 91 transitions the process to S81. When the second movement amount is on a decreasing trend (S64: YES), the CPU 91 transitions the process to S71.

第一張力、第二張力が増加傾向にある時（Ｓ６２：ＹＥＳ）、又は第一移動量、第二移動量が減少傾向にある時（Ｓ６４：ＹＥＳ）、ＣＰＵ９１は糸切れの発生を予知したとして、糸切れ予知カウンタＵの値に１を加算する（Ｓ７１）。ＣＰＵ９１は糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘ未満であるか否かを判断する（Ｓ７２）。糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘ未満である時（Ｓ７２：ＹＥＳ）、ＣＰＵ９１は糸切れ回避処理を実行し（Ｓ７３）、処理を第一縫製処理（図１３参照）に戻す。 When the first tension and the second tension are tending to increase (S62: YES), or when the first movement amount and the second movement amount are tending to decrease (S64: YES), the CPU 91 determines that a thread breakage has been predicted, and increments the value of the thread breakage prediction counter U by 1 (S71). The CPU 91 determines whether the value of the thread breakage prediction counter U is less than the thread breakage prediction stop count X (S72). When the value of the thread breakage prediction counter U is less than the thread breakage prediction stop count X (S72: YES), the CPU 91 executes thread breakage avoidance processing (S73), and returns the processing to the first sewing processing (see FIG. 13).

図１６を参照し、糸切れ回避処理を説明する。糸切れ回避処理は糸切れの発生を予知した時に回避制御を実行し、糸切れの発生を回避する為の処理である。ＣＰＵ９１は糸切れ予知カウンタＵの値が１であるか否かを判断する（Ｓ９１）。糸切れ予知カウンタＵの値が１である時（Ｓ９１：ＹＥＳ）、ＣＰＵ９１はスピーカ３９が音を出力することで回避制御の実行を報知する糸切れ回避報知を実行する（Ｓ９２）。ＣＰＵ９１は主モータ２７の回転速度を減速する（Ｓ９３）。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさを小さくし（Ｓ９４）、処理をＳ１０１に移行する。糸切れの発生を連続して予知し、糸切れ予知カウンタＵの値が１より大きい時（Ｓ９１：ＮＯ）、回避制御を実行中であるとして、ＣＰＵ９１は処理をＳ１０１に移行する。 The thread breakage avoidance process will be described with reference to FIG. 16. The thread breakage avoidance process is a process for preventing thread breakage by executing avoidance control when thread breakage is predicted. The CPU 91 judges whether the value of the thread breakage prediction counter U is 1 (S91). When the value of the thread breakage prediction counter U is 1 (S91: YES), the CPU 91 executes thread breakage avoidance notification, which notifies the execution of avoidance control by outputting a sound from the speaker 39 (S92). The CPU 91 reduces the rotation speed of the main motor 27 (S93). The CPU 91 controls the thread tension motor 16 to reduce the magnitude of the upper thread tension applied by the main thread tensioner 22 (S94), and the process proceeds to S101. When thread breakage is continuously predicted and the value of the thread breakage prediction counter U is greater than 1 (S91: NO), the CPU 91 determines that avoidance control is being executed and proceeds to S101.

ＣＰＵ９１は糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘの半分以上であるか否かを判断する（Ｓ１０１）。ＣＰＵ９１は糸切れの発生を連続して予知する時、予知が連続した回数（糸切れ予知カウンタＵ）に応じて多段階で糸切れの発生の予知を報知する。糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘの半分未満である時（Ｓ１０１：ＮＯ）、ＣＰＵ９１は第一糸切れ予知報知を実行し（Ｓ１０２）、処理を第一糸切れ予知処理（図１５参照）に戻す。第一糸切れ予知報知において、ＣＰＵ９１は糸切れＬＥＤ７１を黄色で発光する。糸切れの発生を連続して予知し、糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘの半分以上である時（Ｓ１０１：ＹＥＳ）、ＣＰＵ９１は第二糸切れ予知報知を実行し（Ｓ１０３）、処理を第一糸切れ予知処理に戻す。第二糸切れ予知報知において、ＣＰＵ９１は糸切れＬＥＤ７１を橙色で発光する。 The CPU 91 judges whether the value of the thread breakage prediction counter U is equal to or greater than half the number of thread breakage prediction stops X (S101). When the CPU 91 predicts the occurrence of thread breakage continuously, it notifies the occurrence of thread breakage in multiple stages according to the number of consecutive predictions (thread breakage prediction counter U). When the value of the thread breakage prediction counter U is less than half the number of thread breakage prediction stops X (S101: NO), the CPU 91 executes a first thread breakage prediction notification (S102) and returns the process to the first thread breakage prediction process (see FIG. 15). In the first thread breakage prediction notification, the CPU 91 causes the thread breakage LED 71 to emit yellow light. When the occurrence of thread breakage is continuously predicted and the value of the thread breakage prediction counter U is equal to or greater than half the number of thread breakage prediction stops X (S101: YES), the CPU 91 executes a second thread breakage prediction notification (S103) and returns the process to the first thread breakage prediction process. In the second yarn breakage warning, the CPU 91 causes the yarn breakage LED 71 to light up in orange.

図１５の如く、第一張力、第二張力の何れかが増加傾向になく（Ｓ６１：ＮＯ又はＳ６２：ＮＯ）、第一移動量、第二移動量の何れかが減少傾向にない時（Ｓ６３：ＮＯ又はＳ６４：ＮＯ）、ＣＰＵ９１は糸切れの発生を予知しないとして、処理をＳ８１に移行する。ＣＰＵ９１は糸切れ予知カウンタＵの値が１以上であるか否かを判断する（Ｓ８１）。 As shown in FIG. 15, when either the first tension or the second tension is not increasing (S61: NO or S62: NO) and either the first movement amount or the second movement amount is not decreasing (S63: NO or S64: NO), the CPU 91 does not predict the occurrence of thread breakage and shifts the process to S81. The CPU 91 determines whether the value of the thread breakage prediction counter U is 1 or greater (S81).

糸切れ予知カウンタＵの値が１以上である時（Ｓ８１：ＹＥＳ）、ＣＰＵ９１は第一糸切れ予知報知（Ｓ１０２、図１６参照）、第二糸切れ予知報知（Ｓ１０３、図１６参照）を終了し、糸切れＬＥＤ７１を消灯する（Ｓ８２）。ＣＰＵ９１は糸切れ回避報知（Ｓ９２、図１６参照）を終了し、スピーカ３９の音の出力を停止する（Ｓ８３）。ＣＰＵ９１は主モータ２７の回転速度をＳ９３（図１６参照）で減速する前の回転速度迄加速する（Ｓ８４）。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさをＳ９４（図１６参照）で小さくする前の大きさ迄大きくする（Ｓ８５）。ＣＰＵ９１は糸切れ予知カウンタＵの値を０にして（Ｓ８６）、処理を第一縫製処理（図１３参照）に戻す。糸切れ予知カウンタＵの値が０である時（Ｓ８１：ＮＯ）、ＣＰＵ９１は処理を第一縫製処理に戻す。 When the value of the thread breakage prediction counter U is 1 or more (S81: YES), the CPU 91 ends the first thread breakage prediction notification (S102, see FIG. 16) and the second thread breakage prediction notification (S103, see FIG. 16), and turns off the thread breakage LED 71 (S82). The CPU 91 ends the thread breakage avoidance notification (S92, see FIG. 16), and stops the sound output from the speaker 39 (S83). The CPU 91 accelerates the rotation speed of the main motor 27 to the rotation speed before it was decelerated in S93 (see FIG. 16) (S84). The CPU 91 controls the thread tension motor 16 to increase the magnitude of the upper thread tension applied by the main thread tensioner 22 to the magnitude before it was reduced in S94 (see FIG. 16) (S85). The CPU 91 sets the value of the thread breakage prediction counter U to 0 (S86), and returns the process to the first sewing process (see FIG. 13). When the value of the thread breakage prediction counter U is 0 (S81: NO), the CPU 91 returns the process to the first sewing process.

縫製中、ＣＰＵ９１は第一糸切れ予知処理を繰返し実行し、糸切れの発生の予知の有無を判定する。糸切れの発生を予知した時、ＣＰＵ９１は糸切れ回避処理（Ｓ７３）にて糸切れの発生を回避する回避制御を実行する。糸切れ回避処理（Ｓ７３）の実行後も連続して糸切れの発生を予知し、糸切れ予知カウンタＵの値が糸切れ予知停止数Ｘに到達した時（Ｓ７２：ＮＯ）、ＣＰＵ９１は糸切れ予知停止フラグを１に設定し（Ｓ７４）、処理を第一縫製処理に戻す。 During sewing, the CPU 91 repeatedly executes the first thread breakage prediction process to determine whether thread breakage has been predicted. When thread breakage is predicted, the CPU 91 executes avoidance control to avoid thread breakage in thread breakage avoidance process (S73). When thread breakage continues to be predicted even after the thread breakage avoidance process (S73) is executed and the value of the thread breakage prediction counter U reaches the thread breakage prediction stop number X (S72: NO), the CPU 91 sets the thread breakage prediction stop flag to 1 (S74) and returns the process to the first sewing process.

図１７を参照し、第一目飛び予知処理を説明する。第一目飛び予知処理は目飛びの発生を予知する為の処理である。ＣＰＵ９１はＳ３４（図１３参照）で取得した五つの第一張力に基づいて、第一張力が減少傾向にあるか否かを判断する（Ｓ１１１）。第一張力が減少傾向にない時（Ｓ１１１：ＮＯ）、ＣＰＵ９１は処理をＳ１１３に移行する。第一張力が減少傾向にある時（Ｓ１１１：ＹＥＳ）、ＣＰＵ９１はＳ３４で取得した五つの第二張力に基づいて、第二張力が増加傾向にあるか否かを判断する（Ｓ１１２）。第二張力が増加傾向にない時（Ｓ１１２：ＮＯ）、ＣＰＵ９１は処理をＳ１１３に移行する。第二張力が増加傾向にある時（Ｓ１１２：ＹＥＳ）、ＣＰＵ９１は処理をＳ１２１に移行する。 The first stitch skip prediction process will be described with reference to FIG. 17. The first stitch skip prediction process is a process for predicting the occurrence of a stitch skip. The CPU 91 determines whether the first tension is on a decreasing trend (S111) based on the five first tensions obtained in S34 (see FIG. 13). If the first tension is not on a decreasing trend (S111: NO), the CPU 91 transitions the process to S113. If the first tension is on a decreasing trend (S111: YES), the CPU 91 determines whether the second tension is on an increasing trend (S112) based on the five second tensions obtained in S34. If the second tension is not on an increasing trend (S112: NO), the CPU 91 transitions the process to S113. If the second tension is on an increasing trend (S112: YES), the CPU 91 transitions the process to S121.

ＣＰＵ９１はＳ３４で取得した五つの第三移動量に基づいて、第三移動量が減少傾向にあるか否かを判断する（Ｓ１１３）。第三移動量が減少傾向にない時（Ｓ１１３：ＮＯ）、ＣＰＵ９１は処理をＳ１３１に移行する。第三移動量が減少傾向にある時（Ｓ１１３：ＹＥＳ）、ＣＰＵ９１は処理をＳ１２１に移行する。 Based on the five third movement amounts acquired in S34, the CPU 91 determines whether the third movement amount is on a decreasing trend (S113). If the third movement amount is not on a decreasing trend (S113: NO), the CPU 91 transitions the process to S131. If the third movement amount is on a decreasing trend (S113: YES), the CPU 91 transitions the process to S121.

第一張力が減少傾向にあり且つ第二張力が増加傾向にある時（Ｓ１１２：ＹＥＳ）、又は第三移動量が減少傾向にある時（Ｓ１１３：ＹＥＳ）、ＣＰＵ９１は目飛びの発生を予知したとして、目飛び予知カウンタＶの値に１を加算する（Ｓ１２１）。ＣＰＵ９１は目飛び予知カウンタＶの値が目飛び予知停止数Ｙ未満であるか否かを判断する（Ｓ１２２）。目飛び予知カウンタＶの値が目飛び予知停止数Ｙ未満である時（Ｓ１２２：ＹＥＳ）、ＣＰＵ９１は目飛び回避処理を実行し（Ｓ１２３）、処理を第一縫製処理（図１３参照）に戻す。 When the first tension is decreasing and the second tension is increasing (S112: YES), or when the third movement amount is decreasing (S113: YES), the CPU 91 predicts the occurrence of a stitch skip and adds 1 to the value of the stitch skip prediction counter V (S121). The CPU 91 determines whether the value of the stitch skip prediction counter V is less than the stitch skip prediction stop number Y (S122). When the value of the stitch skip prediction counter V is less than the stitch skip prediction stop number Y (S122: YES), the CPU 91 executes a stitch skip avoidance process (S123) and returns the process to the first sewing process (see FIG. 13).

図１８を参照し、目飛び回避処理を説明する。目飛び回避処理は目飛びの発生を予知した時に回避制御を実行し、目飛びの発生を回避する為の処理である。ＣＰＵ９１は目飛び予知カウンタＶの値が１であるか否かを判断する（Ｓ１４１）。目飛び予知カウンタＶの値が１である時（Ｓ１４１：ＹＥＳ）、ＣＰＵ９１はスピーカ３９から音を出力することで回避制御の実行を報知する目飛び回避報知を実行する（Ｓ１４２）。ＣＰＵ９１は主モータ２７の回転速度を減速する（Ｓ１４３）。Ｓ１４３はＳ９３（図１６参照）と同様の処理である。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさを小さくし（Ｓ１４４）、処理をＳ１５１に移行する。Ｓ１４４はＳ９４（図１６参照）と同様の処理である。目飛びの発生を連続して予知し、目飛び予知カウンタＶの値が１より大きい時（Ｓ１４１：ＮＯ）、回避制御を実行中であるとして、ＣＰＵ９１は処理をＳ１５１に移行する。 The stitch skip avoidance process will be described with reference to FIG. 18. The stitch skip avoidance process is a process for executing avoidance control when the occurrence of a stitch skip is predicted, and for preventing the occurrence of a stitch skip. The CPU 91 judges whether the value of the stitch skip prediction counter V is 1 (S141). When the value of the stitch skip prediction counter V is 1 (S141: YES), the CPU 91 executes a stitch skip avoidance notification that notifies the execution of the avoidance control by outputting a sound from the speaker 39 (S142). The CPU 91 reduces the rotation speed of the main motor 27 (S143). S143 is the same process as S93 (see FIG. 16). The CPU 91 controls the thread tension motor 16 to reduce the magnitude of the upper thread tension applied by the main thread tensioner 22 (S144), and the process proceeds to S151. S144 is the same process as S94 (see FIG. 16). When the occurrence of skipped stitches is continuously predicted and the value of the skipped stitch prediction counter V is greater than 1 (S141: NO), it is determined that avoidance control is being executed, and the CPU 91 transitions to S151.

