The present invention relates generally to tufting machines, and particularly to tufting machines adapted to determine the position of a knife on the tufting machine.
It is known to provide a tufting machine with a system for detecting jammed or broken yarn. See, e.g., U.S. Pat. No. 5,588,383 of Davis et al; U.S. Pat. No. 3,364,888 of Sibley, Jr. et al.; U.S. Pat. No. 3,529,560 of Jackson. However, such conventional tufting machines are not adapted to detect the actual position of a knife, compare the actual position of the knife to the desired position of the knife, and determine when the knife is not in the desired position. It is also known to provide a tufting machine with a system for detecting the position of a needle. See, e.g., U.S. Pat. No. 5,979,344 of Christman, Jr.; U.S. Pat. No. 5,503,092 of Aubourg et al. However, such conventional tufting machines are not adapted to detect the actual position of a knife, compare the actual position of the knife to the desired position of the knife, and determine when the knife is not in the desired position.
It would be desirable, therefore, if an apparatus could be provided that would detect the position of a knife on a tufting machine, compare the actual position of the knife to the desired position of the knife, and determine when the knife is not in the desired position. It would also be desirable if a method could be provided for detecting the position of a knife on a tufting machine, comparing the actual position of the knife to the desired position of the knife, and determining when the knife is not in the desired position. It would be further desirable if an apparatus and method could be provided that would reduce the number of manufacturing defects in and the amount of repair required for a tufted floor covering.
Accordingly, it is an advantage of the preferred embodiments of the invention described and claimed herein to provide an apparatus that detects the position of a knife on a tufting machine, compares the actual position of the knife to the desired position of the knife, and determines when the knife is not in the desired position. It is also an advantage of the preferred embodiments of the invention described and claimed herein to provide a method for detecting the position of a knife on a tufting machine, comparing the actual position of the knife to the desired position of the knife, and determining when the knife is not in the desired position. It is a further advantage of the preferred embodiments of the invention described and claimed herein to provide an apparatus and method that reduces the number of manufacturing defects in and the amount of repair required for a tufted floor covering.
Additional advantages of the invention will become apparent from an examination of the drawings and the ensuing description.
Explanation of Technical Terms
As used herein, the term “alarm” refers to any indication that the actual position of a knife is not the same as the desired position of the knife, including but not limited to visible indications, audible indications, tactile indications, combinations thereof and the like.
As used herein, the term “electrically-insulated knife” refers to a knife, blade or other suitable cutting device, mechanism, assembly or combination thereof that is electrically insulated or electrically isolated from the knife shaft of the tufting machine.
As used herein, the term “knife signal” refers to any transmitted electrical impulse, electric current, electromagnetic wave or any combination thereof that represents the actual position of a knife. The term “knife signal” also contemplates the absence of a signal.
As used herein, the term “pattern signal” refers to any transmitted electrical impulse, electric current, electromagnetic wave or any combination thereof. The term “pattern signal” also contemplates the absence of a signal.
As used herein, the term “programmable logic controller” refers to any device, mechanism, assembly or combination thereof that is adapted to receive, interpret and/or execute instructions.
As used herein, the term “solenoid” refers to any device, mechanism, assembly or combination thereof that is adapted to move the electrically-insulated knife in response to a pattern signal as that term is defined above.
As used herein, the term “switch” refers to any device, mechanism, assembly or combination thereof adapted to send an instruction to the programmable logic controller as that term is defined above.
The invention includes an apparatus for detecting the position of a knife on a tufting machine. The apparatus includes a grounded needle adapted to be moved between a penetrating position and a non-penetrating position. The apparatus also includes an electrically-insulated knife that is adapted to be moved between a cutting position and a non-cutting position. The knife is also adapted to send a knife signal when the knife is in the cutting position and the needle is in the penetrating position. The apparatus further includes a solenoid that is adapted to receive a pattern signal prescribing either the cutting position or the non-cutting position for the electrically-insulated knife. The solenoid is also adapted to cause the electrically-insulated knife to move between the cutting position and the non-cutting position in response to the pattern signal. The apparatus still further includes a programmable logic controller that is adapted to send the pattern signal to the solenoid, receive the knife signal from the electrically-insulated knife, compare the knife signal to the pattern signal, and determine if the electrically-insulated knife is in the position prescribed by the pattern signal.
The invention also includes a method for detecting the position of a knife on a tufting machine comprising providing an apparatus for detecting the position of a knife on a tufting machine as described immediately above. The method also includes inputting the pattern signal into the programmable logic controller, sending the pattern signal from the programmable logic controller to the solenoid, sending a knife signal from the electrically-insulated knife to the programmable logic controller, comparing the knife signal to the pattern signal, and determining if the electrically-insulated knife is in the position prescribed by the pattern signal.
