Variable stroke drive system for tufting machine
10995439 · 2021-05-04
Assignee
Inventors
Cpc classification
D05C15/00
TEXTILES; PAPER
D05C15/10
TEXTILES; PAPER
D05C15/20
TEXTILES; PAPER
International classification
D05C15/20
TEXTILES; PAPER
D05C15/10
TEXTILES; PAPER
D05C15/00
TEXTILES; PAPER
Abstract
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).
Claims
1. A tufting machine, comprising: at least one needle bar having a series of spaced needles therealong for forming tufts of yarns in the backing material; a needle bar drive system including one or more drive assemblies for driving the at least one needle bar in a reciprocating motion so that the needles are moved into and out of the backing material, the one or more drive assemblies comprising: a pair of first drive members driven by at least one motor; a pair of second drive members each linked to an associated one of the first drive members so as to be driven by the first drive members; cam arms coupled to the second drive members; a rocker arm extending between the cam arms; and at least one push rod having a proximal end attached to the rocker arm and a distal end linked to the at least one needle bar; wherein as the first drive members of each drive assembly are driven, the cam arms are moved in a reciprocating motion, driving the push rod and thus the needles carried by the at least one needle bar along a selected stroke, and wherein as the first drive members are driven at varying rates, movement of each of the cam arms is varied so as to change the selected stroke of the needles.
2. The variable drive system of claim 1, further comprising drive belts or chains linking each first drive member to its associated one of the second drive members.
3. The variable drive system of claim 1, wherein the proximal ends of the cam arms are each mounted to one of the second drive members at an off-center location.
4. The variable drive system of claim 1, wherein the at least one motor comprises a pair of variable speed drive motors each operatively connected to a drive shaft to which one of the first drive members is linked.
5. The tufting machine of claim 1, wherein the one or more drive assemblies comprise a plurality of drive assemblies mounted in spaced series across the tufting machine, and the at least one motor further comprises at least 4 variable speed motors, coupled to the first drive members of each of the series of the drive assemblies by a series of drive shafts.
6. The tufting machine of claim 1, further comprising a yarn feed mechanism configured to selectively control feeding of yarns to the needles for forming tufts of yarns in the backing material as the needles are reciprocated into and out of engagement with the backing material.
7. The tufting machine of claim 1, further comprising at least one shift mechanism for shifting the at least one needle bar transversely across the backing material.
8. The tufting machine of claim 1, further comprising a series of loop pile loopers, cut pile hooks, or level cut loop loopers mounted below the backing material and reciprocated into engagement with the needles to form tufts of yarns therein.
9. A method of operating a tufting machine to form tufted articles, comprising: moving a backing material through the tufting machine; reciprocating a plurality of needles along a selected stroke into and out of the backing material by operating a plurality of drive assemblies, each drive assembly comprising a series of drive gears driving cam arms in a reciprocating motion, a rocker arm connected between the cam arms, and a push rod coupled to the rocker arm and to at least one needle bar for imparting the reciprocating motion of the cam arms to the at least one needle bar for moving the needles mounted therealong into and out of the backing material; feeding yarns to the needles carried by the at least one needle bar for forming a series of tufts of yarns in the backing material; and varying a rate at which selected ones of the drive gears are rotated in response to which, the rocker arms of the drive assemblies are reoriented so as to adjust a length of stroke of the needle bar.
10. The method of claim 9, wherein varying the rate at which selected ones of the series of drive gears are rotated comprises operating drive motors coupled to first drive gears of each series of drive gears at different rates.
11. The method of claim 9, wherein varying the rate at which selected ones of the drive gears are rotated further comprises adjusting the rate of rotation of the selected ones of drive gears during a stitch cycle to adjust a dwell time of the needles during reciprocation thereof.
12. The method of claim 9, further comprising shifting the at least one needle bar in a direction transverse to the movement of the backing material through the tufting zone.
13. The method of claim 9, further comprising varying the feeding of at least selected yarns to the needles so as to pull the selected yarns low or out of the backing material.
14. The method of claim 9, wherein reorienting the rocker arms comprises driving the cam arms of each pair of cam arms between which the rocker arms are mounted in an out-of-phase relationship to cause pivoting of the rocker arms with respect to the push rods connected thereto.
15. The method of claim 9, further comprising engaging the needles with a series of loop pile loopers, cut pile hooks or level cut loop loopers as the needles are reciprocated into the backing material to form a series of loop and/or cut pile tufts.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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(5) The embodiments of the invention and the various features thereof are explained below in detail with reference to non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of certain components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments and/or features of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the embodiments of the invention. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the invention, which is defined solely by the appended claims and applicable law.
(6) Those skilled in the art will appreciate and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and that the dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein.
DETAILED DESCRIPTION OF THE INVENTION
(7) Referring now to the drawings in greater detail in which like numerals indicate like parts throughout the several views,
(8) As illustrated in
(9) The tufting machine controller 21, in one embodiment, can include a Command Performance™ tufting machine control system as manufactured by Card-Monroe Corp. In one example embodiment, the tufting machine controller 21 can include an operator interface 22, such as a touch screen, monitor with a keyboard and/or mouse, and/or other, similar interface through which the operator can input and/or adjust various operating parameters for the tufting machine, such as backing feed rates, yarn feed and other pattern information for the article being formed. The tufting machine controller further can be linked to a server, design center or other machine control systems, and will monitor and control the various operative elements of the tufting machine.