ＣＰＵ９１は目飛び予知カウンタＶの値が目飛び予知停止数Ｙの半分以上であるか否かを判断する（Ｓ１５１）。ＣＰＵ９１は目飛びの発生を連続して予知する時、予知が連続した回数（目飛び予知カウンタＶ）に応じて多段階で目飛びの発生の予知を報知する。目飛び予知カウンタＶの値が目飛び予知停止数Ｙの半分未満である時（Ｓ１５１：ＮＯ）、ＣＰＵ９１は第一目飛び予知報知を実行し（Ｓ１５２）、処理を第一目飛び予知処理（図１７参照）に戻す。第一目飛び予知報知において、ＣＰＵ９１は目飛びＬＥＤ７２を黄色で発光する。目飛びの発生を連続して予知し、目飛び予知カウンタＶの値が目飛び予知停止数Ｙの半分以上である時（Ｓ１５１：ＹＥＳ）、ＣＰＵ９１は第二目飛び予知報知を実行し（Ｓ１５３）、処理を第一目飛び予知処理に戻す。第二目飛び予知報知において、ＣＰＵ９１は目飛びＬＥＤ７２を橙色で発光する。 The CPU 91 judges whether the value of the stitch skip prediction counter V is equal to or greater than half the stitch skip prediction stop number Y (S151). When the CPU 91 predicts the occurrence of stitch skips continuously, it notifies the prediction of the occurrence of stitch skips in multiple stages according to the number of consecutive predictions (stitch skip prediction counter V). When the value of the stitch skip prediction counter V is less than half the stitch skip prediction stop number Y (S151: NO), the CPU 91 executes a first stitch skip prediction notification (S152) and returns the process to the first stitch skip prediction process (see FIG. 17). In the first stitch skip prediction notification, the CPU 91 causes the stitch skip LED 72 to emit yellow light. When the occurrence of stitch skips is predicted continuously and the value of the stitch skip prediction counter V is equal to or greater than half the stitch skip prediction stop number Y (S151: YES), the CPU 91 executes a second stitch skip prediction notification (S153) and returns the process to the first stitch skip prediction process. In the second stitch skip prediction notification, the CPU 91 causes the stitch skip LED 72 to emit orange light.

図１７の如く、第一張力が減少傾向にない（Ｓ１１１：ＮＯ）、又は第二張力が増加傾向になく（Ｓ１１２：ＮＯ）、第三移動量が減少傾向にない時（Ｓ１１３：ＮＯ）、ＣＰＵ９１は目飛びの発生を予知しないとして、処理をＳ１３１に移行する。ＣＰＵ９１は目飛び予知カウンタＶの値が１以上であるか否かを判断する（Ｓ１３１）。 As shown in FIG. 17, when the first tension is not decreasing (S111: NO), or the second tension is not increasing (S112: NO), or the third movement amount is not decreasing (S113: NO), the CPU 91 does not predict the occurrence of a skip and proceeds to S131. The CPU 91 determines whether the value of the skip prediction counter V is 1 or greater (S131).

目飛び予知カウンタＶの値が１以上である時（Ｓ１３１：ＹＥＳ）、ＣＰＵ９１は第一目飛び予知報知（Ｓ１５２、図１８参照）、第二目飛び予知報知（Ｓ１５３、図１８参照）を終了し、目飛びＬＥＤ７２を消灯する（Ｓ１３２）。ＣＰＵ９１は目飛び回避報知（Ｓ１４２、図１８参照）を終了し、スピーカ３９の音の出力を停止する（Ｓ１３３）。ＣＰＵ９１は主モータ２７の回転速度をＳ１４３（図１８参照）で減速する前の回転速度迄加速する（Ｓ１３４）。Ｓ１３４はＳ８４（図１５参照）と同様の処理である。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさをＳ１４４（図１８参照）で小さくする前の大きさ迄大きくする（Ｓ１３５）。Ｓ１３５はＳ８５（図１５参照）と同様の処理である。ＣＰＵ９１は目飛び予知カウンタＶの値を０にして（Ｓ１３６）、処理を第一縫製処理（図１３参照）に戻す。目飛び予知カウンタＶの値が０である時（Ｓ１３１：ＮＯ）、ＣＰＵ９１は処理を第一縫製処理に戻す。 When the value of the stitch skip prediction counter V is 1 or more (S131: YES), the CPU 91 ends the first stitch skip prediction notification (S152, see FIG. 18) and the second stitch skip prediction notification (S153, see FIG. 18), and turns off the stitch skip LED 72 (S132). The CPU 91 ends the stitch skip avoidance notification (S142, see FIG. 18), and stops the sound output from the speaker 39 (S133). The CPU 91 accelerates the rotation speed of the main motor 27 to the rotation speed before it was decelerated in S143 (see FIG. 18) (S134). S134 is the same process as S84 (see FIG. 15). The CPU 91 controls the thread tension motor 16 to increase the magnitude of the upper thread tension applied by the main thread tensioner 22 to the magnitude before it was reduced in S144 (see FIG. 18) (S135). S135 is the same process as S85 (see FIG. 15). The CPU 91 sets the value of the stitch skip prediction counter V to 0 (S136) and returns the process to the first sewing process (see FIG. 13). When the value of the stitch skip prediction counter V is 0 (S131: NO), the CPU 91 returns the process to the first sewing process.

縫製中、ＣＰＵ９１は第一目飛び予知処理を繰返し実行し、目飛びの発生の予知の有無を判定する。目飛びの発生を予知した時、ＣＰＵ９１は目飛び回避処理（Ｓ１２３）にて目飛びの発生を回避する回避制御を実行する。目飛び回避処理（Ｓ１２３）の実行後も連続して目飛びの発生を予知し、目飛び予知カウンタＶの値が目飛び予知停止数Ｙに到達した時（Ｓ１２２：ＮＯ）、ＣＰＵ９１は目飛び予知停止フラグを１に設定し（Ｓ１２４）、処理を第一縫製処理に戻す。 During sewing, the CPU 91 repeatedly executes the first stitch skip prediction process to determine whether or not a stitch skip has been predicted. When a stitch skip is predicted, the CPU 91 executes avoidance control to avoid the occurrence of a stitch skip in a stitch skip avoidance process (S123). Even after the execution of the stitch skip avoidance process (S123), the occurrence of a stitch skip is continuously predicted. When the value of the stitch skip prediction counter V reaches the stitch skip prediction stop number Y (S122: NO), the CPU 91 sets the stitch skip prediction stop flag to 1 (S124) and returns the process to the first sewing process.

図１９を参照し、第一締り不良予知処理を説明する。第一締り不良予知処理は締り不良の発生を予知する為の処理である。ＣＰＵ９１はＳ３４（図１３参照）で取得した五つの第一張力に基づいて、第一張力が増加傾向にあるか否かを判断する（Ｓ１６１）。第一張力が増加傾向にない時（Ｓ１６１：ＮＯ）、ＣＰＵ９１は処理をＳ１６２に移行する。第一張力が増加傾向にある時（Ｓ１６１：ＹＥＳ）、ＣＰＵ９１は処理をＳ１７１に移行する。 The first tightening failure prediction process will be described with reference to FIG. 19. The first tightening failure prediction process is a process for predicting the occurrence of a tightening failure. The CPU 91 determines whether the first tension is on an increasing trend (S161) based on the five first tensions acquired in S34 (see FIG. 13). If the first tension is not on an increasing trend (S161: NO), the CPU 91 transitions the process to S162. If the first tension is on an increasing trend (S161: YES), the CPU 91 transitions the process to S171.

ＣＰＵ９１はＳ３４で取得した五つの第一移動量に基づいて、第一移動量が増加傾向にあるか否かを判断する（Ｓ１６２）。第一移動量が増加傾向にない時（Ｓ１６２：ＮＯ）、ＣＰＵ９１は処理をＳ１８１に移行する。第一移動量が増加傾向にある時（Ｓ１６２：ＹＥＳ）、ＣＰＵ９１は処理をＳ１７１に移行する。 Based on the five first movement amounts acquired in S34, the CPU 91 determines whether the first movement amount is on an increasing trend (S162). If the first movement amount is not on an increasing trend (S162: NO), the CPU 91 transitions the process to S181. If the first movement amount is on an increasing trend (S162: YES), the CPU 91 transitions the process to S171.

第一張力が増加傾向にある時（Ｓ１６１：ＹＥＳ）、又は第一移動量が増加傾向にある時（Ｓ１６２：ＹＥＳ）、ＣＰＵ９１は締り不良の発生を予知したとして、締り不良予知カウンタＷの値に１を加算する（Ｓ１７１）。ＣＰＵ９１は締り不良予知カウンタＷの値が締り不良予知停止数Ｚ未満であるか否かを判断する（Ｓ１７２）。締り不良予知カウンタＷの値が締り不良予知停止数Ｚ未満である時（Ｓ１７２：ＹＥＳ）、ＣＰＵ９１は締り不良回避処理を実行し（Ｓ１７３）、処理を第一縫製処理（図１３参照）に戻す。 When the first tension is increasing (S161: YES), or when the first movement amount is increasing (S162: YES), the CPU 91 predicts the occurrence of a tightening failure and increments the value of the tightening failure prediction counter W by 1 (S171). The CPU 91 determines whether the value of the tightening failure prediction counter W is less than the tightening failure prediction stop number Z (S172). When the value of the tightening failure prediction counter W is less than the tightening failure prediction stop number Z (S172: YES), the CPU 91 executes a tightening failure avoidance process (S173) and returns the process to the first sewing process (see FIG. 13).

図２０を参照し、締り不良回避処理を説明する。締り不良回避処理は締り不良の発生を予知した時に回避制御を実行し、締り不良の発生を回避する為の処理である。ＣＰＵ９１は締り不良予知カウンタＷの値が１であるか否かを判断する（Ｓ１９１）。締り不良予知カウンタＷの値が１である時（Ｓ１９１：ＹＥＳ）、ＣＰＵ９１はスピーカ３９から音を出力することで回避制御の実行を報知する締り不良回避報知を実行する（Ｓ１９２）。ＣＰＵ９１は主モータ２７の回転速度を減速する（Ｓ１９３）。Ｓ１９３はＳ９３（図１６参照）と同様の処理である。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさを小さくし（Ｓ１９４）、処理をＳ２０１に移行する。Ｓ１９４はＳ９４（図１６参照）と同様の処理である。締り不良の発生を連続して予知し、締り不良予知カウンタＷの値が１より大きい時（Ｓ１９１：ＮＯ）、回避制御を実行中であるとして、ＣＰＵ９１は処理をＳ２０１に移行する。 The tightening failure avoidance process will be described with reference to FIG. 20. The tightening failure avoidance process is a process for executing avoidance control when the occurrence of a tightening failure is predicted, and for avoiding the occurrence of a tightening failure. The CPU 91 judges whether the value of the tightening failure prediction counter W is 1 or not (S191). When the value of the tightening failure prediction counter W is 1 (S191: YES), the CPU 91 executes a tightening failure avoidance notification that notifies the execution of the avoidance control by outputting a sound from the speaker 39 (S192). The CPU 91 reduces the rotation speed of the main motor 27 (S193). S193 is the same process as S93 (see FIG. 16). The CPU 91 controls the thread tension motor 16 to reduce the magnitude of the upper thread tension applied by the main thread tensioner 22 (S194), and the process proceeds to S201. S194 is the same process as S94 (see FIG. 16). When the occurrence of a tightening failure is continuously predicted and the value of the tightening failure prediction counter W is greater than 1 (S191: NO), it is determined that avoidance control is being executed, and the CPU 91 transitions to processing S201.

ＣＰＵ９１は締り不良予知カウンタＷの値が締り不良予知停止数Ｚの半分以上であるか否かを判断する（Ｓ２０１）。ＣＰＵ９１は締り不良の発生を連続して予知する時、予知が連続した回数に応じて多段階で締り不良の発生の予知を報知する。締り不良予知カウンタＷの値が締り不良予知停止数Ｚの半分未満である時（Ｓ２０１：ＮＯ）、ＣＰＵ９１は第一締り不良予知報知を実行し（Ｓ２０２）、処理を第一締り不良予知処理（図１９参照）に戻す。第一締り不良予知報知において、ＣＰＵ９１は締り不良ＬＥＤ７３を黄色で発光する。締り不良の発生を連続して予知し、締り不良予知カウンタＷの値が締り不良予知停止数Ｚの半分以上である時（Ｓ２０１：ＹＥＳ）、ＣＰＵ９１は第二締り不良予知報知を実行し（Ｓ２０３）、処理を第一締り不良予知処理に戻す。第二締り不良予知報知において、ＣＰＵ９１は締り不良ＬＥＤ７３を橙色で発光する。 The CPU 91 judges whether the value of the poor tightening prediction counter W is equal to or greater than half the number of poor tightening prediction stops Z (S201). When the CPU 91 predicts the occurrence of poor tightening continuously, it notifies the occurrence of poor tightening in multiple stages according to the number of consecutive predictions. When the value of the poor tightening prediction counter W is less than half the number of poor tightening prediction stops Z (S201: NO), the CPU 91 executes a first poor tightening prediction notification (S202) and returns the process to the first poor tightening prediction process (see FIG. 19). In the first poor tightening prediction notification, the CPU 91 causes the poor tightening LED 73 to emit yellow light. When the occurrence of poor tightening is predicted continuously and the value of the poor tightening prediction counter W is equal to or greater than half the number of poor tightening prediction stops Z (S201: YES), the CPU 91 executes a second poor tightening prediction notification (S203) and returns the process to the first poor tightening prediction process. In the second tightening failure prediction notification, the CPU 91 causes the tightening failure LED 73 to emit orange light.

