Patent Application
20240200252
The disclosure and figures made in U.S. Provisional Patent Application No. 63/432,717, filed on Dec. 15, 2022, is specifically incorporated by reference herein as if set forth in its entirety.
The present disclosure generally relates to carpet tufting machines and in particular to yarn feed systems and/or pattern attachments including a series of yarn feed devices and drive mechanisms therefor for controlling the feeding of yarns to the needles of a tufting machine.
In the carpet-tufting field, considerable emphasis has been placed on developing new, eye-catching carpet patterns, including patterns with multiple colors and more intricate designs to keep up with changing consumer tastes and increased competition in the marketplace. With the development of tufting machines or systems such as “ColorPoint” by Card-Monroe Corp., designers have been enabled greater freedom to design and develop more complex tufted pattern designs to meet increasing customer demands. Such increasingly complex patterned tufted carpets include multi-colored tufted patterns, and tufted patterns with different pile heights, combinations of cut and loop pile tufts and other sculptured effects, which can be formed by controlling feeding of the yarns to the needles. Single-end and double-end yarn feed attachments have been developed to control of the feeding of the yarns through the use of an increased number of feed rolls and drive motors for feeding single yarns to each of the needles of a tufting machine. However, as the number of yarn feed rolls and the number of motors for driving such yarn feed rolls is increased, there is a corresponding increase in the costs and complexity of such yarn feed attachments. In addition, increasing the number of motors and yarn feed rolls also increases the size or footprint of the yarn feed attachments, which further increases the complexity of manufacturing and installation of such yarn feed attachments as a part of a tufting machine when the tufting machine is installed in the field.
Accordingly, it can be seen that needs exist for tufting machines and yarn feed systems that address these and other related and unrelated problems in the art.
Briefly described, the present disclosure generally relates to tufting machines and systems for production of tufted articles, including, without limitation, carpets, rugs, artificial grass or turf, and other tufted products; and to yarn feed systems, including, in embodiments, pattern yarn feed attachments that can be removably mounted on a tufting machine, which are adapted to feed a series of yarns to each of the needles of the tufting machine. The feeding of the yarns to each needle can be independently controlled by the yarn feed system to provide enhanced precision and control of the feeding of the yarns as needed or desired to form tufts of yarns (e.g., loop pile tufts, cut pile tufts, or combinations thereof) in a backing material being passed through the tufting machine, in accordance with tufted pattern instructions or designs.
In embodiments, each yarn feed unit can include a frame defining a housing in which a series of yarn feed devices are received and supported. Each of the yarn feed devices generally can include a yarn feed roll assembly mounted in an operative or driven relationship with an associated motor configured to drive rotation of one or more yarn feed rolls of the yarn feed device. In some embodiments, the yarn feed devices can be arranged in sets or groups that can be removably mounted within frames, thus defining modules that can be removably received within the housing of a yarn feed unit. In embodiments, such modules can include two or more yarn feed devices mounted with a common frame or housing, or otherwise packaged together, and which can include a plurality of yarn feed roll assemblies and motors.
In embodiments, each of the yarn feed devices will include one or more yarn feed roll assemblies, each of which can include a housing or roll support structure received and/or releasably mounted over a forward or operative end of a drive shaft of an associated motor, with the drive shaft of motor extending therethrough. One or more series or sets of yarn feed rolls, for example, in one embodiment, two sets of 2-3 yarn feed rolls, can be located along a front facing portion of the housing or roll support structure. In one embodiment, the forward body portions of the yarn feed rolls of each set of yarn feed rolls can be located in a spaced-apart arrangement, substantially out of contact with each other; and with at least one of the yarn feed rolls being engaged and driven by the drive shaft of the associated motor.
In embodiments, the yarn feed rolls can be formed as substantially unitary or one-piece structures, or, in some embodiments, can include a series of components combined into an assembly. For example, in embodiments, each of the yarn feed rolls can comprise injection molded or extruded rollers formed of a lightweight, high strength plastic, composite or synthetic material, with each yarn feed roll including a body having a first, proximal or drive end and a second, distal or feed end. A gear such as a spur, helical, spiral or other type of gear or sprocket having a series of radially projecting teeth also can be located or formed at or about the body of each yarn feed roll adjacent the drive ends thereof, or can be formed separately and mounted to each yarn feed roll. In addition, in embodiments, the bodies of the yarn feed rolls can include textured roll surfaces configured to provide increased traction or grip for pulling the yarns therebetween.
