A tufting machine and method for operating a tufting machine operating a needle selection mechanism based on pattern data by selecting a needle with yarn required for the pattern such that the selected needle is driven by a needle bar through the backing medium, to form a tuft while a needle that is not required for the pattern is not selected by the needle selection mechanism. Yarn is fed via a yarn feed mechanism comprising a plurality of actively driven yarn drives each driving a respective yarn to a respective needle, the yarn drives being at a location between a yarn creel and the needle. The method being characterised by operating the yarn feed mechanism to deliver at least 70% of the yarn required for a tuft as the needle moves from top dead center to bottom dead center.

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.

A shiftable backing feed is utilized with a tufting machine having reciprocating needles and gauge parts for seizing yarns at a plurality of fixed heights, wherein fabric support apparatus reciprocates in synchronization with the cycles of the needle bar to support the backing during penetration of the backing fabric yet allow backing shifts between stitches.

A computer implemented method (100) and system (200) for indexed tufting of a backing material (200) by a robot tufter. The method comprises: receiving (102) or accessing grid geometry of a backing material (200) wherein the grid geometry is based on a periodicity and dimensions of grid locations (204) of the backing material (200) and representative of optimal locations to receive a tufting needle; determining (104) indexed positions of grid locations of the backing material relative to the tufting needle of the robot tufter using a reference point that is fixed relative to the backing material (200); and controlling (106) the robot tufter to penetrate one or more specified indexed grid locations of the backing material with the tufting needle to create a tuft at the one or more specified indexed grid locations.

A computer implemented method (100) and system (200) for indexed tufting of a backing material (200) by a robot tufter. The method comprises: receiving (102) or accessing grid geometry of a backing material (200) wherein the grid geometry is based on a periodicity and dimensions of grid locations (204) of the backing material (200) and representative of optimal locations to receive a tufting needle; determining (104) indexed positions of grid locations of the backing material relative to the tufting needle of the robot tufter using a reference point that is fixed relative to the backing material (200); and controlling (106) the robot tufter to penetrate one or more specified indexed grid locations of the backing material with the tufting needle to create a tuft at the one or more specified indexed grid locations.

A multi-needle tufting gun for use in robotic tufting includes a support and a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

A multi-needle tufting gun for use in robotic tufting includes a support and a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

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 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 move 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 pull back the 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.