A pattern data processing system configured to determine and compensate for any points of entanglement between different yarns. A point of entanglement is defined as a point where the yarn from one needle crosses and traps the yarn from another needle on the back face of the backing medium. The pattern data processing system is configured to calculate the additional length of back stich caused by each point of entanglement by subtracting an ideal back stich length, calculated as the path which would have been taken by the yarn had it not been entangled in another yarn, from an actual yarn path, calculated as the actual length of the entangled yarn. A controller is configured to include in the amount of yarn fed by a respective yarn feed mechanism for each stitch an amount equivalent to the additional length of back stitch. The invention also includes a tufting machine and method of operating the tufting machine with the pattern data processing system.

A hair feeding device configured to perform a feeding operation for pulling out flocking hairs one by one from a bundle of flocking hairs, the device includes a feeder configured to hold the bundle of flocking hairs and separates hair ends of a plurality of the flocking hairs in a direction different from that of the bundle, a detector configured to detect three-dimensional positions of the separated hair ends of the plurality of flocking hairs, a head for capturing the hair ends of the flocking hairs, a conveyance mechanism configured to convey the head to any three-dimensional position, and a control device that controls the conveyance mechanism so that the head captures the hair ends of the flocking hairs at three-dimensional positions of the hair ends of one flocking hair among the plurality of hairs detected by the detector.

A variable stroke drive system for a tufting machine includes a series of drive assemblies mounted along the frame of the tufting machine. Primary drive shafts extend through the drive assemblies and are each driven by a drive motor. A series of first drive members are mounted to the primary drive shafts and are linked to associated second drive members such that the driving of the first drive members by the primary drive shafts in turn drives the second drive members. Cam arms are connected to the second drive members and to rocker arms to which push rods are mounted, the cam arms being vertically reciprocated by the rotational movement of the second drive members so as to drive the reciprocation of the push rods, and thus the needle bar(s) connected thereto along a desired stroke or reciprocating path of travel. Controlling the rate at which the primary drive shafts are driven enables control of the stroke of the needle bar(s).

A variable stroke drive system for a tufting machine includes a series of drive assemblies mounted along the frame of the tufting machine. Primary drive shafts extend through the drive assemblies and are each driven by a drive motor. A series of first drive members are mounted to the primary drive shafts and are linked to associated second drive members such that the driving of the first drive members by the primary drive shafts in turn drives the second drive members. Cam arms are connected to the second drive members and to rocker arms to which push rods are mounted, the cam arms being vertically reciprocated by the rotational movement of the second drive members so as to drive the reciprocation of the push rods, and thus the needle bar(s) connected thereto along a desired stroke or reciprocating path of travel. Controlling the rate at which the primary drive shafts are driven enables control of the stroke of the needle bar(s).

A tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by activators to extend or retract the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yarns to the needles further will be controlled to back-rob yarns not picked-up by the gauge parts, while the backing feed will be controlled to enable formation of tufts at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

A tufting machine for selectively forming tufts of yarns, including different color or type yarns, for forming patterned tufted articles such as carpets. A series of needles are reciprocated into and out of a backing material being fed through the tufting machine and are engaged by a series of gauge parts so as to pick-up loops of yarns from the needles. The gauge parts will be selectively controlled by activators to extend or retract the gauge parts to positions or elevations sufficient to pick-up or not pick-up loops of yarns from the needles. The feeding of the yarns to the needles further will be controlled to back-rob yarns not picked-up by the gauge parts, while the backing feed will be controlled to enable formation of tufts at an increased rate over the pattern stitch rate for the pattern of the tufted article being formed.

A tufting machine comprising a plurality of needle holders (11) associated with a needle bar (5) and slidably supported in a frame for reciprocation in a needle reciprocation direction. A respective needle (10) is attached to each needle holder (11), each needle holder having an engagement portion. The needle bar (5) has means (7, 13) for selectively latching with the engagement portion of each selected needle holder so as to selectively drive latched needle holders in the needle reciprocation direction. A stop bar (21) is positioned to limit the upward movement of the needle holders (11). At least one magnet (20) retains non-latched needle holders in its uppermost position as the needle bar is reciprocated. The magnets (20) are embedded in the stop bar (21). The machine further comprises a cushioning member (27) attached to the magnet (20) and facing the top of each needle holder (11).

A tufting machine comprising a plurality of needle holders (11) associated with a needle bar (5) and slidably supported in a frame for reciprocation in a needle reciprocation direction. A respective needle (10) is attached to each needle holder (11), each needle holder having an engagement portion. The needle bar (5) has means (7, 13) for selectively latching with the engagement portion of each selected needle holder so as to selectively drive latched needle holders in the needle reciprocation direction. A stop bar (21) is positioned to limit the upward movement of the needle holders (11). At least one magnet (20) retains non-latched needle holders in its uppermost position as the needle bar is reciprocated. The magnets (20) are embedded in the stop bar (21). The machine further comprises a cushioning member (27) attached to the magnet (20) and facing the top of each needle holder (11).

A shiftable backing feed and shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein marginal step yarn placement techniques can be utilized in connection with a row of needles to minimize over-sewing needle positioning, and three axis shifting may be employed to optimize stitch locations in the backing fabric.

A shiftable backing feed or shiftable needle assembly is utilized with a tufting machine having reciprocating needles and gauge parts for seizing or cutting yarns wherein yarn placement patterns can be utilized to tuft at different gauge densities while maintaining the same pattern sizes and appearance, and gauge parts are adapted for high density stitching.