According to one aspect, the housing or roll support structure for each yarn feed roll assembly can comprise one or more sections or portions. For example, in an embodiment, the housing or roll support structure can include one or more plates; including, in embodiments, a base plate configured to mount to the housing of the yarn feed unit, and which further can be configured along a rear or drive side thereof to receive and releasably engage its corresponding motor, e.g., being mounted thereto such as by releasable fasteners. In addition, a cover plate can be mounted to the front side of the base plate, and can include recesses or openings defined in a front facing surface thereof. In embodiments, the yarn feed rolls of one or more yarn feed roll assemblies generally can be removably received within the recesses or openings formed in the front facing surface of the cover plate; for example, being arranged in a staggered or offset arrangement with their gear teeth engaging and intermeshing with each other, and with the forward portions thereof spaced apart so as to provide multiple points and/or a substantially increased area of contact between the yarns and the roll surfaces, and without the yarns being engaged and pinched therebetween. In embodiments, the yarn feed roll assemblies, including the sets of yarn feed rolls thereof can be removed with the housings or roll support structures as a unit, without necessarily having to remove the entire yarn feed device from the yarn feed unit or attachment. Alternatively, the yarn feed rolls could also be removed individually.
According to other aspects, each of the yarn feed roll assemblies can include two or more sets of yarn feed rolls, and at least one yarn feed roll of each set of yarn feed rolls can be linked to the drive shaft of its associated motor so as to be driven or rotated by the associated motor. In embodiments, each yarn feed roll assembly can be coupled or connected to a pair of associated motors coupled together with a shared motor controller. In embodiments, the motors can be arranged in a motor package or module. For example, in some embodiments, a motor package including two or more motors and a shared or integrated motor controller configured and operable to control each motor independently of the other motor, can be coupled to the yarn feed roll assemblies of each yarn feed device, with each motor being independently controlled by the shared motor controller to drive rotation of the set of yarn feed rolls connected thereto at different rates as needed to feed the yarns to the needles of the tufting machine.
In embodiments, such a motor package can be configured with a reduced footprint and can enable a reduction the number of electrical connections. In some embodiments, the motor packages further can enable a potential reduction in overall size and weight of the motors for driving the yarn feed roll, and thus can potentially enable a reduction in size and weight of the yarn feed devices; and in embodiments, further can help reduce the size, footprint and overall weight of the yarn feed unit.
In addition, in some embodiments, one or more status indicators can be provided, and can be configured to provide a visual or other indication of an operational status of the motors. For example, in embodiments, one or more indicators, such as LED's or other lights, can be located along the housing or roll support structure and can be linked to the motor controller. In some embodiments, the lights can be arranged behind or can be located along the cover plate of each housing or roll support structure. In some embodiments, the cover plate can be formed from an at least partially translucent material so that the lights can be seen therethrough when illuminated. The lights can flash or be illuminated to provide an indication of motor status, e.g., showing different colors to indicate different operating conditions and/or to indicate an error or fault condition.
During operation, in embodiments, the motor of each yarn feed device will drive at least one of the yarn feed rolls, with the remaining yarn feed rolls being driven by the engagement with the at least one driven yarn feed roll. As the yarn feed rolls are rotated, the yarns fed therebetween will be engaged and directed to selected needles of the tufting machine for formation of tufts of yarns within the backing material passing through the tufting machine. The configuration and structure of the present yarn feed roll assembly is configured to enable controlled feeding of the yarns thereby, as well as the efficient removal and replacement of the yarn feed rolls of each of the yarn feed devices individually and/or as a unit with the removal of the housing or roll support structure, without necessarily requiring removal of the entire yarn feed device. In addition, in embodiments, the motor packages can be removed and/or substituted either for removal/substitution of an entire yarn feed device, or to replace the motors. In embodiments, the sizing and spacing of the yarn feed rolls of the yarn feed drive system also can be varied for feeding different sizes, numbers or types of yarns, or as needed for other applications.