図１９の如く、第一張力が増加傾向になく（Ｓ１６１：ＮＯ）、第一移動量が増加傾向にない時（Ｓ１６２：ＮＯ）、ＣＰＵ９１は締り不良の発生を予知しないとして、処理をＳ１８１に移行する。ＣＰＵ９１は締り不良予知カウンタＷの値が１以上であるか否かを判断する（Ｓ１８１）。 As shown in FIG. 19, when the first tension is not increasing (S161: NO) and the first movement amount is not increasing (S162: NO), the CPU 91 does not predict the occurrence of a tightening failure and shifts the process to S181. The CPU 91 determines whether the value of the tightening failure prediction counter W is 1 or greater (S181).

締り不良予知カウンタＷの値が１以上である時（Ｓ１８１：ＹＥＳ）、ＣＰＵ９１は第一締り不良予知報知（Ｓ２０２、図２０参照）、第二締り不良予知報知（Ｓ２０３、図２０参照）を終了し、締り不良ＬＥＤ７３を消灯する（Ｓ１８２）。ＣＰＵ９１は締り不良回避報知（Ｓ１９２、図２０参照）を終了し、スピーカ３９の音の出力を停止する（Ｓ１８３）。ＣＰＵ９１は主モータ２７の回転速度をＳ１９３（図２０参照）で減速する前の回転速度迄加速する（Ｓ１８４）。Ｓ１８４はＳ８４（図１５参照）と同様の処理である。ＣＰＵ９１は糸調子モータ１６を制御して主糸調子器２２が付与する上糸張力の大きさをＳ１９４（図２０参照）で小さくする前の大きさ迄大きくする（Ｓ１８５）。Ｓ１８５はＳ８５（図１５参照）と同様の処理である。ＣＰＵ９１は締り不良予知カウンタＷの値を０にして（Ｓ１８６）、処理を第一縫製処理（図１３参照）に戻す。締り不良予知カウンタＷの値が０である時（Ｓ１８１：ＮＯ）、ＣＰＵ９１は処理を第一縫製処理に戻す。 When the value of the tightening failure prediction counter W is 1 or more (S181: YES), the CPU 91 ends the first tightening failure prediction notification (S202, see FIG. 20) and the second tightening failure prediction notification (S203, see FIG. 20), and turns off the tightening failure LED 73 (S182). The CPU 91 ends the tightening failure avoidance notification (S192, see FIG. 20), and stops the sound output from the speaker 39 (S183). The CPU 91 accelerates the rotation speed of the main motor 27 to the rotation speed before it was decelerated in S193 (see FIG. 20) (S184). S184 is the same process as S84 (see FIG. 15). The CPU 91 controls the thread tension motor 16 to increase the magnitude of the upper thread tension applied by the main thread tensioner 22 to the magnitude before it was reduced in S194 (see FIG. 20) (S185). S185 is the same process as S85 (see FIG. 15). The CPU 91 sets the value of the tightening failure prediction counter W to 0 (S186) and returns the process to the first sewing process (see FIG. 13). When the value of the tightening failure prediction counter W is 0 (S181: NO), the CPU 91 returns the process to the first sewing process.

縫製中、ＣＰＵ９１は第一締り不良予知処理を繰返し実行し、締り不良の発生の予知の有無を判定する。締り不良の発生を予知した時、ＣＰＵ９１は締り不良回避処理（Ｓ１７３）にて締り不良の発生を回避する回避制御を実行する。締り不良回避処理（Ｓ１７３）の実行後も連続して締り不良の発生を予知し、締り不良予知カウンタＷの値が締り不良予知停止数Ｚに到達した時（Ｓ１７２：ＮＯ）、ＣＰＵ９１は締り不良予知停止フラグを１に設定し（Ｓ１７４）、処理を第一縫製処理に戻す。 During sewing, the CPU 91 repeatedly executes the first tightening failure prediction process to determine whether or not the occurrence of a tightening failure has been predicted. When the occurrence of a tightening failure is predicted, the CPU 91 executes avoidance control to avoid the occurrence of a tightening failure in the tightening failure avoidance process (S173). When the occurrence of a tightening failure continues to be predicted even after the tightening failure avoidance process (S173) is executed, and the value of the tightening failure prediction counter W reaches the tightening failure prediction stop number Z (S172: NO), the CPU 91 sets the tightening failure prediction stop flag to 1 (S174) and returns the process to the first sewing process.

図１３の如く、第一締り不良予知処理（Ｓ３７）の実行後、ＣＰＵ９１は糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグの何れかが１であるか否かを判断する（Ｓ３８）。糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグが何れも０である時（Ｓ３８：ＮＯ）、ＣＰＵ９１は処理をＳ２３に移行する。 As shown in FIG. 13, after the first tightening failure prediction process (S37) is executed, the CPU 91 judges whether any of the yarn breakage prediction stop flag, the stitch skip prediction stop flag, and the tightening failure prediction stop flag is 1 (S38). When the yarn breakage prediction stop flag, the stitch skip prediction stop flag, and the tightening failure prediction stop flag are all 0 (S38: NO), the CPU 91 shifts the process to S23.

ＣＰＵ９１はＳ２１～Ｓ２３を繰返し実行する。ペダル３８からＯＦＦ信号を受信した時、ＣＰＵ９１は縫製を終了すると判断する（Ｓ２３：ＹＥＳ）。ＣＰＵ９１は、ソレノイド１７Ａを制御して糸切りを実行する（Ｓ４１）。ＣＰＵ９１は駆動部の駆動を停止する（Ｓ４２）。ミシン１は縫製を終了する。ＣＰＵ９１は処理をＳ４４に移行する。 The CPU 91 repeatedly executes S21 to S23. When an OFF signal is received from the pedal 38, the CPU 91 determines that sewing is to end (S23: YES). The CPU 91 controls the solenoid 17A to perform thread cutting (S41). The CPU 91 stops driving the drive unit (S42). The sewing machine 1 ends sewing. The CPU 91 proceeds to S44.

回避制御を実行した後、更に連続して縫製不良の発生を予知する時がある。該時、糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグの何れかは１となる（図１５、図１７、図１９参照）。糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグの何れかが１である時（Ｓ３８：ＹＥＳ）、ＣＰＵ９１は予知停止処理を実行し（Ｓ４３）、処理をＳ４４に移行する。 After executing the avoidance control, there may be cases where further occurrences of sewing defects are predicted. At that time, any one of the thread breakage prediction stop flag, the stitch skip prediction stop flag, and the tightness defect prediction stop flag becomes 1 (see FIG. 15, FIG. 17, and FIG. 19). When any one of the thread breakage prediction stop flag, the stitch skip prediction stop flag, and the tightness defect prediction stop flag is 1 (S38: YES), the CPU 91 executes prediction stop processing (S43) and proceeds to S44.

図２１を参照し、予知停止処理を説明する。予知停止処理は回避制御を実行後、更に連続して縫製不良の発生を予知する時に縫製を停止する為の処理である。ＣＰＵ９１は連続して発生の予知をした縫製不良が糸切れであるか否かを判断する（Ｓ２１１）。 The prediction stop process will be described with reference to FIG. 21. The prediction stop process is a process for stopping sewing when the occurrence of a sewing defect is predicted continuously after the avoidance control has been executed. The CPU 91 determines whether the sewing defect that has been predicted to occur continuously is a thread break (S211).

糸切れ予知停止フラグが１であり、連続して発生の予知をした縫製不良が糸切れである時（Ｓ２１１：ＹＥＳ）、ＣＰＵ９１は第一糸切れ予知報知、第二糸切れ予知報知を終了する（Ｓ２１２）。ＣＰＵ９１は糸切れ回避報知を終了する（Ｓ２１３）。ＣＰＵ９１は糸切れ予知停止報知を実行する（Ｓ２１４）。糸切れ予知停止報知において、ＣＰＵ９１は糸切れＬＥＤ７１を赤色で発光し、スピーカ３９から音を出力する。ＣＰＵ９１は処理をＳ２４１に移行する。 When the thread breakage prediction stop flag is 1 and the consecutively predicted sewing defects are thread breakages (S211: YES), the CPU 91 ends the first thread breakage prediction notification and the second thread breakage prediction notification (S212). The CPU 91 ends the thread breakage avoidance notification (S213). The CPU 91 executes a thread breakage prediction stop notification (S214). In the thread breakage prediction stop notification, the CPU 91 causes the thread breakage LED 71 to emit red light and outputs a sound from the speaker 39. The CPU 91 transitions to S241.

糸切れ予知停止フラグが０であり、連続して発生の予知をした縫製不良が糸切れでない時（Ｓ２１１：ＮＯ）、ＣＰＵ９１は連続して発生の予知をした縫製不良が目飛びであるか否かを判断する（Ｓ２２１）。目飛び予知停止フラグが１であり、連続して発生の予知をした縫製不良が目飛びである時（Ｓ２２１：ＹＥＳ）、ＣＰＵ９１は第一目飛び予知報知、第二目飛び予知報知を終了する（Ｓ２２２）。ＣＰＵ９１は目飛び回避報知を終了する（Ｓ２２３）。ＣＰＵ９１は目飛び予知停止報知を実行する（Ｓ２２４）。目飛び予知停止報知において、ＣＰＵ９１は目飛びＬＥＤ７２を赤色で発光し、スピーカ３９から音を出力する。ＣＰＵ９１は処理をＳ２４１に移行する。 When the thread breakage prediction stop flag is 0 and the consecutively predicted sewing defects are not thread breakage (S211: NO), the CPU 91 judges whether the consecutively predicted sewing defects are stitch skips (S221). When the stitch skip prediction stop flag is 1 and the consecutively predicted sewing defects are stitch skips (S221: YES), the CPU 91 ends the first stitch skip prediction notification and the second stitch skip prediction notification (S222). The CPU 91 ends the stitch skip avoidance notification (S223). The CPU 91 executes a stitch skip prediction stop notification (S224). In the stitch skip prediction stop notification, the CPU 91 causes the stitch skip LED 72 to emit red light and outputs a sound from the speaker 39. The CPU 91 transitions to S241.

糸切れ予知停止フラグ、目飛び予知停止フラグが何れも０であり、連続して発生の予知をした縫製不良が締り不良である時（Ｓ２２１：ＮＯ）、ＣＰＵ９１は第一締り不良予知報知、第二締り不良予知報知を終了する（Ｓ２３２）。ＣＰＵ９１は締り不良回避報知を終了する（Ｓ２３３）。ＣＰＵ９１は締り不良予知停止報知を実行する（Ｓ２３４）。締り不良予知停止報知において、ＣＰＵ９１は締り不良ＬＥＤ７３を赤色で発光し、スピーカ３９から音を出力する。ＣＰＵ９１は処理をＳ２４１に移行する。 When the thread breakage prediction stop flag and the stitch skip prediction stop flag are both 0 and the consecutively predicted sewing defects are tightness defects (S221: NO), the CPU 91 ends the first tightness defect prediction notification and the second tightness defect prediction notification (S232). The CPU 91 ends the tightness defect avoidance notification (S233). The CPU 91 executes a tightness defect prediction stop notification (S234). In the tightness defect prediction stop notification, the CPU 91 causes the tightness defect LED 73 to emit red light and outputs a sound from the speaker 39. The CPU 91 proceeds to S241.

ＣＰＵ９１は駆動部の駆動を停止する（Ｓ２４１）。ミシン１は縫製を終了する。ＣＰＵ９１は処理を第一縫製処理（図１３参照）に戻す。 The CPU 91 stops driving the drive unit (S241). The sewing machine 1 ends sewing. The CPU 91 returns the process to the first sewing process (see FIG. 13).

図１３の如く、ＣＰＵ９１はミシン１の電源をＯＦＦする操作があるか否かを判断する（Ｓ４４）。ミシン１の電源をＯＦＦにする操作がないと判断した時（Ｓ４４：ＮＯ）、ＣＰＵ９１は処理をＳ１（図１２参照）に戻す。作業者は縫製後の布６９に替えて、未縫製の布６９を針板７に載置し、ペダル３８を操作して（Ｓ１１：ＹＥＳ）、縫製を再開する。ミシン１の電源をＯＦＦにする操作があると判断した時（Ｓ４４：ＹＥＳ）、ＣＰＵ９１は第一縫製処理を終了する。 As shown in FIG. 13, the CPU 91 determines whether or not there has been an operation to turn off the power of the sewing machine 1 (S44). When it is determined that there has been no operation to turn off the power of the sewing machine 1 (S44: NO), the CPU 91 returns the process to S1 (see FIG. 12). The operator places unsewn cloth 69 on the needle plate 7 in place of the sewn cloth 69, and operates the pedal 38 (S11: YES) to resume sewing. When it is determined that there has been an operation to turn off the power of the sewing machine 1 (S44: YES), the CPU 91 ends the first sewing process.

