Long Stitch versus Skipped Stitch

When you are having stitching issues, you should first check to see if you are having LONG stitches or SKIPPED stitches.  When the needle goes down into the fabric and does not catch the bottom thread, you end up with a hole in your fabric but no stitch.  This is called a SKIPPED stitch.  But when your machine moves and the needle does not go down when it should, you end up with a LONG stitch.

The video to the right shows a machine starting out and almost immediately doing a LONG stitch.  You might not see this as obviously if it happens on your quilt, but recognizing that the needle did not go down when it was supposed to is key in identifying a LONG stitch.

The good news about a LONG stitch versus a SKIPPED or poor quality stitch is that it can be pinned down to the 'stitch regulation' on the machine and not the Pro-Stitcher. If the length of the stitch (space between the holes) it is an issue with stitch regulation on the machine and not the Pro-Stitcher. Read on to better understand why this is the case and how to troubleshoot it.

It took J.P. from Handi Quilter support to finally drill it into my head. It is important to understand what is happening when you hit RUN on your Pro-Stitcher tablet.  Pressing RUN on the tablet is simply the equivalent of hitting the START button on the handlebars.  The Pro-Stitcher tablet is controlling the motors on the carriage, not the machine.  Let me repeat that.  The Pro-Stitcher tablet is controlling the motors on the carriage, not the machine. 

To quote J.P., "The Pro-Stitcher is just dragging the machine around.  The stitching is done by the 'stiches-per-inch' setting and the stitch regulation built into the machine."  The same stitch regulation that is using in free-motion mode. The main components of the stitch regulation are the Encoders and the cables to the machine.  

Amara/Forte X-axis Encoder (back of table)

Amara/Forte Y-axis Encoder (side of the machine)

Amara/Forte encoders have audio style jack connection.

Older Machines use ribbon cables to the C-Pods

You will notice that even the Infinity still uses a ribbon cable for the X-axis encoder.  But the Y-axis encoder is built into axial between the back wheels.

Infinity X-axis Encoder

Infinity Y-axis Encoder built-in

Troubleshooting

1. Check for dirt on the encoder wheels and track it rides on.  Lint and residue should be cleaned away.
2. Make sure the spring is applying adequate pressure to hold it firmly down.
3. Disconnect and reconnect the cable.  Look at cable for exposed wires and any sign of damage.
4. Make sure the connection is tight and that other cables are not dragging across it.
5. Check the surface of the track the wheel is riding on for imperfections.  One area of the table could be out of balance causing flexing that affects the wheel making contact.
6. If you can't put on a practice sandwich to quilt on, take the needle out of the machine and do practice stitching in the area of the table/quilt where the problem is seen.  (You may need to disable the thread sensor.)  If you try to stitch squares, you will usually be able to tell it is a problem with the Y-axis or X-axis.  (up-down vs. left-right)

Intermittent problems can be very deceiving.  I can personally confess that I was convinced that a problem could not be an issue with the encoders until J.P. made me a believer.  A bad cable or connection can happen intermittently because the machine is moving and vibrating, making the cables move and vibrate.  There is a small chance that the controller hardware in the machine has a problem, but J.P. insists that the vast majority of the problems are due to bad cables and dirt.  Cables can be bumped and tugged while a quilt is being loaded.  People walk behind the tables and catch a cable.  The new audio jack style connectors don't get gently pushed in all the way.

Advanced Troubleshooting

• Handi Quilter support may ask you to 'swap the cables' to see if the problem switches axis'.  On the Amara and Forte, the cables barely reach.  Make sure you are using the right ports as the laser light option plugs into the same side as the X-axis encoder.
• Remember that you can disengage the Pro-Stitcher and do the stitch regulation manually. 
• Pay attention to specific areas on the table where problems may occur.  Watch for the wheels on the carriage or machine not making contact with the track.
• I have personally taken the cover off an older encoder and found dirt on the sensor wheel.  It had been assembled poorly causing the shaft to rub on the plastic cover.  The shavings/dust from the cover stuck to the sensor wheel causing false readings.

Summary

We spend a lot of time troubleshooting tension related stitch issues.  There are many different variables that can effect whether the loop is made properly as the needle comes up so the hook can catch it.  But it can save you a lot of time if you can recognize a stitch length (LONG STITCH) issue so you can start troubleshooting the stitch regulation components.

Special thanks as always to the people at Handi Quilter support for their patience and instruction.  MK Quilts urges all of it's machine owners to reach out to our support line before calling HQ support.  Good retailers are supposed to provide this support.  If you do not have a good retailer supporting you, we won't turn you away.  But understand we must give our owners priority.