In embodiments, a series of yarn feed tubes also can be connected to the yarn feed devices. The yarn feed tubes can be configured to feed individual yarns from a yarn supply to each of the yarn feed devices, with the yarns being engaged and guided between the drive and idler rolls of their associated yarn feed devices.
According to another aspect, a control system is provided, and can include a system controller having one or more processors configured to execute instructions for forming various tufted patterns. The system controller can communicate with the motor controllers of each motor package of each of the yarn feed devices to provide pattern/operating instructions thereto. In embodiments, each of the motor controllers generally can be directly integrated with the motors of its motor package (e.g., with the motors of the motor package sharing and being independently controlled by an associated motor controller), and will be configured to control their motors in accordance with control instructions received from the system controller, such as being provided with instructions for controlling the feeding of one or more yarns fed by the yarn feed rolls linked thereto from the system control to form a tufted pattern. In addition, in some embodiments, each of the motor controllers can be directly linked to system controller by a communications network cable over which they can receive pattern control instructions from and provide direct feedback to the system controller regarding the current operation of the motors, and, in embodiments, feedback regarding the feeding of the yarns. In some embodiments, a wireless connection also can be provided.
In embodiments, the system controller can monitor feedback from the motor controllers, and provide pattern control instructions to the motor controllers for controlling the speed of each of their associated motors to individually control the feeding of one or more yarns to corresponding selected needles, e.g., by driving the rotation of the yarn feed rolls connected to the motors to feed varying amounts or lengths of yarns to form high or low tufts or yarns in the backing, or to selectively pull back certain yarns, as needed to form the desired or programmed pattern. In some embodiments, the system controller can be provided as a separate control cabinet or workstation having an input mechanism, such as a keyboard, mouse, etc. and a monitor and which generally will be in communication with a tufting machine control that monitors various operative elements of the tufting machine. Alternatively, in embodiments, the controller and/or at least some its functions can be incorporated or provided by a remote server, or further could be included as part of the system controller which can be mounted to the tufting machine frame, or provided as in control cabinet or station incorporated with the tufting machine.
In addition, in embodiments, the control system can be connected to a design center on which an operator can design a desired carpet patterns and which generally includes a computer that will calculate the parameters of such a design, including parameters including yarn feed rates, pile heights, stitch length, etc. This information can be created as a pattern data file, designed or programmed using pattern design software or a design system and input or electronically communicated to the control system controller and/or the system controller thereof via a network connection, disk or other file transfer. Alternatively, the control system can be provided with the design center components or functionality programmed therein so as to enable the operator to design or program carpet patterns at the tufting machine.
According to some aspects, a tufting machine is provided, comprising: at least one needle bar having a plurality of needles configured to carry a plurality of needles mounted therealong; a yarn feed system including a plurality of yarn feed devices configured to feed the plurality of yarns to the needles, each yarn feed device comprising at least one motor package, comprising at least two motors coupled together in a side-by-side or stacked configuration and a shared motor controller directly connected to each motor so as to form a substantially unitary component; and a plurality of yarn feed rolls coupled to each motor of the at least one motor package, each set of yarn feed rolls including at least two yarn feed rolls configured to feed one or more yarns to selected needles; and a control system including programming configured to control feeding of a backing and feeding of each of the plurality of yarns to the needles to form with a selected pattern; wherein the motor controller of each motor package is configured to receive instructions from the control system and independently control each motor of its motor package so as to drive rotation of the yarn feed rolls to selectively feed each yarn to the needles as needed to form high or low tufts of yarns in a backing material, or to pull certain yarns back, as needed to form the selected pattern.
In embodiments of the tufting machine, each set of yarn feed rolls can comprise three yarn feed rolls.
In embodiments of the tufting machine, each yarn feed device further comprises a housing or roll support structure positioned in front of the at least one motor package and configured to receive a drive shaft of each motors of the at least one motor package therethrough; and wherein each of the sets of yarn feed rolls are removably received within the roll support structure.
In embodiments of the tufting machine, the roll support structure can comprise a base plate positioned in front of the motors of the at least one motor package and having at least two openings configured to receive the drive shafts of each motor therethrough; a cover plate received over the base plate and the drive shaft of each motor; and at least one indicator located along the cover plate.