以上の如く、第一縫製処理を実行する時、ＣＰＵ９１は縫製中に周期的に変動する変動張力、変動移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５１）。ＣＰＵ９１はＲＡＭ９３に記憶の変動張力、変動移動量から特徴量を取得する（Ｓ３４）。ＣＰＵ９１は取得した特徴量の推移に基づき縫製不良の発生を予知する（Ｓ３５～Ｓ３７）。故にミシン１は縫製不良の発生を未然に防ぐことができる。 As described above, when the first sewing process is executed, the CPU 91 acquires the fluctuating tension and fluctuating movement amount that fluctuate periodically during sewing, and stores them in the RAM 93 (S51). The CPU 91 acquires characteristic amounts from the fluctuating tension and fluctuating movement amount stored in the RAM 93 (S34). The CPU 91 predicts the occurrence of sewing defects based on the progress of the acquired characteristic amounts (S35 to S37). Therefore, the sewing machine 1 can prevent the occurrence of sewing defects in advance.

ＣＰＵ９１は一針分の縫製期間を予知単位とした特徴量の推移に基づき縫製不良の発生を予知する。特徴量は予知単位で周期的に変動する。ミシン１は予知単位での特徴量の推移に依り予知するので、縫製不良の発生を未然に防ぐ精度を向上できる。 The CPU 91 predicts the occurrence of sewing defects based on the transition of the feature amount, with the sewing period of one stitch being the prediction unit. The feature amount fluctuates periodically in the prediction unit. The sewing machine 1 makes predictions based on the transition of the feature amount in the prediction unit, thereby improving the accuracy of preventing the occurrence of sewing defects.

特徴量は一針分の縫製期間における天秤引上期間、釜捕捉期間、縫針１０の上死点に到達時の変動張力、変動移動量に基づく第一張力、第二張力、第一移動量、第二移動量、第三移動量である。第一張力、第二張力、第一移動量、第二移動量、第三移動量夫々は縫製不良の発生前に変動して特徴を示す量である。故にミシン１は縫製不良の発生を未然に防ぐ精度を向上できる。 The characteristic quantities are the thread take-up period during the sewing period for one stitch, the shuttle capture period, the fluctuating tension when the sewing needle 10 reaches the top dead point, and the first tension, second tension, first movement amount, second movement amount, and third movement amount based on the fluctuating movement amount. The first tension, second tension, first movement amount, second movement amount, and third movement amount are quantities that fluctuate before a sewing defect occurs and indicate characteristics. Therefore, the sewing machine 1 can improve the accuracy of preventing the occurrence of sewing defects.

特徴量である第一張力、第二張力、第一移動量、第二移動量は天秤引上期間、釜捕捉期間における変動張力、変動移動量の大きさである。特徴量である第三移動量は一針分の縫製期間における変動移動量の大きさである。第一張力、第二張力、第一移動量、第二移動量、第三移動量夫々は縫製不良の発生前に変動して特徴を示す量である。故にミシン１は縫製不良の発生を未然に防ぐ精度を向上できる。 The characteristic quantities, first tension, second tension, first movement amount, and second movement amount, are the magnitude of the fluctuating tension and fluctuating movement amount during the period when the thread take-up lever is raised and the period when the hook is captured. The characteristic quantity, third movement amount, is the magnitude of the fluctuating movement amount during the sewing period of one stitch. The first tension, second tension, first movement amount, second movement amount, and third movement amount are each quantities that fluctuate before a sewing defect occurs and indicate characteristics. Therefore, the sewing machine 1 can improve the accuracy of preventing the occurrence of sewing defects.

ＣＰＵ９１は縫製不良の発生を予知する時、糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷにて縫製不良の発生を連続で予知する回数を計数する（Ｓ７１、Ｓ１２１、Ｓ１７１）。ＣＰＵ９１は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷの値が大きい程、縫製不良の発生する可能性が高いと判断する。ミシン１は縫製不良の発生を予知する時に糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷにて予知レベルを認識する。ミシン１は縫製不良が発生する可能性を複数段階で予知できるので、縫製不良の発生を未然に防ぐ精度を向上できる。 When predicting the occurrence of a sewing defect, the CPU 91 counts the number of consecutive predictions of the occurrence of a sewing defect using the thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness defect prediction counter W (S71, S121, S171). The CPU 91 determines that the greater the value of the thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness defect prediction counter W, the greater the possibility of the occurrence of a sewing defect. When predicting the occurrence of a sewing defect, the sewing machine 1 recognizes the prediction level using the thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness defect prediction counter W. Since the sewing machine 1 can predict the possibility of the occurrence of a sewing defect at multiple levels, the accuracy of preventing the occurrence of a sewing defect can be improved.

ＣＰＵ９１は磁気センサ５３の検出結果に基づいて上糸張力を取得する。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて上糸移動量を取得する。ＣＰＵ９１は一針分の縫製期間で変動する上糸張力、上糸移動量の特徴量である第一張力、第二張力、第一移動量、第二移動量、第三移動量の予知単位あたりの推移に基づき縫製不良の発生を予知する。ＣＰＵ９１は上糸張力を磁気センサ５３の検出結果に基づき容易に取得できる。ＣＰＵ９１は上糸移動量をエンコーダ１６Ａの検出結果に基づいて容易に取得できる。故にミシン１は縫製不良の発生を未然に防ぐことが容易になる。 The CPU 91 obtains the upper thread tension based on the detection result of the magnetic sensor 53. The CPU 91 obtains the upper thread movement amount based on the detection result of the encoder 16A. The CPU 91 predicts the occurrence of sewing defects based on the trends per prediction unit of the first tension, second tension, first movement amount, second movement amount, and third movement amount, which are characteristic amounts of the upper thread tension and upper thread movement amount that fluctuate during the sewing period of one stitch. The CPU 91 can easily obtain the upper thread tension based on the detection result of the magnetic sensor 53. The CPU 91 can easily obtain the upper thread movement amount based on the detection result of the encoder 16A. This makes it easy for the sewing machine 1 to prevent the occurrence of sewing defects.

縫製不良は糸切れを含む。ＣＰＵ９１は上糸張力、上糸移動量の特徴量である第一張力、第二張力、第一移動量、第二移動量の予知単位あたりの推移に基づき糸切れの発生を予知する（Ｓ６１～Ｓ６４）ので、推移を比較し易い。故にミシン１は糸切れの発生を未然に防ぐことができる。 Sewing defects include thread breakage. The CPU 91 predicts thread breakage based on the trends per prediction unit of the first tension, second tension, first movement amount, and second movement amount, which are characteristic quantities of the upper thread tension and the upper thread movement amount (S61 to S64), making it easy to compare the trends. Therefore, the sewing machine 1 can prevent thread breakage from occurring.

縫製不良は目飛びを含む。ＣＰＵ９１は上糸張力、上糸移動量の特徴量である第一張力、第二張力、第三移動量の予知単位あたりの推移に基づき目飛びの発生を予知する（Ｓ１１１～Ｓ１１３）ので、推移を比較し易い。故にミシン１は目飛びの発生を未然に防ぐことができる。 Sewing defects include skipped stitches. The CPU 91 predicts the occurrence of skipped stitches based on the trends per prediction unit of the first tension, second tension, and third movement amount, which are characteristic quantities of the upper thread tension and the upper thread movement amount (S111 to S113), making it easy to compare the trends. Therefore, the sewing machine 1 can prevent the occurrence of skipped stitches.

縫製不良は締り不良を含む。ＣＰＵ９１は上糸張力、上糸移動量の特徴量である第一張力、第一移動量の予知単位あたりの推移に基づき締り不良の発生を予知する（Ｓ１６１、Ｓ１６２）ので、推移を比較し易い。故にミシン１は締り不良の発生を未然に防ぐことができる。 Sewing defects include tightening defects. The CPU 91 predicts the occurrence of tightening defects based on the trends in the first tension and first movement amount, which are characteristic quantities of the upper thread tension and the upper thread movement amount, per prediction unit (S161, S162), making it easy to compare the trends. Therefore, the sewing machine 1 can prevent the occurrence of tightening defects in advance.

ＣＰＵ９１は天秤引上期間における上糸張力の第一張力、釜捕捉期間における上糸張力の第二張力夫々が増加傾向にある時（Ｓ６１：ＹＥＳ、Ｓ６２：ＹＥＳ）、糸切れの発生を予知する。ＣＰＵ９１は天秤引上期間における上糸移動量の第一移動量、釜捕捉期間における上糸移動量の第二移動量夫々が減少傾向にある時（Ｓ６３：ＹＥＳ、Ｓ６４：ＹＥＳ）、糸切れの発生を予知する。第一張力、第二張力、第一移動量、第二移動量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。ミシン１は第一張力、第二張力、第一移動量、第二移動量の推移に基づき糸切れの発生を予知するので、糸切れの発生を未然に防ぐ精度を向上できる。 The CPU 91 predicts thread breakage when the first tension of the needle thread during the thread take-up period and the second tension of the needle thread during the hook capture period tend to increase (S61: YES, S62: YES). The CPU 91 predicts thread breakage when the first movement amount of the needle thread during the thread take-up period and the second movement amount of the needle thread during the hook capture period tend to decrease (S63: YES, S64: YES). If the first tension, second tension, first movement amount, and second movement amount change from normal sewing, this is likely to lead to poor sewing. The sewing machine 1 predicts thread breakage based on the changes in the first tension, second tension, first movement amount, and second movement amount, and therefore can improve the accuracy of preventing thread breakage.

ＣＰＵ９１は天秤引上期間における上糸張力の第一張力が減少傾向にある時（Ｓ１１１：ＹＥＳ）、目飛びの発生を予知する。ＣＰＵ９１は一針分の縫製期間の上糸移動量である第三移動量が減少傾向にある時（Ｓ１１３：ＹＥＳ）、目飛びの発生を予知する。第一張力、第三移動量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。ミシン１は第一張力、第三移動量の推移に基づき目飛びの発生を予知するので、目飛びの発生を未然に防ぐ精度を向上できる。 The CPU 91 predicts the occurrence of a skipped stitch when the first tension of the needle thread tension during the thread take-up lift period is on a decreasing trend (S111: YES). The CPU 91 predicts the occurrence of a skipped stitch when the third movement amount, which is the needle thread movement amount during the sewing period for one stitch, is on a decreasing trend (S113: YES). If the first tension and the third movement amount change from those during normal sewing, this is likely to lead to poor sewing. Since the sewing machine 1 predicts the occurrence of a skipped stitch based on the changes in the first tension and the third movement amount, the accuracy of preventing skipped stitches can be improved.

ＣＰＵ９１は天秤引上期間における上糸張力の第一張力が減少傾向にあり（Ｓ１１１：ＹＥＳ）、且つ釜捕捉期間における上糸張力の第二張力が増加傾向にある時（Ｓ１１２：ＹＥＳ）、目飛びの発生を予知する。第一張力、第二張力は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。ミシン１は第一張力、第二張力の推移に基づき目飛びの発生を予知するので、目飛びの発生を未然に防ぐ精度を向上できる。 When the first tension of the needle thread tension during the thread take-up period is on a decreasing trend (S111: YES) and the second tension of the needle thread tension during the hook capture period is on an increasing trend (S112: YES), the CPU 91 predicts the occurrence of a skipped stitch. If the first tension and the second tension change from the normal sewing time, this can easily lead to poor sewing. Since the sewing machine 1 predicts the occurrence of a skipped stitch based on the changes in the first tension and the second tension, the accuracy of preventing the occurrence of skipped stitches can be improved.

ＣＰＵ９１は天秤引上期間における上糸張力の第一張力が増加傾向にある時（Ｓ１６１：ＹＥＳ）、締り不良の発生を予知する。ＣＰＵ９１は天秤引上期間における上糸移動量の第一移動量が増加傾向にある時（Ｓ１６２：ＹＥＳ）、締り不良の発生を予知する。第一張力、第一移動量は、正常な縫製時に対して変化すると縫製不良の発生につながりやすい。ミシン１は第一張力、第一移動量の推移に基づき締り不良の発生を予知するので、締り不良の発生を未然に防ぐ精度を向上できる。 The CPU 91 predicts the occurrence of a tightening defect when the first tension of the upper thread tension during the lever pull-up period is on the rise (S161: YES). The CPU 91 predicts the occurrence of a tightening defect when the first movement amount of the upper thread movement amount during the lever pull-up period is on the rise (S162: YES). If the first tension and the first movement amount change from those during normal sewing, this is likely to lead to the occurrence of a sewing defect. Since the sewing machine 1 predicts the occurrence of a tightening defect based on the changes in the first tension and the first movement amount, the accuracy of preventing the occurrence of a tightening defect can be improved.

縫製不良の発生を予知した時、ＣＰＵ９１は駆動部を制御して縫製不良の発生を回避する回避制御を実行する（Ｓ７３、Ｓ１２３、Ｓ１７３）。縫製不良の発生を予知する時、ＣＰＵ９１は回避制御を実行することで縫製不良の発生を回避する。故にミシン１は縫製不良の発生を未然に防ぐことができる。 When the occurrence of a sewing defect is predicted, the CPU 91 controls the drive unit to execute avoidance control to prevent the occurrence of the sewing defect (S73, S123, S173). When the occurrence of a sewing defect is predicted, the CPU 91 executes avoidance control to prevent the occurrence of the sewing defect. Therefore, the sewing machine 1 can prevent the occurrence of the sewing defect in advance.

縫製不良の発生を予知した時、回避制御としてＣＰＵ９１は主モータ２７の回転速度を減速する（Ｓ９３、Ｓ１４３、Ｓ１９３）。主モータ２７の回転速度を減速することで、特徴量の単位あたりの変動が小さくなる。故にミシン１は縫製不良の発生を未然に防ぐ精度を向上できる。 When the occurrence of a sewing defect is predicted, the CPU 91 reduces the rotation speed of the main motor 27 as a preventive control (S93, S143, S193). By reducing the rotation speed of the main motor 27, the fluctuation per unit of the characteristic amount becomes smaller. Therefore, the sewing machine 1 can improve the accuracy of preventing the occurrence of sewing defects.