(10) In addition, as also shown in
(11) As additionally indicated in
(12) As illustrated in
(13) As illustrated in
(14) The gauge parts 30 (such as the loop pile loopers 31 shown in
(15) As illustrated in
(16) In one embodiment, a pair of drive motors 46 can be connected to one end, i.e., to either the proximal or distal end 42 or 43 of each of the primary driveshafts, and with the primary driveshafts accordingly being rotatably driven by operation of their respective drive motors. In other embodiments, pairs of drive motors 46 can be provided at opposite ends of the tufting machine frame, with a drive motor being linked or connected to each of the proximal and distal ends 42 and 43 of each of the primary driveshafts 41A and 41B, as illustrated in
(17) As a further alternative, the primary driveshafts 41A and 41B can be formed in sections or as multiple driveshafts, which can be linked via connecting bushings between each of the drive assemblies 40. For example, the primary driveshafts can include two pairs of driveshafts that extend through multiple ones of the drive assemblies from opposite directions, and are linked at an intermediate point across the width of the tufting machine. Alternatively, the driveshafts can be formed in multiple sections, each extending through one or more drive assemblies, with the multiple driveshaft sections being operatively connected together, such as by bushings or other connectors in between the drive assemblies 40. Still further, additional motors, such as shown at 47 in
(18) As shown in
(19) As further shown in
(20) Each of the drive assemblies 40 further will include a pair of cam arms 65 and 66, each connected at an upper or proximal end 67 to one of the second drive members. The cam arms 65 and 66 further are each pivotally connected to a rocker arm 68 mounted between the lower or distal ends 69 thereof. As indicated in
(21) As further illustrated in
(22) As further illustrated in
(23) In operation of the variable stroke drive system 10 according to the principles of the present invention, the primary driveshafts 41A and 41B will be driven by their respective drive motors 46. As the primary driveshafts are rotated, the first drive members 55A and 55B of each of the drive assemblies 40 likewise will be driven or rotated with the rotation of the primary driveshafts. The connecting belts 62 between each associated set of the first and second drive members 55A/60A and 55B/60B in turn will cause the rotation of the second drive members 60A and 60B at a rate generally equivalent to the rate at which their associated first drive members are rotated. As the second or lower drive members 60A and 60B are rotated, the cam arms 65 and 66, which generally are mounted to the second drive members in a cammed or offset mounting, accordingly will be caused to be driven in a vertically reciprocating manner or motion, as indicated by arrows 74/74′ in
(24) When the drive motors are generally driven at substantially the same or equivalent speed or rate, such that each of the first and second sets of drive members are driven in a synchronized fashion at substantially the same rate, the cam arms 65/66 generally can be moved along a substantially similar, in-phase or synchronized vertically substantially linear, reciprocating motion or path of travel. As a result, the cam arms will push down and pull up on the opposite ends of each of their connected rocker arms in a generally synchronized fashion. This substantially linear, vertically reciprocating motion will be imparted to the push rods connected to each of the rocker arms, which in turn will translate or impart this motion to the one or more needle bars of the tufting machine. Accordingly, by operating the drive motors in a substantially synchronized fashion, the resultant stroke of the needle bar, and thus the penetration of the needles into and out of the backing material, generally will be substantially consistent along its path of travel.
(25) In order to vary or change the stroke of the needle bar, the drive motors can be operated at different rates so as to correspondingly drive the linked or associated sets of first and second or upper and lower drive members 55A/60A and 55B/60B at different rates. This will cause the cam arms to be vertically reciprocated or moved in an out-of-phase relationship, such as indicated in
(26) The stroke of the needle bar(s) can be adjusted as needed to vary the upstroke or down stroke of the needle bar(s) such as for adjusting or changing between different style or pile heights of the tufted articles being produced. In addition, the variable stroke drive system enables the adjustment of the needle bar stroke during individual tuft or stitch cycles of the tufting machine to enable a desired deeper penetration of the needles, if needed, and/or alternatively to provide a longer dwell or delay time on the upstroke of the needle bar(s) so that the needles remain out of the backing material for a longer time such as while the needle bars are shifted to enable a desired shift distance, i.e., double or triple gauge shifts or jumps or greater, without interference with or engagement of the needles by the backing material.
(27) Accordingly, the variable needle bar stroke system 10 enables controlled adjustment or variation of the stroke of the needles, including adjustment of the stroke on-the-fly, or otherwise during individual tuft operations or stitch formation. Such adjustments can provide for formation of tufts having different or varied pile heights at desired locations or areas of the pattern being formed, enabling formation of sculpted and various other pattern effects to be formed as needed or desired and with increased precision and/or consistency. Additionally, the variable control of the needle bar stroke further can enable variations in the amount or length of the shifting or stepping of the needle bar and/or length or depth of penetration of the needles without substantially reducing or delaying the production of the tufting machine.
(28) The foregoing description generally illustrates and describes various embodiments of the present invention. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present invention without departing from the spirit and scope of the invention as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present invention.
(29) It further will be understood that the disclosed invention is not limited to the particular methodology, devices, apparatus, materials, applications, etc., described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
(30) Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art in the field to which this invention is directed, and it will be understood that any methods and materials similar or equivalent to those described herein can be used in the practice or construction of the invention.
(31) Accordingly, various features and characteristics of the present invention as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the invention, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.