In embodiments of the tufting machine, the cover plate comprises a plurality of recesses formed therealong; and wherein the yarn feed rolls of each set of yarn feed rolls are received within the recesses formed along the cover plate and each include a series of gear teeth located adjacent one end thereof, wherein the yarn feed rolls of each set of each yarn feed rolls are received within the recesses of the cover plate with the gear teeth of the yarn feed rolls in intermeshing engagement such that the yarn feed rolls are driven together by the driving of at least one yarn feed roll by at least one of the motors.
In embodiments of the tufting machine, each set of yarn feed rolls of each yarn feed device comprises at least three yarn feed rolls; and wherein each yarn feed device further comprises at least one indicator configured to generate an indication of a motor state of each motor.
In embodiments of the tufting machine, the tufting machine can include one or more indicators adapted to provide an indication of a motor state of each motor.
In some embodiments, the at least one indicator can comprise at least one light configured to be illuminated to indicate one or more motor states, and wherein the yarn feed device further includes a cover plate positioned in front of the at least one indicator and comprising a substantially translucent material, such that when illuminated, the at least one light is visible through the cover plate.
According to other aspects, a system is provided, comprising: at least one yarn feed unit having a plurality of yarn feed devices received therein, the yarn feed devices configured for feeding yarns to a plurality of needles of a tufting machine; wherein the yarn feed devices each comprise: at least one motor package comprising two or more motors and a motor controller coupled to each of the motors so as to be substantially integrated therewith; and two or more yarn feed roll assemblies, each yarn feed roll assembly comprising a plurality of yarn feed rolls; wherein the yarn feed rolls are arranged in sets of at least two yarn feed rolls and each comprise a body having a forward portion about which one or more yarns are passed and a rear portion; wherein the motor controller of the at least one motor package is configured to independently control operation of each motor of the motor package to drive rotation of the yarn feed rolls so as to feed selected amounts of yarns to the needles; wherein each motor drives at least one yarn feed roll of a set of yarn feed rolls of a yarn feed roll assembly associated therewith; wherein rotation of the at least one yarn feed roll drives rotation of other yarn feed rolls of the set of yarn feed rolls such that the one more yarns extended about the forward portions of each of the yarn feed rolls are drawn thereabout and fed to the needles of the tufting machine.
In embodiments of the system, each yarn feed roll assembly of each yarn feed device further comprises a roll support structure over the motors of the at least one motor package and within which the sets of yarn feed rolls of the yarn feed roll drive assembly are received; wherein the roll support structure, with the sets of yarn feed rolls received therein, is configured to be removeable.
In embodiments of the system, each yarn feed roll drive assembly comprises two sets of yarn feed roll and a roll support structure positioned in front of the at least one motor package; wherein the yarn feed rolls of each set of yarn feed rolls are received within recesses defined in a front portion of the roll support structure; and wherein each of the sets of yarn feed rolls are removable from engagement with the motors and the roll support structure as a unit.
In embodiments of the system, each of the yarn feed rolls comprises a textured surface along the forward portions thereof and a series of gear teeth located adjacent the rear portion of the body thereof, and wherein the yarn feed rolls each are received within a recess formed within a roll support structure positioned over the motors, with the gear teeth of each yarn feed roll of each set of yarn feed rolls intermeshing engagement such that the yarn feed rolls are rotated together by the driving of the at least one yarn feed roll.
In some embodiments of the system, each yarn feed roll of at least one set of yarn feed rolls comprises a different number of gear teeth so as to cause different ones of the yarn feed rolls of the at least one set of yarn feed rolls to be driven at different rates.
In embodiments of the system, each yarn feed roll assembly comprises at least two sets of yarn feed rolls and a roll support structure mountable over the drive motors; wherein the roll support structure includes a base plate having openings configured to receive a drive shaft of each motor therethrough and a cover plate along which the sets of yarn feed rolls are received.
In embodiments of the system, the cover plate comprises a substantially translucent material; and wherein each yarn feed device further comprises at least one indicator, including at least one light configured to be illuminated to indicate one or more motor states; wherein when illuminated, the at least one light is visible through the cover plate.