縫製不良の発生を予知した時、回避制御に依りＣＰＵ９１は主糸調子器２２が付与する上糸張力の大きさを小さくする（Ｓ９４、Ｓ１４４、Ｓ１９４）。主糸調子器２２が付与する上糸張力の変動を制御できるので、特徴量の単位あたりの変動が小さくなる。故にミシン１は縫製不良の発生を未然に防ぐ精度を向上できる。 When the occurrence of a sewing defect is predicted, the CPU 91 reduces the magnitude of the upper thread tension applied by the main thread tensioner 22 through avoidance control (S94, S144, S194). Since the fluctuation in the upper thread tension applied by the main thread tensioner 22 can be controlled, the fluctuation per unit of the characteristic quantity is reduced. Therefore, the sewing machine 1 can improve the accuracy of preventing the occurrence of sewing defects.

回避制御を実行した後、更に連続して縫製不良の発生を予知する時、ＣＰＵ９１は予知停止処理を実行し（Ｓ４３）、駆動部の駆動を停止する（Ｓ２４１）。回避制御を実行後でも、縫製不良の発生を予知する時、ＣＰＵ９１は駆動部を停止することで縫製を中止する。故にミシン１は回避できない縫製不良の発生を予知した時に縫製不良の発生を未然に防ぐことができる。 When the occurrence of a sewing defect is predicted continuously after the avoidance control is executed, the CPU 91 executes a prediction stop process (S43) and stops the drive unit (S241). When the occurrence of a sewing defect is predicted even after the avoidance control is executed, the CPU 91 stops sewing by stopping the drive unit. Therefore, when the sewing machine 1 predicts the occurrence of an unavoidable sewing defect, it can prevent the occurrence of the sewing defect in advance.

糸切れの発生を予知した時、ＣＰＵ９１は糸切れＬＥＤ７１を発光する第一糸切れ予知報知（Ｓ１０２）、第二糸切れ予知報知（Ｓ１０３）を実行する。目飛びの発生を予知した時、ＣＰＵ９１は目飛びＬＥＤ７２を発光する第一目飛び予知報知（Ｓ１５２）、第二目飛び予知報知（Ｓ１５３）を実行する。締り不良の発生を予知した時、ＣＰＵ９１は締り不良ＬＥＤ７３を発光する第一締り不良予知報知（Ｓ２０２）、第二締り不良予知報知（Ｓ２０３）を実行する。故にミシン１作業者が縫製不良の発生を予知したことを把握できる。 When the occurrence of thread breakage is predicted, the CPU 91 executes a first thread breakage prediction notification (S102) and a second thread breakage prediction notification (S103) by illuminating the thread breakage LED 71. When the occurrence of a stitch skip is predicted, the CPU 91 executes a first stitch skip prediction notification (S152) and a second stitch skip prediction notification (S153) by illuminating the stitch skip LED 72. When the occurrence of a tightening defect is predicted, the CPU 91 executes a first tightening defect prediction notification (S202) and a second tightening defect prediction notification (S203) by illuminating the tightening defect LED 73. Therefore, the operator of the sewing machine 1 can know that the occurrence of a sewing defect has been predicted.

ＣＰＵ９１は糸切れの発生を連続して予知する時、糸切れ予知カウンタＵの値に応じて第一糸切れ予知報知（Ｓ１０２）、第二糸切れ予知報知（Ｓ１０３）の何れか一方を実行する。ＣＰＵ９１は目飛びの発生を連続して予知する時、目飛び予知カウンタＶの値に応じて第一目飛び予知報知（Ｓ１５２）、第二目飛び予知報知（Ｓ１５３）の何れか一方を実行する。ＣＰＵ９１は締り不良の発生を連続して予知する時、締り不良予知カウンタＷの値に応じて第一締り不良予知報知（Ｓ２０２）、第二締り不良予知報知（Ｓ２０３）の何れか一方を実行する。ミシン１は縫製不良の発生を予知する時に糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷにて予知レベルを認識する。ＣＰＵ９１は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷの値に応じて多段階で縫製不良の発生の予知を報知する。故にミシン１は縫製不良が発生する可能性の度合を作業者が把握できる。 When the CPU 91 continuously predicts the occurrence of thread breakage, it executes either the first thread breakage prediction notification (S102) or the second thread breakage prediction notification (S103) according to the value of the thread breakage prediction counter U. When the CPU 91 continuously predicts the occurrence of stitch skipping, it executes either the first stitch skip prediction notification (S152) or the second stitch skip prediction notification (S153) according to the value of the stitch skip prediction counter V. When the CPU 91 continuously predicts the occurrence of tightening defects, it executes either the first tightening defect prediction notification (S202) or the second tightening defect prediction notification (S203) according to the value of the tightening defect prediction counter W. When the sewing machine 1 predicts the occurrence of sewing defects, it recognizes the prediction level using the thread breakage prediction counter U, stitch skip prediction counter V, and tightening defect prediction counter W. The CPU 91 notifies the operator of the occurrence of sewing defects in multiple stages according to the values of the thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness defect prediction counter W. Therefore, the sewing machine 1 allows the operator to grasp the degree of possibility of occurrence of sewing defects.

糸切れの発生を回避する糸切れ回避処理を実行した時、ＣＰＵ９１はスピーカ３９から音を出力する糸切れ回避報知（Ｓ９２）を実行する。目飛びの発生を回避する目飛び回避処理を実行した時、ＣＰＵ９１はスピーカ３９から音を出力する目飛び回避報知（Ｓ１４２）を実行する。締り不良の発生を回避する締り不良回避処理を実行した時、ＣＰＵ９１はスピーカ３９から音を出力する締り不良回避報知（Ｓ１９２）を実行する。ミシン１は縫製不良の発生を予知した時に縫製不良の発生を回避することを、作業者が把握できる。 When thread breakage avoidance processing is executed to avoid the occurrence of thread breakage, the CPU 91 executes a thread breakage avoidance notification (S92) that outputs a sound from the speaker 39. When stitch skip avoidance processing is executed to avoid the occurrence of stitch skipping, the CPU 91 executes a stitch skip avoidance notification (S142) that outputs a sound from the speaker 39. When tightening defect avoidance processing is executed to avoid the occurrence of tightening defects, the CPU 91 executes a tightening defect avoidance notification (S192) that outputs a sound from the speaker 39. The operator can know that the sewing machine 1 will avoid the occurrence of a sewing defect when it predicts the occurrence of a sewing defect.

糸切れの発生を連続して予知し、駆動部の駆動を停止する時、ＣＰＵ９１は糸切れＬＥＤ７１を発光し、スピーカ３９から音を出力する糸切れ予知停止報知（Ｓ２１４）を実行する。目飛びの発生を連続して予知し、駆動部の駆動を停止する時、ＣＰＵ９１は目飛びＬＥＤ７２を発光し、スピーカ３９から音を出力する目飛び予知停止報知（Ｓ２２４）を実行する。締り不良の発生を連続して予知し、駆動部の駆動を停止する時、ＣＰＵ９１は締り不良ＬＥＤ７３を発光し、スピーカ３９から音を出力する締り不良予知停止報知（Ｓ２３４）を実行する。故にミシン１は回避できない縫製不良の発生の予知により縫製を停止したことを、作業者が把握できる。 When continuously predicting thread breakage and stopping the drive unit, the CPU 91 executes a thread breakage prediction stop notification (S214) in which the thread breakage LED 71 is illuminated and a sound is output from the speaker 39. When continuously predicting stitch skipping and stopping the drive unit, the CPU 91 executes a stitch skip prediction stop notification (S224) in which the stitch skip LED 72 is illuminated and a sound is output from the speaker 39. When continuously predicting tightness defects and stopping the drive unit, the CPU 91 executes a tightness defect prediction stop notification (S234) in which the tightness defect LED 73 is illuminated and a sound is output from the speaker 39. Therefore, the operator can know that the sewing machine 1 has stopped sewing due to a prediction of an unavoidable sewing defect.

図１２、図２２～図２４を参照し、ミシン１の第二縫製処理を説明する。作業者はミシン１の電源をＯＮし、入力部２４を操作して第二縫製処理の実行指示を入力する。第二縫製処理の実行指示の入力を検知した時、ＣＰＵ９１はＲＯＭ９２からプログラムを読み出して第二縫製処理を開始する。 The second sewing process of the sewing machine 1 will be described with reference to Figures 12 and 22 to 24. The operator turns on the power of the sewing machine 1 and operates the input unit 24 to input an instruction to execute the second sewing process. When the input of an instruction to execute the second sewing process is detected, the CPU 91 reads a program from the ROM 92 and starts the second sewing process.

第二縫製処理において、累積針落ち数Ｌの値が所定の予知実行数Ｍの倍数である時、縫製不良の発生を予知する。即ち、第二縫製処理における予知単位は予知実行数Ｍである。ＣＰＵ９１は一針分の縫製期間において第一張力、第二張力、第一移動量、第二移動量、第三移動量を取得する。ＣＰＵ９１は取得した第一張力、第二張力、第一移動量、第二移動量、第三移動量夫々の予知単位における平均値を算出し、ＲＡＭ９３に記憶する。第一張力、第二張力、第一移動量、第二移動量、第三移動量の予知単位における平均値を平均第一張力、平均第二張力、平均第一移動量、平均第二移動量、平均第三移動量と夫々称す。 In the second sewing process, when the value of the cumulative number of needle drops L is a multiple of a predetermined number of predicted executions M, the occurrence of a sewing defect is predicted. That is, the prediction unit in the second sewing process is the number of predicted executions M. The CPU 91 acquires the first tension, second tension, first movement amount, second movement amount, and third movement amount during the sewing period of one stitch. The CPU 91 calculates the average value in the prediction unit of each of the acquired first tension, second tension, first movement amount, second movement amount, and third movement amount, and stores them in the RAM 93. The average values in the prediction unit of the first tension, second tension, first movement amount, second movement amount, and third movement amount are referred to as the average first tension, average second tension, average first movement amount, average second movement amount, and average third movement amount, respectively.

平均第一張力、平均第二張力、平均第一移動量、平均第二移動量、平均第三移動量は第二縫製処理における特徴量である。第二縫製処理において、ＣＰＵ９１は平均第一張力、平均第二張力が増加傾向にある時、又は平均第一移動量、平均第二移動量が減少傾向にある時、糸切れの発生を予知する。ＣＰＵ９１は平均第一張力が減少傾向にあり且つ平均第二張力が増加傾向にある時、又は平均第三移動量が減少傾向にある時、目飛びの発生を予知する。ＣＰＵ９１は平均第一張力が増加傾向にある時、又は平均第一移動量が増加傾向にある時、締り不良の発生を予知する。 The average first tension, the average second tension, the average first movement amount, the average second movement amount, and the average third movement amount are characteristic quantities in the second sewing process. In the second sewing process, the CPU 91 predicts the occurrence of thread breakage when the average first tension and the average second tension are on an increasing trend, or when the average first movement amount and the average second movement amount are on a decreasing trend. The CPU 91 predicts the occurrence of skipped stitches when the average first tension is on a decreasing trend and the average second tension is on an increasing trend, or when the average third movement amount is on a decreasing trend. The CPU 91 predicts the occurrence of poor tightening when the average first tension is on an increasing trend, or when the average first movement amount is on an increasing trend.

ＣＰＵ９１が第二縫製処理で使用するフラグは第一縫製処理と同じである。第二縫製処理で糸切れ予知カウンタＵを使用しないことを除き、ＣＰＵ９１が第二縫製処理で使用するカウンタは第一縫製処理と同じである。 The flags that the CPU 91 uses in the second sewing process are the same as those in the first sewing process. Except for the fact that the thread breakage prediction counter U is not used in the second sewing process, the counters that the CPU 91 uses in the second sewing process are the same as those in the first sewing process.

第二縫製処理は第一縫製処理におけるＳ２１、Ｓ２２、Ｓ３１～Ｓ３７の処理に替えてＳ３２１、Ｓ２２、Ｓ３１、Ｓ３３２～Ｓ３３７の処理を実行する点のみ第一縫製処理と相違する。以下、第一縫製処理と同様の処理は同一の符号を付して説明を省略し、第一縫製処理と相違する処理を説明する。 The second sewing process differs from the first sewing process only in that the processes of S321, S22, S31, and S332 to S337 are executed instead of the processes of S21, S22, and S31 to S37 in the first sewing process. In the following, the same processes as those in the first sewing process are denoted by the same reference numerals and their explanation is omitted, and the processes that differ from the first sewing process are explained.

図２２の如く、Ｓ１１、Ｓ１３（図１２参照）で縫製を開始した後、ＣＰＵ９１は第二特徴量処理を実行する（Ｓ３２１）。第二特徴量処理は第二縫製処理における特徴量を取得する為の処理である。 22, after starting sewing in S11 and S13 (see FIG. 12), the CPU 91 executes the second characteristic amount process (S321). The second characteristic amount process is a process for acquiring the characteristic amount in the second sewing process.

図２３を参照し、第二特徴量処理を説明する。ＣＰＵ９１は変動張力、変動移動量を取得し、ＲＡＭ９３に記憶する（Ｓ５１）。ＣＰＵ９１は上軸角が天秤引上期間内であるか否かを判断する（Ｓ５２）。上軸角が天秤引上期間内でない時（Ｓ５２：ＮＯ）、ＣＰＵ９１は処理をＳ５５に移行する。上軸角が天秤引上期間内である時（Ｓ５２：ＹＥＳ）、ＣＰＵ９１は磁気センサ５３の検出結果に基づいて第一張力を取得し、平均第一張力を算出してＲＡＭ９３に記憶する（Ｓ３５３）。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第一移動量を取得し、平均第一移動量を算出してＲＡＭ９３に記憶する（Ｓ３５４）。ＣＰＵ９１は処理をＳ５５に移行する。 The second feature amount processing will be described with reference to FIG. 23. The CPU 91 acquires the fluctuating tension and fluctuating movement amount, and stores them in the RAM 93 (S51). The CPU 91 determines whether the upper shaft angle is within the balance pull-up period (S52). When the upper shaft angle is not within the balance pull-up period (S52: NO), the CPU 91 shifts the processing to S55. When the upper shaft angle is within the balance pull-up period (S52: YES), the CPU 91 acquires the first tension based on the detection result of the magnetic sensor 53, calculates the average first tension, and stores it in the RAM 93 (S353). The CPU 91 acquires the first movement amount based on the detection result of the encoder 16A, calculates the average first movement amount, and stores it in the RAM 93 (S354). The CPU 91 shifts the processing to S55.

