Quilting machine for fabrics

Abstract

The invention relates to a quilting machine for fabrics, including at least three pairs of drive rollers between which the fabric can pass, one pair of rollers being the master pair and the other pairs of rollers being the slave pairs, generating a sewing area and a post-sewing area. Each pair of rollers consists of two opposing rollers associated with a set of chains and sprockets allowing the rollers to rotate in opposite directions to one another. The machine also includes pneumatic cylinders, associated with the pairs of drive rollers, for varying the distance between paired rollers, stabiliser bars for maintaining paired rollers parallel to one another, a sewing head, and a controller for controlling all of the pairs of drive rollers and the sewing head independently, exerting tension on the fabric in the sewing and post-sewing areas.

Claims

1. A quilting machine for fabrics comprising: at least three pairs of drive rollers between which fabric (1) can pass, one pair of the rollers (2), (2′) being a master pair and the rest being slave pairs of rollers (3), (3′), (4), (4′) with respect to the master pair of rollers (2), (2′), arranged in such a way that the rollers generate a sewing area and a post-sewing area, and each pair of the rollers consists of two opposing rollers associated with a set of chains (5) and sprockets (6) allowing the rollers to rotate in opposite directions to one another, with each pair of drive rollers being linked to a servomotor (7) with a variable speed drive and gear reducer which modifies the speed and degree of rotation of the rollers, pneumatic cylinders (8) associated with the pairs of drive rollers and being configured for varying the distance between paired rollers, stabiliser bars (9) linked to each of the pairs of drive rollers and being configured for maintaining paired rollers parallel to one another, at least one independent sewing head (10) arranged in the sewing area, and a controller associated with each of the variable speed drives and servomotors and being configured (7) for controlling all of the pairs of drive rollers and the sewing head (10) independently and simultaneously, varying the speed and degree of rotation of the slave pairs of rollers (3), (3′), (4), (4′) based on the master pair of rollers (2), (2′) and exerting tension on the fabric in the sewing and post-sewing areas.

2. The quilting machine for fabrics according to claim 1, wherein the slave pairs of rollers (3), (3′), (4), (4′) apply a maximum tension of 2000 N to the fabric (1) in the sewing and post-sewing areas.

3. The quilting machine for fabrics according to claim 1, wherein each pair of drive rollers consists of a fixed roller (2), (3), (4) and a movable roller (2′), (3′), (4′), with the fixed roller (2), (3), (4) being driven by the associated servomotor (7) which transmits movement to the movable roller (2′), (3′), (4′) by means of the set of chains (5) and sprockets (6).

4. The quilting machine for fabrics according to claim 1, wherein each roller (2), (2′), (3), (3′), (4), (4′) has a diameter between 75 and 200 mm.

5. The quilting machine for fabrics according to claim 1, wherein each roller (2), (2′), (3), (3′), (4), (4′) has a wall thickness between 3 and 20 mm.

6. The quilting machine for fabrics according to claim 1, further comprising a pair of feed drive rollers (11), (11′) associated with a pneumatic cylinder (8) and with a stabiliser bar (9), each roller of the pair of feed drive rollers having a diameter between 75 and 200 mm and a wall thickness between 3 and 20 mm, for introducing unsewn fabric (1) in the machine, generating an accumulation area of the fabric (1) before the sewing area.

7. The quilting machine for fabrics according to claim 6, further comprising a sensor (12) for measuring a linear length of fabric (1) in the accumulation area of the fabric (1) before the sewing area.

8. The quilting machine for fabrics according to claim 1, further comprising a pair of removal drive rollers (13), (13′) configured for removing sewn fabric (1) associated with a pneumatic cylinder (8) and a stabiliser bar (9), each roller having a diameter between 75 and 200 mm and a wall thickness between 3 and 20 mm, for driving the sewn fabric (1) generating an accumulation area of sewn fabric (1) after the post-sewing area.

9. The quilting machine for fabrics according to claim 8, further comprising a sensor (14) for measuring a linear length of fabric (1) in the accumulation area of the fabric after the post-sewing area.

10. The quilting machine for fabrics according to claim 1, has further comprising at least one free roller (15) before the sewing area and at least one free roller (15) after the post-sewing area.

11. The quilting machine for fabrics according to claim 1, wherein each of the drive rollers (2), (2′), (3), (3′), (4), (4′), is covered with rubber.

Description

DESCRIPTION OF THE DRAWINGS

(1) To complement the description that will be made below and for the purpose of helping to better understand the features of the invention according to a preferred practical embodiment thereof, a set of drawings is attached as an integral part of said description, in which the following is depicted in an illustrative and non-limiting manner:

(2) FIG. 1 shows a depiction corresponding to the cross-section of a quilting machine and the fabric to be sewn according to the object of the present invention.

(3) FIG. 2 shows a partial depiction of a perspective view of the rear part of the quilting machine.