In the preferred embodiments of the invention, the knife signal is produced and sent to the programmable logic controller when the electrically-insulated knife contacts the grounded needle. Also in the preferred embodiments of the invention, the programmable logic controller is adapted to activate an alarm, discontinue the operation of the tufting machine and/or store data relating to the knife signal and the pattern signal when the electrically-insulated knife is not in the position prescribed by the pattern signal a predetermined number of consecutive times.
The presently preferred embodiments of the invention are illustrated in the accompanying drawings, in which like reference numerals represent like parts throughout, and in which:
Referring now to the drawings, the preferred embodiments of the knife position detection system and method for detecting the position of a knife on a tufting machine are illustrated by
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In the preferred embodiments of the knife position detection system, programmable logic controller 18 is adapted to activate an alarm when electrically-insulated knife 14 is not in the position prescribed by the pattern signal. In another preferred embodiment of the knife position detection system, programmable logic controller 18 is adapted to activate an alarm when electrically-insulated knife 14 is not in the position prescribed by the pattern signal a predetermined number of consecutive times. In still another preferred embodiment of the knife position detection system, programmable logic controller 18 is adapted to discontinue the operation of the tufting machine when electrically-insulated knife 14 is not in the position prescribed by the pattern signal. In yet another preferred embodiment of the knife position detection system, programmable logic controller 18 is adapted to discontinue the operation of the tufting machine when the electrically-insulated knife is not in the position prescribed by the pattern signal a predetermined number of consecutive times.
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If, on the other hand, the actual position of the knife is not the same as the desired position of the knife, i.e., the knife signal is not consistent with the pattern signal, then the preferred method for detecting the position of a knife on a tufting machine determines whether the knife is experiencing a cutting position problem (i.e., the knife is sticking in the “up” position when it should be in the “down” position) or a non-cutting position problem (i.e., the knife is sticking in the “down” position when it should be in the “up” position). More particularly, the preferred method determines whether the knife is in the cutting position when the pattern signal prescribes the non-cutting position (a cutting position problem) or whether the knife is in the non-cutting position when the pattern signal prescribes the cutting position (a non-cutting position problem).
If the preferred method determines that there is a cutting position problem, a cutting position problem counter is increased by one and a non-cutting position problem counter is cleared. If the preferred method determines that there is a non-cutting position problem, the non-cutting position problem counter is increased by one and the cutting position problem counter is cleared. It is also contemplated within the scope of the invention that if the preferred method determines that there is a cutting position problem, then the cutting position problem counter is increased by one but the non-cutting position counter is not cleared. Similarly, it is also contemplated within the scope of the invention that if the preferred method determines that there is a non-cutting position problem, the non-cutting position problem counter is increased by one but the cutting position problem counter is not cleared. The counter may be any suitable device, mechanism, assembly or combination thereof adapted to maintain an accurate count of the number of incidences in which the knife signal is not consistent with the pattern signal.
Next, the preferred method compares the cutting position problem counter and the non-cutting position problem counter with the predetermined number of consecutive times that has been set to activate the alarm, discontinue the operation of the tufting machine and/or store the data relating to the knife signal and the pattern signal. If the preferred method determines that either of the position problem counter equals the predetermined number of consecutive times that has been set to activate the alarm, discontinue the operation of the tufting machine and/or store the data relating to the knife signal and the pattern signal, then the alarm is activated, the operation of the tufting machine is discontinued and/or the data relating to the knife signal and the pattern signal is stored. If, on the other hand, neither of the position problem counters equals the predetermined number of consecutive times that has been set to activate the alarm, discontinue the operation of the tufting machine and/or store the data relating to the knife signal and the pattern signal, then the method returns to the start.
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In operation, several advantages of the preferred embodiments of the invention are achieved. For example, the preferred embodiments of the invention provide an apparatus that detects the position of a knife on a tufting machine, compares the actual position of the knife to the desired position of the knife, and determines when the knife is not in the desired position. The preferred embodiments of the invention also provide a method for detecting the position of a knife on a tufting machine, comparing the actual position of the knife to the desired position of the knife, and determining when the knife is not in the desired position. The preferred embodiments of the invention further provide an apparatus and method that reduces the number of manufacturing defects in and the amount of repair required for a tufted floor covering.
Although this description contains many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments thereof, as well as the best mode contemplated by the inventors of carrying out the invention. The invention, as described herein, is susceptible to various modifications and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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Number | Date | Country |
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0058510 | Aug 1982 | EP |