ＣＰＵ９１は上軸角が釜捕捉期間内であるか否かを判断する（Ｓ５５）。上軸角が釜捕捉期間内でない時（Ｓ５５：ＮＯ）、ＣＰＵ９１は処理をＳ５８に移行する。上軸角が釜捕捉期間内である時（Ｓ５５：ＹＥＳ）、ＣＰＵ９１は磁気センサ５３の検出結果に基づいて第二張力を取得し、平均第二張力を算出してＲＡＭ９３に記憶する（Ｓ３５６）。ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第二移動量を取得し、平均第二移動量を算出してＲＡＭ９３に記憶する（Ｓ３５７）。ＣＰＵ９１は処理をＳ５８に移行する。 The CPU 91 determines whether the upper shaft angle is within the shuttle capture period (S55). When the upper shaft angle is not within the shuttle capture period (S55: NO), the CPU 91 transitions to S58. When the upper shaft angle is within the shuttle capture period (S55: YES), the CPU 91 obtains the second tension based on the detection result of the magnetic sensor 53, calculates the average second tension, and stores it in the RAM 93 (S356). The CPU 91 obtains the second movement amount based on the detection result of the encoder 16A, calculates the average second movement amount, and stores it in the RAM 93 (S357). The CPU 91 transitions to S58.

ＣＰＵ９１は縫針１０が上死点に在るか否かを判断する（Ｓ５８）。上軸角が３６０°でなく、縫針１０が上死点にない時（Ｓ５８：ＮＯ）、ＣＰＵ９１は処理を第二縫製処理（図２２参照）に戻す。上軸角が３６０°であり、縫針１０が上死点に在る時（Ｓ５８：ＹＥＳ）、ＣＰＵ９１はエンコーダ１６Ａの検出結果に基づいて第三移動量を取得し、平均第三移動量を算出してＲＡＭ９３に記憶する（Ｓ３５９）。ＣＰＵ９１は上糸移動量の大きさを０にして（Ｓ６０）、処理を第二縫製処理に戻す。 The CPU 91 determines whether the sewing needle 10 is at the top dead point (S58). When the upper shaft angle is not 360° and the sewing needle 10 is not at the top dead point (S58: NO), the CPU 91 returns the process to the second sewing process (see FIG. 22). When the upper shaft angle is 360° and the sewing needle 10 is at the top dead point (S58: YES), the CPU 91 obtains the third movement amount based on the detection result of the encoder 16A, calculates the average third movement amount and stores it in the RAM 93 (S359). The CPU 91 sets the magnitude of the upper thread movement amount to 0 (S60) and returns the process to the second sewing process.

図２２の如く、第二特徴量処理（Ｓ３２１）の実行後、ＣＰＵ９１は縫針１０が上死点に在るか否かを判断する（Ｓ２２）。縫針１０が上死点にない時（Ｓ２２：ＮＯ）、ＣＰＵ９１はペダル３８の検出結果に基づき縫製を終了するか否かを判断する（Ｓ２３）。ペダル３８からＯＮ信号を受信した時、ＣＰＵ９１は縫製を終了しないと判断し（Ｓ２３：ＮＯ）、処理をＳ２１に戻す。 As shown in FIG. 22, after executing the second characteristic amount process (S321), the CPU 91 determines whether the sewing needle 10 is at the top dead point (S22). If the sewing needle 10 is not at the top dead point (S22: NO), the CPU 91 determines whether sewing should be ended based on the detection result of the pedal 38 (S23). If an ON signal is received from the pedal 38, the CPU 91 determines not to end sewing (S23: NO) and returns the process to S21.

ＣＰＵ９１はＳ３２１、Ｓ２２、Ｓ２３を繰返し実行する。縫針１０が上死点に在る時（Ｓ２２：ＹＥＳ）、ＣＰＵ９１は針落ち数Ｎ、累積針落ち数Ｌの値に１を加算する（Ｓ３１）。ＣＰＵ９１は累積針落ち数Ｌの値が予知実行数Ｍの倍数であるか否かを判断する（Ｓ３３２）。累積針落ち数Ｌの値が予知実行数Ｍの倍数でない時（Ｓ３３２：ＮＯ）、ＣＰＵ９１は処理をＳ２３に移行する。 The CPU 91 repeatedly executes S321, S22, and S23. When the sewing needle 10 is at the top dead point (S22: YES), the CPU 91 adds 1 to the number of needle points N and the cumulative number of needle points L (S31). The CPU 91 determines whether the value of the cumulative number of needle points L is a multiple of the predicted execution number M (S332). When the value of the cumulative number of needle points L is not a multiple of the predicted execution number M (S332: NO), the CPU 91 transitions to S23.

累積針落ち数Ｌの値が予知実行数Ｍの倍数である時（Ｓ３３２：ＹＥＳ）、ＣＰＵ９１は累積針落ち数Ｌの値が予知実行数Ｍの５倍以上であるか否かを判断する（Ｓ３３３）。累積針落ち数Ｌの値が予知実行数Ｍの５倍未満である時（Ｓ３３３：ＮＯ）、ＣＰＵ９１は縫製不良の発生を予知できないとして、処理をＳ２３に移行する。累積針落ち数Ｌの値が予知実行数Ｍの５倍以上である時（Ｓ３３３：ＹＥＳ）、ＣＰＵ９１はＲＡＭ９３に記憶した夫々の特徴量の内、記憶した順が新しい五つを取得する（Ｓ３４）。ＣＰＵ９１は第二糸切れ予知処理（Ｓ３３５）を実行する。 When the value of the cumulative number of needle points L is a multiple of the predicted execution number M (S332: YES), the CPU 91 judges whether the value of the cumulative number of needle points L is five times or more than the predicted execution number M (S333). When the value of the cumulative number of needle points L is less than five times the predicted execution number M (S333: NO), the CPU 91 determines that the occurrence of a sewing defect cannot be predicted and shifts the process to S23. When the value of the cumulative number of needle points L is five times or more than the predicted execution number M (S333: YES), the CPU 91 acquires the five most recent feature amounts stored in the RAM 93 (S34). The CPU 91 executes the second thread breakage prediction process (S335).

図２４を参照し、第二糸切れ予知処理を説明する。第二糸切れ予知処理は糸切れの発生を予知する為の処理である。ＣＰＵ９１はＳ３４（図２２参照）で取得した五つの平均第一張力に基づいて、平均第一張力が増加傾向にあるか否かを判断する（Ｓ３６１）。平均第一張力が増加傾向にない時（Ｓ３６１：ＮＯ）、ＣＰＵ９１は処理をＳ３６３に移行する。平均第一張力が増加傾向にある時（Ｓ３６１：ＹＥＳ）、ＣＰＵ９１はＳ３４で取得した五つの平均第二張力に基づいて、平均第二張力が増加傾向にあるか否かを判断する（Ｓ３６２）。平均第二張力が増加傾向にない時（Ｓ３６２：ＮＯ）、ＣＰＵ９１は処理をＳ３６３に移行する。平均第二張力が増加傾向にある時（Ｓ３６２：ＹＥＳ）、ＣＰＵ９１は処理をＳ３７４に移行する。 The second yarn breakage prediction process will be described with reference to FIG. 24. The second yarn breakage prediction process is a process for predicting the occurrence of yarn breakage. The CPU 91 determines whether the average first tension is on an increasing trend (S361) based on the five average first tensions acquired in S34 (see FIG. 22). When the average first tension is not on an increasing trend (S361: NO), the CPU 91 shifts the process to S363. When the average first tension is on an increasing trend (S361: YES), the CPU 91 determines whether the average second tension is on an increasing trend (S362) based on the five average second tensions acquired in S34. When the average second tension is not on an increasing trend (S362: NO), the CPU 91 shifts the process to S363. When the average second tension is on an increasing trend (S362: YES), the CPU 91 shifts the process to S374.

ＣＰＵ９１はＳ３４で取得した五つの平均第一移動量に基づいて、平均第一移動量が減少傾向にあるか否かを判断する（Ｓ３６３）。平均第一移動量が減少傾向にない時（Ｓ３６３：ＮＯ）、ＣＰＵ９１は処理を第二縫製処理（図２２参照）に戻す。平均第一移動量が減少傾向にある時（Ｓ３６３：ＹＥＳ）、ＣＰＵ９１はＳ３４で取得した五つの平均第二移動量に基づいて、平均第二移動量が減少傾向にあるか否かを判断する（Ｓ３６４）。平均第二移動量が減少傾向にない時（Ｓ３６４：ＮＯ）、ＣＰＵ９１は処理を第二縫製処理に戻す。平均第二移動量が減少傾向にある時（Ｓ３６４：ＹＥＳ）、ＣＰＵ９１は処理をＳ３７４に移行する。 Based on the five average first movement amounts obtained in S34, the CPU 91 determines whether the average first movement amount is on a decreasing trend (S363). When the average first movement amount is not on a decreasing trend (S363: NO), the CPU 91 returns the process to the second sewing process (see FIG. 22). When the average first movement amount is on a decreasing trend (S363: YES), the CPU 91 determines whether the average second movement amount is on a decreasing trend (S364) based on the five average second movement amounts obtained in S34. When the average second movement amount is not on a decreasing trend (S364: NO), the CPU 91 returns the process to the second sewing process. When the average second movement amount is on a decreasing trend (S364: YES), the CPU 91 transitions the process to S374.

平均第一張力、平均第二張力が増加傾向にある時（Ｓ３６２：ＹＥＳ）、又は平均第一移動量、平均第二移動量が減少傾向にある時（Ｓ３６４：ＹＥＳ）、ＣＰＵ９１は糸切れの発生を予知したとして、糸切れ予知停止フラグを１に設定し（Ｓ３７４）、処理を第二縫製処理に戻す。第二縫製処理において糸切れの発生を予知した時、ＣＰＵ９１は糸切れの発生を回避する回避制御を実行せず、即座に予知停止処理（Ｓ４３、図２２参照）を実行する。 When the average first tension and the average second tension are on the rise (S362: YES), or when the average first movement amount and the average second movement amount are on the decline (S364: YES), the CPU 91 determines that it has predicted thread breakage, sets the thread breakage prediction stop flag to 1 (S374), and returns the process to the second sewing process. When it predicts thread breakage in the second sewing process, the CPU 91 does not execute avoidance control to avoid thread breakage, but immediately executes prediction stop processing (S43, see FIG. 22).

図２２の如く、第二糸切れ予知処理（Ｓ３３５）の実行後、ＣＰＵ９１は第二目飛び予知処理を実行する（Ｓ３３６）。第二目飛び予知処理と第一目飛び予知処理とは平均第一張力、平均第二張力、平均第三移動量の推移に基づき目飛びの発生を予知する点のみ相違するので、第二目飛び予知処理の説明を省略する。第二目飛び予知処理（Ｓ３３６）の実行後、ＣＰＵ９１は第二締り不良予知処理を実行する（Ｓ３３７）。第二締り不良予知処理と第一締り不良予知処理とは平均第一張力、平均第一移動量の推移に基づき締り不良の発生を予知する点のみ相違するので、第二締り不良予知処理の説明を省略する。 As shown in FIG. 22, after executing the second yarn breakage prediction process (S335), the CPU 91 executes the second stitch skip prediction process (S336). The second stitch skip prediction process and the first stitch skip prediction process differ only in that the occurrence of a stitch skip is predicted based on the changes in the average first tension, the average second tension, and the average third movement amount, so the description of the second stitch skip prediction process is omitted. After executing the second stitch skip prediction process (S336), the CPU 91 executes the second tightening failure prediction process (S337). The second tightening failure prediction process and the first tightening failure prediction process differ only in that the occurrence of a tightening failure is predicted based on the changes in the average first tension and the average first movement amount, so the description of the second tightening failure prediction process is omitted.

ＣＰＵ９１は糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグの何れかが１であるか否かを判断する（Ｓ３８）。糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグが何れも０である時（Ｓ３８：ＮＯ）、ＣＰＵ９１は処理をＳ２３に移行する。糸切れ予知停止フラグ、目飛び予知停止フラグ、締り不良予知停止フラグの何れかが１である時（Ｓ３８：ＹＥＳ）、ＣＰＵ９１は予知停止処理を実行し（Ｓ４３）、処理をＳ４４に移行する。 The CPU 91 determines whether any of the yarn breakage prediction stop flag, the stitch skip prediction stop flag, and the tightness failure prediction stop flag is 1 (S38). When the yarn breakage prediction stop flag, the stitch skip prediction stop flag, and the tightness failure prediction stop flag are all 0 (S38: NO), the CPU 91 shifts the process to S23. When any of the yarn breakage prediction stop flag, the stitch skip prediction stop flag, and the tightness failure prediction stop flag is 1 (S38: YES), the CPU 91 executes the prediction stop process (S43) and shifts the process to S44.

以上の如く、第二縫製処理を実行する時、ＣＰＵ９１は糸切れの発生を予知した時、糸切れ予知停止フラグを１に設定し（Ｓ３７４）、駆動部の駆動を停止する（Ｓ４３）。糸切れの発生を予知した時、ＣＰＵ９１は駆動部の駆動を停止することで縫製を中止する。故にミシン１は糸切れの発生を未然に防ぐことができる。 As described above, when executing the second sewing process, if the CPU 91 predicts the occurrence of thread breakage, it sets the thread breakage prediction stop flag to 1 (S374) and stops driving the drive unit (S43). When it predicts the occurrence of thread breakage, the CPU 91 stops driving the drive unit to stop sewing. Therefore, the sewing machine 1 can prevent thread breakage from occurring.