(4) FIG. 3 shows a schematic depiction of the detail of the set of chains and sprockets in charge of transmitting movement between the rollers making up each of the pairs.

(5) FIG. 4 shows a partial depiction of a perspective view of the front part of the quilting machine.

PREFERRED EMBODIMENT OF THE INVENTION

(6) As can be seen in FIGS. 1, 2, and 4, in the present preferred embodiment the quilting machine comprises five pairs of drive rollers, between which a fabric (1), formed by two outer layers and one or more intermediate layers of padding, tightly passes. Each of the rollers making up the pair rotates in the opposite direction to the other roller, driving the fabric (1) and enabling it to move forward or backward through the quilting machine. The rollers (2), (3), (4), (11), and (13) are fixed and linked to a servomotor (7) with a gear reducer and variable speed drive, as observed in FIGS. 2 and 4, whereas the rollers (2′), (3′), (4′), (11′), and (13′) are movable. Pneumatic cylinders (8) linked to each pair of rollers at each of their ends allow varying the distance between paired rollers, therefore varying the pressure applied on the fabric (1).

(7) FIGS. 2 and 3 show in detail a set of chains (5) and sprockets (6) in charge of transmitting movement from the fixed rollers, rollers (2), (3), (4), (11), and (13), to the movable rollers (2′), (3′), (4′), (11′), and (13′).

(8) In one of the operating modes of the quilting machine, the unsewn fabric (1) is introduced through its lower part, moving forward vertically through said machine, as observed in FIGS. 1, 2, and 4. Three free rollers (15) guide the travel of the fabric (1) increasing its radius of curvature, facilitating a smooth entry into the machine, whereas the fabric (1) is driven by the pair of feed rollers (11), (11′), generating an accumulation area of the fabric (1). As described in detail above, the accumulation area allows the sewing operation to be isolated from external conditions before the quilting machine. A sensor (12) for measuring the linear length of the fabric, preferably a sensor roller, determines the amount of fabric (1) present in the accumulation area, which information is transmitted to the controller to regulate the speed and degree of rotation of the feed rollers (11), (11′).

(9) Then, a slave pair of drive rollers (3), (3′) drive the fabric (1), introducing it into the sewing area where one or more sewing heads (10), up to a maximum of 8 sewing heads, execute the sewing operation. The sewing heads (10) move laterally and independently, whereas the fabric (1) moves forward vertically in both directions of forward movement, giving rise to the sewing pattern. Advantageously, the use of a plurality of sewing heads allows production speed to increase.

(10) Next, the sewn fabric (1) is driven by the master pair of drive rollers (2), (2′), entering the post-sewing area due to the drive exerted by the slave pair of rollers (4), (4′).

(11) Therefore, the slave pairs of drive rollers (3), (3′) and (4), (4′) apply a maximum tension of 2000 N on the fabric (1) in the sewing and post-sewing areas, so the master pair of rollers (2), (2′) receives at all times tensed fabric, assuring the precision and correct execution of the predetermined sewing pattern, preventing creasing in the cloth during the forward and backward movement of the fabric (1).

(12) Advantageously, as described in detail above, a controller governs all of the pairs of rollers simultaneously, such that the master pair of rollers, (2), (2′) executes the sewing pattern, and the slave pairs of rollers, (3), (3′), (4), (4′) drive and tauten the fabric (1) in synchronisation with the actuation of the master pair (2), (2′).

(13) On the other hand, a pair of removal drive rollers (13), (13′) drives the sewn fabric (1), after passing through three free rollers (15) which increase the radius of curvature of the sewn fabric (1), generating an accumulation area at the outlet of the quilting machine, in which minimum tension is applied on the fabric (1), and which allows the sewing operation to be isolated from factors external to the operation after the quilting machine. In this accumulation area there is arranged a sensor (14) for measuring the linear length of fabric (1), preferably a distance sensor, in charge of transmitting to the controller information relative to the amount of fabric (1) accumulated in the mentioned area, for the regulation of the pair of drive rollers (13), (13′) driving the sewn fabric (1).

(14) As can be observed in the mentioned figures, each pair of drive rollers is linked to a stabiliser bar (9), which maintains a parallel position between paired rollers, preventing the fabric (1) from being subjected to greater pressure at one end of the machine that at the other, which results in the quality of the executed sewing pattern.

(15) Advantageously, the configuration described above enables the controller to act on the different servomotors (7) and variable speed drives to move the fabric (1) in both directions, i.e., moving forward or backward through the quilting machine based on the predetermined sewing pattern and production needs.

(16) The rollers making up each drive pair have a diameter between 75 and 200 mm, preferably 140 mm, and a wall thickness between 3 and 20 mm, preferably 8 mm. These dimensions cause the rollers to offer the stiffness needed to prevent vibrations and deformations in same.

(17) Lastly, it should be pointed out that the drive rollers are covered with rubber or a similar material in order to increase the friction coefficient with the fabric (1) to be quilted and to facilitate the movement of the fabric and protect its surface.