In embodiments, the yarn feed system of the present disclosure is adapted to provide for the manufacture of standardized yarn feed attachments or units, each of which can include a plurality of yarn feed devices. In embodiments, such yarn feed attachments or units can be removably installed on a tufting machine without requiring the custom design and installation of such a pattern attachment. In embodiments, the yarn feed devices of such a yarn feed unit further can include motor packages with multiple motors coupled to a shared or integrated motor controller included in the motor package, which motor controller can control each of the motors independently. Additionally, in embodiments, multiple sets of yarn feed roll assemblies can be coupled to the motor packages and can be driven thereby for feeding yarns to each of the needles. The yarn feed devices can thus be provided with a reduced footprint, size, and/or weight, and can be removable in whole or in part, e.g., the motor packages, the yarn feed roll assemblies, or the entire yarn feed devices can be quickly and easily removed and replaced in the yarn feed system. In embodiments, the yarn feed devices, and/or the motor packages further can include mounting alignment features adapted to guide and/or align the motor packages into position within a yarn feed unit of the yarn feed system.
Various additional aspects of tufting machines and systems for production of tufted articles are disclosed herein, including, without limitation, a tufting machine, comprising backing feed rolls configured to feed a backing material through the tufting machine; a plurality of needles carrying a plurality of yarns and driven in a reciprocating motion into and out of the backing material as the backing material is fed through the tufting machine; and a yarn feed system including a plurality of yarn feed devices configured to feed a plurality of yarns to the needles, each of the yarn feed devices comprising a series of yarn feed roll assemblies, each including at least one set of yarn feed rolls about which a selected number of yarns are fed; and at least one motor package including at least two motors and a shared motor controller coupled to each motor; wherein each motor of the at least one motor package is coupled to at least one yarn feed roll of at least one set of yarn feed rolls; and wherein the motor controller of the at least one motor package is configured to control each motor of the at least one motor package independently so as to enable selective control of the feeding of selected yarns by the yarn feed rolls coupled thereto.
In embodiments of the tufting machine, the at least one set of yarn feed rolls comprises three yarn feed rolls.
In embodiments of the tufting machine, the yarn feed rolls each can comprise a body having a series of gear teeth arranged adjacent one end of the body; wherein the yarns being fed by each yarn feed device are extended about the bodies of each of the yarn feed rolls; and wherein the gear teeth of each of the yarn feed rolls are configured to engage with gear teeth of one or more adjacent yarn feed rolls in an intermeshing engagement; such that all of the yarn feed rolls are caused to rotate upon rotation of at least one of the yarn feed rolls by a motor coupled thereto.
In some embodiments, at least one yarn feed roll of each set of yarn feed rolls, can comprise a textured roll surface.
In embodiments of the tufting machine, each yarn feed roll assembly of each yarn feed device further can comprise a housing or roll support structure having openings configured to receive a drive shaft of the motors of the at least one motor package therethrough; and wherein the feed rolls of each yarn feed roll assembly are removably mountable within the roll support structure.
In some embodiments, the roll support structure further can comprise a base plate positioned in front of the motors of the motor package with the drive shaft of each motor extending therethrough; a cover plate received over the base plate and each of the drive shafts of the motors; and at least one indicator located along the cover plate.
In other embodiments, each yarn feed roll assembly can comprise at least two sets of yarn feed rolls; wherein each yarn feed roll of each set of yarn feed rolls is received within a recess formed within the cover plate and includes a series of gear teeth located adjacent one end thereof; and wherein the gear teeth of the yarn feed rolls of each set of each yarn feed rolls are engaged together in intermeshing engagement such that the yarn feed rolls are driven together by the driving of at least one yarn feed roll by at least one of the motors.
In embodiments, each set of yarn feed rolls includes three yarn feed rolls.
In embodiments, the motors and motor controller of each motor package can be arranged in a vertically stacked configuration. In some embodiments, the motors and motor controller of each motor package can be arranged in a side-by-side configuration.
In embodiments of the tufting machine, each yarn feed roll assembly of each yarn feed device can comprise at least two sets of yarn feed rolls and a roll support structure positioned in front of the motors; wherein the roll support structure can include a base plate having openings configured to receive a drive shaft of each motor therethrough; and a cover plate positioned over the base plate.
In some embodiments, each yarn feed roll assembly is configured to be removable from the motors of the at least one motor package as a unit.
In some embodiments, each yarn feed device can further include at least one indicator positioned along the cover plate.