上記実施形態において、ミシン１は本発明のミシン、不良予知装置の一例である。Ｓ５１を実行するＣＰＵ９１は本発明の取得部の一例である。ＲＡＭ９３は本発明の記憶部の一例である。Ｓ３５～Ｓ３７、Ｓ３３５～Ｓ３３７を実行するＣＰＵ９１は本発明の予知部の一例である。予知単位は本発明の単位の一例である。変動張力、変動移動量は本発明の変量の一例である。天秤引上期間、釜捕捉期間は所定時機の一例である。糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷは本発明の予知レベルの一例である。Ｓ５１で磁気センサ５３の検出結果に基づいて上糸張力を取得するＣＰＵ９１は本発明の張力取得部の一例である。Ｓ５１で磁気センサ５３の検出結果に基づいて上糸移動量を取得するＣＰＵ９１は本発明の移動量取得部の一例である。 In the above embodiment, the sewing machine 1 is an example of the sewing machine and defect prediction device of the present invention. The CPU 91 that executes S51 is an example of the acquisition unit of the present invention. The RAM 93 is an example of the storage unit of the present invention. The CPU 91 that executes S35 to S37 and S335 to S337 is an example of the prediction unit of the present invention. The prediction unit is an example of the unit of the present invention. The variable tension and the variable movement amount are examples of the variables of the present invention. The thread take-up period and the hook capture period are examples of predetermined timings. The thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness failure prediction counter W are examples of prediction levels of the present invention. The CPU 91 that acquires the upper thread tension based on the detection result of the magnetic sensor 53 in S51 is an example of the tension acquisition unit of the present invention. The CPU 91 that acquires the upper thread movement amount based on the detection result of the magnetic sensor 53 in S51 is an example of the movement amount acquisition unit of the present invention.

Ｓ７３、Ｓ１２３、Ｓ１７３を実行するＣＰＵ９１は本発明の回避制御部の一例である。主モータ２７は本発明の針棒駆動部の一例である。主糸調子器２２は本発明の糸調子機構の一例である。Ｓ４３を実行するＣＰＵ９１は本発明の予知停止部の一例である。第二縫製処理でＳ４３を実行するＣＰＵ９１は本発明の糸切れ予知停止部の一例である。Ｓ１０２、Ｓ１０３、Ｓ１５２、Ｓ１５３、Ｓ２０２、Ｓ２０３を実行するＣＰＵ９１は本発明の報知部の一例である。Ｓ１０２、Ｓ１０３、Ｓ１５２、Ｓ１５３、Ｓ２０２、Ｓ２０３を実行するＣＰＵ９１は本発明の予知レベル報知部の一例である。Ｓ９２、Ｓ１４２、Ｓ１９２を実行するＣＰＵ９１は本発明の回避報知部の一例である。Ｓ２１４、Ｓ２２４、Ｓ２３４を実行するＣＰＵ９１は本発明の停止報知部の一例である。 The CPU 91 that executes S73, S123, and S173 is an example of the avoidance control unit of the present invention. The main motor 27 is an example of the needle bar drive unit of the present invention. The main thread tensioner 22 is an example of the thread tension mechanism of the present invention. The CPU 91 that executes S43 is an example of the prediction stop unit of the present invention. The CPU 91 that executes S43 in the second sewing process is an example of the thread breakage prediction stop unit of the present invention. The CPU 91 that executes S102, S103, S152, S153, S202, and S203 is an example of the notification unit of the present invention. The CPU 91 that executes S102, S103, S152, S153, S202, and S203 is an example of the prediction level notification unit of the present invention. The CPU 91 that executes S92, S142, and S192 is an example of the avoidance notification unit of the present invention. The CPU 91 that executes S214, S224, and S234 is an example of the stop notification unit of the present invention.

本発明は上記実施形態の他に種々の変更ができる。ミシン１は釜４９を有する本縫いミシンに限らず、環縫いミシンでもよい。縫製不良の発生を予知するＣＰＵ９１をミシン１と別体の装置に設け、該装置によりミシン１の縫製不良の発生を予知してもよい。該時、縫製不良の発生を予知するＣＰＵ９１を有する装置は本発明の不良予知装置の一例である。 The present invention can be modified in various ways in addition to the above embodiment. The sewing machine 1 is not limited to a lock stitch sewing machine having a shuttle 49, but may be a chain stitch sewing machine. The CPU 91 that predicts the occurrence of sewing defects may be provided in a device separate from the sewing machine 1, and the occurrence of sewing defects in the sewing machine 1 may be predicted by this device. In such a case, the device having the CPU 91 that predicts the occurrence of sewing defects is an example of a defect prediction device of the present invention.

ミシン１の装置の構成、数は適宜変更してもよい。例えば、ソレノイドにより上糸６６に張力を付与する糸調子機構を主糸調子器２２に替えて設けてもよい。該糸調子機構を設け、変動移動量の推移に基づき縫製不良の発生を予知する時、上糸移動量を検出するセンサを更に設けることが望ましい。 The configuration and number of devices in the sewing machine 1 may be changed as appropriate. For example, a thread tension mechanism that applies tension to the upper thread 66 using a solenoid may be provided in place of the main thread tensioner 22. When providing such a thread tension mechanism and predicting the occurrence of sewing defects based on the transition of the amount of fluctuating movement, it is desirable to further provide a sensor that detects the amount of movement of the upper thread.

特徴量は上記実施形態以外のものでもよい。例えば撚り戻りにより増加する上糸６６の径の大きさを特徴量としてもよい。上糸６６の径の大きさを検出する為に光学センサを設けてもよい。第二縫製処理において予知単位において第一張力等が所定の閾値を超えた回数を特徴量としてもよい。該時、ＣＰＵ９１は所定の閾値を超えた回数が増加傾向にある時に縫製不良の発生を予知する。該時、所定の閾値は本発明の変量閾値の一例である。 The characteristic quantity may be something other than that of the above embodiment. For example, the diameter of the upper thread 66 that increases due to untwisting may be the characteristic quantity. An optical sensor may be provided to detect the diameter of the upper thread 66. The characteristic quantity may be the number of times that the first tension, etc., exceeds a predetermined threshold in the prediction unit in the second sewing process. At that time, the CPU 91 predicts the occurrence of a sewing defect when the number of times that the predetermined threshold is exceeded tends to increase. At that time, the predetermined threshold is an example of a variable threshold of the present invention.

ミシン１は縫製不良の発生を予知する時に予知単位で推移する特徴量を取得する数を適宜変更してもよい。ミシン１は糸切れ、目飛び、締り不良夫々で異なる数の特徴量を取得し、縫製不良の発生を予知してもよい。ミシン１は縫針１０が上死点以外の位置に在る時に縫製不良の発生を予知してもよい。 The sewing machine 1 may appropriately change the number of feature values acquired that change in the prediction unit when predicting the occurrence of a sewing defect. The sewing machine 1 may acquire a different number of feature values for each of thread breakage, skipped stitches, and tightness problems, and predict the occurrence of a sewing defect. The sewing machine 1 may predict the occurrence of a sewing defect when the sewing needle 10 is in a position other than the top dead center.

第二縫製処理における予知実行数Ｍの値は適宜変更してもよい。予知実行数Ｍの値は糸切れ、目飛び、締り不良夫々で異なってもよい。第二縫製処理においてＣＰＵ９１は針落ち数Ｎの値が予知実行数Ｍの倍数である時に縫製不良の発生を予知してもよい。該時、一回の縫製における針落ち数が既知であれば、予知実行数Ｍは一回の縫製における針落ち数より小さいことが望ましい。 The value of the predicted number of executions M in the second sewing process may be changed as appropriate. The value of the predicted number of executions M may be different for each of thread breakage, skipped stitches, and tightness problems. In the second sewing process, the CPU 91 may predict the occurrence of a sewing defect when the value of the number of needle points N is a multiple of the predicted number of executions M. At that time, if the number of needle points in one sewing is known, it is desirable that the predicted number of executions M is smaller than the number of needle points in one sewing.

ミシン１は糸切れ、目飛び、締り不良以外の縫製不良の発生を予知してもよい。ミシン１は一種類の縫製不良の発生を予知すればよく、他の縫製不良の発生を予知しなくてもよい。ミシン１は糸切れ、目飛び、締り不良、他の縫製不良の発生を予知するか否かを個別に設定してもよい。 The sewing machine 1 may predict the occurrence of sewing defects other than thread breakage, skipped stitches, and tightness problems. The sewing machine 1 may only need to predict the occurrence of one type of sewing defect, and may not need to predict the occurrence of other sewing defects. The sewing machine 1 may be individually set to predict or not predict the occurrence of thread breakage, skipped stitches, tightness problems, and other sewing defects.

ミシン１は縫製不良の発生を予知した時に縫製不良の発生の予知を報知しなくてよい。該時、ＣＰＵ９１はＳ１０２、Ｓ１０３、Ｓ１５２、Ｓ１５３、Ｓ２０２、Ｓ２０３の一部又は全部を省略してもよい。 The sewing machine 1 does not need to notify the user of the predicted occurrence of a sewing defect when the sewing machine 1 predicts the occurrence of a sewing defect. In such a case, the CPU 91 may omit some or all of S102, S103, S152, S153, S202, and S203.

ミシン１は一回の縫製中に縫製不良の発生の予知した累積の数に基づき、縫製不良の発生する可能性の高さを判断してもよい。ミシン１は縫製不良の発生を予知した時に、糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷの値に応じて多段階で縫製不良の発生の予知を報知しなくてもよい。ミシン１は縫製不良の発生を予知した時に、三段階以上の段階で縫製不良の発生の予知を報知してもよい。 The sewing machine 1 may determine the likelihood of a sewing defect occurring based on the cumulative number of sewing defects predicted during one sewing run. When the sewing machine 1 predicts a sewing defect, it is not necessary to notify the prediction of the sewing defect in multiple stages according to the values of the thread breakage prediction counter U, the skipped stitch prediction counter V, and the tightness failure prediction counter W. When the sewing machine 1 predicts a sewing defect, it may notify the prediction of the sewing defect in three or more stages.

ミシン１は目飛びの発生を予知した時に目飛び回避処理（Ｓ１２３）を実行しなくてもよい。ミシン１は締り不良の発生を予知した時に締り不良回避処理（Ｓ１７３）を実行しなくてもよい。ミシン１は縫製不良の発生を回避する時に縫製不良の発生の回避を報知しなくてよい。該時、ＣＰＵ９１はＳ９２、Ｓ１４２、Ｓ１９２の一部又は全部を省略してもよい。 The sewing machine 1 may not execute the skip stitch avoidance process (S123) when it predicts the occurrence of a skip stitch. The sewing machine 1 may not execute the tightening defect avoidance process (S173) when it predicts the occurrence of a tightening defect. The sewing machine 1 may not notify the avoidance of a sewing defect when avoiding the occurrence of a sewing defect. In such cases, the CPU 91 may omit some or all of S92, S142, and S192.

ミシン１は糸切れ回避処理（Ｓ７３）、目飛び回避処理（Ｓ１２３）、締り不良回避処理（Ｓ１７３）で夫々異なる回避制御を実行してもよい。回避制御において、主モータ２７の回転速度を加速してもよいし、主糸調子器２２が付与する上糸張力の大きさを大きくしてもよい。回避制御において、ＣＰＵ９１は主糸調子器２２の糸調子モータ１６を制御して上糸移動量を調整してもよい。ミシン１は糸切れ予知カウンタＵ、目飛び予知カウンタＶ、締り不良予知カウンタＷの値に応じて異なる回避制御を実行してもよい。 The sewing machine 1 may execute different avoidance controls for the thread breakage avoidance process (S73), the stitch skip avoidance process (S123), and the tightness failure avoidance process (S173). In the avoidance control, the rotation speed of the main motor 27 may be accelerated, or the upper thread tension applied by the main thread tensioner 22 may be increased. In the avoidance control, the CPU 91 may control the thread tension motor 16 of the main thread tensioner 22 to adjust the upper thread movement amount. The sewing machine 1 may execute different avoidance controls depending on the values of the thread breakage prediction counter U, the stitch skip prediction counter V, and the tightness failure prediction counter W.

ミシン１は回避制御を実行した後に縫製不良の発生を予知した時に駆動部の駆動を停止しなくてもよい。ミシン１は一回の縫製中に縫製不良の発生の予知した累積の数に基づき駆動部の駆動を停止してもよい。縫製不良の発生に因り駆動部の駆動を停止する時に駆動部の駆動を報知しなくてよい。該時、ＣＰＵ９１はＳ２１４、Ｓ２２４、Ｓ２３４の一部又は全部を省略してもよい。 The sewing machine 1 may not stop driving the drive unit when it predicts the occurrence of a sewing defect after executing avoidance control. The sewing machine 1 may stop driving the drive unit based on the cumulative number of predicted occurrences of sewing defects during one sewing operation. It is not necessary to notify the driver of the drive unit when stopping the drive unit due to the occurrence of a sewing defect. In such a case, the CPU 91 may omit some or all of S214, S224, and S234.

ＣＰＵ９１が図１２～図２４の処理を実行する為の指令を含むプログラムはＣＰＵ９１がプログラムを実行する迄にミシン１の記憶機器に記憶すればよい。従って、プログラムの取得方法、取得経路及びプログラムを記憶する機器の各々は適宜変更してもよい。ＣＰＵ９１が実行するプログラムはケーブル又は無線通信を介して他の装置から受信し、不揮発性メモリ等の記憶装置に記憶されてもよい。他の装置は、例えばＰＣ、ネットワーク網を介してミシン１と接続するサーバを含む。 The program including the instructions for the CPU 91 to execute the processes of Figures 12 to 24 may be stored in a storage device of the sewing machine 1 before the CPU 91 executes the program. Therefore, the program acquisition method, acquisition path, and device that stores the program may each be changed as appropriate. The program executed by the CPU 91 may be received from another device via a cable or wireless communication and stored in a storage device such as a non-volatile memory. The other device may include, for example, a PC or a server connected to the sewing machine 1 via a network.