In some embodiments, the at least one indicator can comprise at least one light configured to indicate one or more motor states when illuminated; and wherein the cover plate can comprise a substantially translucent material, such that when illuminated, the at least one light is visible through the cover plate.
In another aspect, a system for feeding yarns to a plurality of needles of a tufting machine comprises at least one yarn feed unit; and a series of yarn feed devices received within the yarn feed unit; wherein the yarn feed devices each comprise a motor package comprising two or more motors and a shared motor controller configured to independently control operation of each motor of the motor package; and two or more yarn feed roll assemblies, each yarn feed assembly comprising at least one set of at least two yarn feed rolls, yarn feed roll each comprising a body having a forward portion about which one or more yarns are passed and a rear portion; wherein each of the motors of each motor package of each yarn feed device drives at least one yarn feed roll of a set of yarn feed rolls of a yarn feed roll assembly associated therewith; and wherein rotation of the at least one yarn feed roll drives rotation of one or more other yarn feed rolls of the at least one set of yarn feed rolls such that the one more yarns extended about the forward portions of each of the yarn feed rolls of the set of yarn feed rolls are drawn thereabout and fed to the needles of the tufting machine.
In embodiments of the system, each yarn feed roll drive assembly can comprise a roll support structure removably mountable over the motors of the at least one motor package, and wherein the one or more sets of yarn feed rolls of each yarn feed roll drive assembly are removably mountable from the roll support structure.
In embodiments of the system, each yarn feed roll drive assembly can comprise at least two sets of yarn feed rolls and a roll support structure positioned in front of the at least one motor package; wherein the yarn feed rolls of each set of yarn feed rolls are received within recesses defined in a front portion of the roll support structure, and wherein the yarn feed rolls are removable with the roll support structure as a unit.
In embodiments of the system, each of the yarn feed rolls can comprise a textured surface along the forward portions thereof and a series of gear teeth at the rear portion of the body thereof. In some embodiments, the yarn feed rolls each are received within a recess formed within a roll support structure, with the gear teeth of each yarn feed roll arranged in intermeshing engagement such that the yarn feed rolls are rotated together by the driving of at least one yarn feed roll one of the motors.
In some embodiments of the system, at least one yarn feed roll of the yarn feed rolls of the at least one of the set of yarn feed rolls comprises a different number of gear teeth so as to cause different ones of the yarn feed rolls to be rotated at different rates.
In embodiments of the system, each yarn feed roll assembly can comprise at least two sets of yarn feed rolls, and a roll support structure mountable over the motors and including a base plate having openings configured to receive a drive shaft of each motor of the at least one motor package therethrough, a cover plate, and at least one indicator visible along the cover plate; wherein each yarn feed roll assembly is removable from the motors of the at least one motor package as a unit.
In some embodiments, the cover plate can comprise a substantially translucent material. In embodiments, the at least one indicator can comprise at least one light that can be illuminated to indicate one or more motor states, wherein the at least one light is visible through the cover plate when illuminated.
In embodiments of the system, the body of each yarn feed roll can comprise a molded or machined structure. In some embodiments can have a textured surface substantially integrally formed therealong. In addition, in embodiments, a series of gear teeth can be formed as a part of the body of each yarn feed roll at a first end thereof so as to define a substantially unitary yarn feed roll.
Various features, objects and advantages of the present disclosure will become apparent to those skilled in the art upon reading the following detailed description when taken in conjunction with the accompanying drawings.
The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced. Those skilled in the art further 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 disclosure described herein.
Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views,
In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of embodiments of the invention. It will be apparent, however, to an artisan of ordinary skill that the present invention may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific features, quantities, or measurements well known to those of ordinary skill in the art have not been described in detail so as not to obscure the invention. Readers should note that although examples of the invention are set forth herein, the claims, and the full scope of any equivalents, are what define the metes and bounds of the invention.
As one of ordinary skill would appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name only. The figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. When referring to the figures described herein, the same reference numerals may be referenced in multiple figures for the sake of simplicity. In the following description and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus, should be interpreted to mean “including, but not limited to.”
As used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural elements of references unless the context clearly dictates otherwise. Thus, for example, reference to a yarn feed device can include one or more yarn feed devices.