図１２～図２４の処理の各ステップについて、ＣＰＵ９１が実行する例に限定せず、他の電子機器（例えば、ＡＳＩＣ）が一部又は全部を実行してもよい。複数の電子機器（例えば、複数のＣＰＵ）が図１２～図２４の処理の各ステップを分散処理してもよい。図１２～図２４の処理の各ステップは適宜順序の変更、ステップの省略、及び追加してもよい。ミシン１上で稼動しているオペレーティングシステム（ＯＳ）等がＣＰＵ９１からの指令に依り図１２～図２４の処理の一部又は全部を行ってもよい。実施形態で挙げた各種数値は単なる例示であり、適宜変更できる。 The steps of the processes in Figures 12 to 24 are not limited to those executed by the CPU 91, and may be executed in part or in whole by another electronic device (e.g., an ASIC). Multiple electronic devices (e.g., multiple CPUs) may perform distributed processing of the steps of the processes in Figures 12 to 24. The order of the steps of the processes in Figures 12 to 24 may be changed as appropriate, steps may be omitted, or steps may be added. An operating system (OS) or the like running on the sewing machine 1 may perform some or all of the processes in Figures 12 to 24 in response to instructions from the CPU 91. The various numerical values given in the embodiments are merely examples and may be changed as appropriate.

１ ミシン
１１ 針棒
１５ 上軸
１６ 糸調子モータ
１６Ａ、２７Ａ エンコーダ
２２ 主糸調子器
２７ 主モータ
３９ スピーカ
４９ 釜
５３ 磁気センサ
７０ 頭部アンプ
９１ ＣＰＵ
９３ ＲＡＭ 1 Sewing machine 11 Needle bar 15 Upper shaft 16 Thread tension motor 16A, 27A Encoder 22 Main thread tension controller 27 Main motor 39 Speaker 49 Hook 53 Magnetic sensor 70 Head amplifier 91 CPU
93 RAM

Claims (17)

上糸を挿通した縫針が縫製中に上下動することに応じて周期的に変動する前記上糸に関する量である変量を取得する取得部と、
前記取得部が取得する前記変量を記憶する記憶部と、
前記縫針の上下動の一以上の周期を単位としたとき、前記記憶部が記憶する前記変量のうち特徴を示す量である特徴量における前記単位あたりの推移が所定数分で連続して増加する増加傾向である、又は前記特徴量における前記単位あたりの推移が所定数分で連続して減少する減少傾向であるかに基づき、ミシンによる縫製中における糸切れ、目飛び、又は締り不良の何れかの縫製不良の発生を予知する予知部と
を備え、
前記取得部は、前記上糸にかかる張力を取得する張力取得部、及び前記上糸の移動量を取得する移動量取得部の少なくとも何れかを備え、
前記変量は、前記張力、前記移動量の少なくとも何れかであり、
前記特徴量は、前記縫針の上下動の一周期の所定時機における前記変量に基づく量であることを特徴とする不良予知装置。 an acquisition unit that acquires a variable that is a quantity related to the upper thread that periodically changes in response to the vertical movement of a sewing needle through which the upper thread is passed during sewing;
a storage unit that stores the variable acquired by the acquisition unit;
a prediction unit which predicts the occurrence of any one of sewing defects, such as thread breakage, skipped stitches, or poor tightening, during sewing by the sewing machine, based on whether a characteristic amount, which is an amount indicating a characteristic among the variables stored in the memory unit, per unit shows an increasing tendency of successively increasing over a predetermined number of minutes, or a decreasing tendency of successively decreasing over a predetermined number of minutes, when one or more periods of the up-down movement of the sewing needle are taken as a unit,
the acquisition unit includes at least one of a tension acquisition unit that acquires a tension applied to the upper thread and a movement amount acquisition unit that acquires a movement amount of the upper thread,
the variable is at least one of the tension and the movement amount,
The defect prediction device is characterized in that the characteristic amount is an amount based on the variable amount at a predetermined time during one cycle of the up and down movement of the sewing needle. 前記特徴量は、前記所定時機における前記変量の大きさ、前記単位において前記所定時機における前記変量の大きさが所定の変量閾値に至った回数の少なくとも何れかであることを特徴とする請求項１に記載の不良予知装置。 2. The defect prediction device according to claim 1, wherein the characteristic quantity is at least one of the magnitude of the variable at the specified time and the number of times that the magnitude of the variable in the unit at the specified time reaches a specified variable threshold value. 前記予知部は、前記特徴量における前記単位あたりの推移に基づき前記縫製不良の発生を予知する時、前記縫製不良が発生する可能性の度合を示す予知レベルを認識することを特徴とする請求項２に記載の不良予知装置。 The defect prediction device according to claim 2, characterized in that the prediction unit recognizes a prediction level indicating the degree of possibility of the occurrence of the sewing defect when predicting the occurrence of the sewing defect based on the per-unit change in the feature amount. 前記ミシンは、前記上糸を引き上げる天秤と、前記縫針に挿通した前記上糸のループを捕捉する釜とを備え、
前記所定時機は、前記天秤が前記上糸を引上げる期間、前記釜が前記上糸のループを捕捉し前記上糸が前記釜を潜り抜ける期間の少なくとも何れかであって、
前記予知部は、
前記所定時機での前記張力の前記特徴量における前記単位あたりの推移が前記増加傾向にある時、
前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が前記減少傾向にある時
の少なくとも何れかの時、前記糸切れの発生を予知すること
を特徴とする請求項１～３の何れかに記載の不良予知装置。 The sewing machine includes a thread take-up that pulls up the upper thread and a shuttle that captures the loop of the upper thread that is inserted into the sewing needle,
The predetermined time is at least one of a period during which the thread take-up lever pulls up the upper thread and a period during which the shuttle captures the loop of the upper thread and the upper thread passes through the shuttle,
The prediction unit is
When the change per unit of the characteristic amount of the tension at the predetermined time is on the increasing trend,
The defect prediction device according to any one of claims 1 to 3, wherein the occurrence of the yarn breakage is predicted at least when the transition per unit of the feature amount of the movement amount at the predetermined time is on the decreasing trend. 前記ミシンは、前記上糸を引き上げる天秤を備え、
前記予知部は、
前記天秤が前記上糸を引上げる期間での前記張力の前記特徴量における前記単位あたりの推移が前記減少傾向にある時、
前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が前記減少傾向にある時
の少なくとも何れかの時、前記目飛びの発生を予知すること
を特徴とする請求項１～３の何れかに記載の不良予知装置。 The sewing machine includes a thread take-up lever that takes up the upper thread,
The prediction unit is
when the change per unit of the characteristic amount of the tension during the period in which the thread take-up is pulling up the upper thread is on the decreasing trend,
The defect prediction device according to any one of claims 1 to 3, wherein the occurrence of skipped stitches is predicted at least when the change per unit in the feature amount of the movement amount at the predetermined time is on the decreasing trend. 前記ミシンは、前記縫針に挿通した前記上糸のループを捕捉する釜を更に備え、
前記変量が前記張力を含む時、
前記予知部は、
前記天秤が前記上糸を引上げる期間での前記張力の前記特徴量における前記単位あたりの推移が前記減少傾向にある時、及び前記所定時機として前記釜が前記上糸のループを捕捉し前記上糸が前記釜を潜り抜ける期間での前記張力の前記特徴量における前記単位あたりの推移が前記増加傾向にある時、前記目飛びの発生を予知すること
を特徴とする請求項５に記載の不良予知装置。 The sewing machine further includes a shuttle that captures the loop of the needle thread that is inserted into the sewing needle.
When the variables include the tension,
The prediction unit is
6. The defect prediction device according to claim 5, wherein the occurrence of skipped stitches is predicted when the change per unit in the characteristic amount of the tension during a period in which the thread take-up is pulling up the upper thread is on the decreasing trend, and when the change per unit in the characteristic amount of the tension during a period in which the hook captures the upper thread loop and the upper thread passes through the hook at the predetermined time is on the increasing trend. 前記ミシンは、前記上糸を引き上げる天秤を備え、
前記所定時機は、前記天秤が前記上糸を引上げる期間であって、
前記予知部は、
前記所定時機での前記張力の前記特徴量における前記単位あたりの推移が前記増加傾向にある時、
前記所定時機での前記移動量の前記特徴量における前記単位あたりの推移が前記増加傾向にある時
の少なくとも何れかである時、前記締り不良の発生を予知すること
を特徴とする請求項１～３の何れかに記載の不良予知装置。 The sewing machine includes a thread take-up lever that takes up the upper thread,
The predetermined time is a period during which the thread take-up lever takes up the upper thread,
The prediction unit is
When the change per unit of the characteristic amount of the tension at the predetermined time is on the increasing trend,
The defect prediction device according to any one of claims 1 to 3, wherein the occurrence of the tightening defect is predicted at least when the change per unit in the characteristic amount of the movement amount at the specified time is on the increasing trend. 前記ミシンは、縫製中に駆動して布を縫製する駆動部を備え、
前記不良予知装置は、前記予知部が前記縫製不良の発生を予知した時、前記駆動部を制御して前記縫製不良の発生を回避する回避制御を実行する回避制御部を更に備えること
を特徴とする請求項１～７の何れかに記載の不良予知装置。 The sewing machine includes a drive unit that drives during sewing to sew the cloth,
The defect prediction device according to any one of claims 1 to 7, further comprising an avoidance control unit that, when the prediction unit predicts the occurrence of the sewing defect, controls the drive unit to execute avoidance control to avoid the occurrence of the sewing defect. 前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部を含み、
前記回避制御部は、前記回避制御として前記針棒駆動部の駆動速度を低下すること
を特徴とする請求項８に記載の不良予知装置。 The drive unit of the sewing machine includes a needle bar drive unit that moves a needle bar to which the sewing needle is attached up and down,
The defect prediction device according to claim 8 , wherein the avoidance control unit reduces a drive speed of the needle bar drive unit as the avoidance control. 前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部と、前記上糸に前記張力を付与する糸調子機構とを含み、
前記回避制御部は、前記回避制御に依り、前記縫針の上下動の一周期における、前記糸調子機構が付与する前記張力を制御すること
を特徴とする請求項８に記載の不良予知装置。 The drive unit of the sewing machine includes a needle bar drive unit that moves a needle bar to which the sewing needle is attached up and down, and a thread tensioning mechanism that applies the tension to the upper thread,
9. The defect prediction device according to claim 8, wherein the avoidance control section controls the tension applied by the thread tensioning mechanism during one period of the up-and-down movement of the sewing needle by the avoidance control. 前記ミシンの前記駆動部は、前記縫針を装着する針棒を上下動する針棒駆動部と、前記上糸に前記張力を付与し且つ前記上糸の前記移動量を回転駆動で調整する糸調子機構とを含み、
前記回避制御部は、前記回避制御に依り、前記縫針の上下動の一周期における、前記糸調子機構が付与する前記張力、前記移動量の変動の少なくとも何れかを制御すること
を特徴とする請求項８に記載の不良予知装置。 The drive unit of the sewing machine includes a needle bar drive unit that moves a needle bar to which the sewing needle is attached up and down, and a thread tensioning mechanism that applies the tension to the upper thread and adjusts the amount of movement of the upper thread by a rotation drive,
The defect prediction device according to claim 8, wherein the avoidance control unit controls at least one of the tension applied by the thread tensioning mechanism and the fluctuation in the amount of movement during one period of the up and down movement of the sewing needle through the avoidance control. 前記回避制御部が前記回避制御を実行後、前記予知部が前記縫製不良の発生を予知する時、前記駆動部を停止する予知停止部を更に備えることを特徴とする請求項８～１１の何れかに記載の不良予知装置。 The defect prediction device according to any one of claims 8 to 11, further comprising a prediction stop unit that stops the drive unit when the prediction unit predicts the occurrence of the sewing defect after the avoidance control unit executes the avoidance control. 前記ミシンは、縫製中に駆動して布を縫製する駆動部を備え、
前記不良予知装置は、前記予知部が前記糸切れの発生を予知した時、前記駆動部を停止する糸切れ予知停止部を更に備えることを特徴とする請求項１～７の何れかに記載の不良予知装置。 The sewing machine includes a drive unit that drives during sewing to sew the cloth,
The defect prediction device according to any one of claims 1 to 7, further comprising a yarn breakage prediction stop unit which stops the drive unit when the prediction unit predicts the occurrence of the yarn breakage. 前記予知部が前記縫製不良の発生を予知した時、前記縫製不良の発生を予知したことを報知する報知部を更に備えることを特徴とする請求項１～１３の何れかに記載の不良予知装置。 The defect prediction device according to any one of claims 1 to 13, further comprising a notification unit that notifies the user of the prediction unit's prediction of the occurrence of the sewing defect when the prediction unit predicts the occurrence of the sewing defect. 前記予知部が認識した前記予知レベルを報知する予知レベル報知部を更に備えることを特徴とする請求項３に記載の不良予知装置。 The failure prediction device according to claim 3, further comprising a prediction level notification unit that notifies the prediction level recognized by the prediction unit. 前記回避制御部が前記回避制御を実行時、前記回避制御の実行を報知する回避報知部を更に備えることを特徴とする請求項８～１２の何れかに記載の不良予知装置。 The failure prediction device according to any one of claims 8 to 12, further comprising an avoidance notification unit that notifies the execution of the avoidance control when the avoidance control unit executes the avoidance control. 前記予知停止部が前記駆動部を停止時、前記駆動部の停止を報知する停止報知部を更に備えることを特徴とする請求項１２に記載の不良予知装置。 The defect prediction device according to claim 12, further comprising a stop notification unit that notifies the driver of the stop when the prediction stop unit stops the driver.
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