“Coupled” refers to either a direct connection or an indirect connection (e.g., at least one intervening connection) between one or more objects or components. The phrase “directly attached” means a direct connection between objects or components.
As used herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numeral ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and are considered to be within the scope of the disclosure.
In embodiments, the yarn feed system 10 can comprise a yarn feed pattern attachment configured to be mountable to a tufting machine 11 (
As indicated in
It will be understood that the yarn feed system of the present disclosure can be utilized on any type of tufting machine, including tufting machines having single and dual needle bars 17, which needle bars also can be shifted in a transverse direction across the backing material. In embodiments, the needle bar or needle bars can have various arrangements of needles mounted therealong. For example, the needle bar or needle bars can have in-line or staggered rows of needles.
As the needle bars are reciprocated, the needles 13 are moved vertically between a raised position out of engagement with the backing material 14 passing therebeneath and a lowered, engaging position extending through the backing material. A series of gauge parts 24 (
The tufting machine 11 further can be include a control system 25 including a system controller or control unit 26 that in embodiments can include programming configured to monitor and control the various operative elements of the tufting machine, such as the reciprocation of the needle bars, the backing feed, shifting of the needle bars, bedplate position, feeding of the yarns, etc. In embodiments, the system controller 26 generally can be linked to and/or incorporated with the tufting machine. For example, in embodiments, such as shown in
Still further, it will be understood by those skilled in the art that while the controller has been disclosed in an example embodiment as including a separate work-station, or as being housed a separate cabinet, the system controller further can be otherwise linked to or coupled to the tufting machine. For example, in some embodiments, the system controller could be mounted to the tufting machine frame, and could include a monitor and operator interface configured to enable an operator to monitor and/or control the operation of the tufting machine. It is also may be possible to include the system controller 26 as part of an overall operational control system, with the control functions of the yarn feed system 10 and other operative components of the tufting machine 11 being controlled and operated with a single operator interface; and in some embodiments, the control system can be linked to a remote server.
The system controller 26 generally will be configured to monitor feedback from and control various operative or drive elements of the tufting machine. For example, in embodiments, such as monitoring and receiving feedback from a main shaft sensor (e.g. in embodiments, an encoder) for controlling the one or more a main shaft drive motors so as to control the reciprocation of the needles; monitoring and controlling one or more drive motors for the backing feed rolls 18, for feeding the backing material through the tufting zone; and monitoring and controlling feeding of the yarns to each needle by the yarn feed system 10. In embodiments, one or more sensors also can be mounted to the frame 16 in a position to provide further position feedback regarding the needles. In addition, in some embodiments, for shiftable needle bar tufting machines, the system controller 26 also can monitor and control the operation of one or more needle bar shift mechanism(s) (
The system controller 26 (
A pattern file and/or possibly graphic representations of a desired carpet pattern can be provided to the control system, which pattern file can include instructions and/or calculations of various parameters required for tufting such a carpet pattern at the tufting machine, including calculating yarn feed rates, pile heights, backing feed or stitch rate, and other required parameters for tufting the pattern. In embodiments, these pattern files then can be downloaded or transferred to the system controller, to a USB, disk or similar recording medium, or can be stored in memory either at the design center or on a network server for later transfer and/or downloading to the system controller.
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As further illustrated in
In embodiments, each yarn feed unit further can be provided with a number or series of yarn feed devices. For example, each yarn feed unit can be provided with a number of yarn feed devices that can generally correspond to some multiple of the needles of the tufting machine, e.g., in some embodiments, each yarn feed unit can be manufactured with about 100-200 yarn feed devices 70 removably mounted therein (although other configurations having greater or fewer yarn feed devices can also be used). The yarn feed units thus can be manufactured as substantially standardized attachments or units that can be manufactured and stored in inventory for use as needed, without requiring the custom manufacture and assembly of a yarn feed unit of the present disclosure with the construction of the tufting machine. Accordingly, in some embodiments, when the yarn feed system of the present disclosure is required, a series of yarn feed units or attachments according to the present disclosure can be removed from inventory and mounted in series across the width of a tufting machine, with the number of yarn feed units selected dependent upon the number of needles of the tufting machine and the number of yarns being controlled by the yarn feed devices thereof.
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As further illustrated in
In addition, in some embodiments such as shown in
Such modules 75 can be removed/replaced as a multi-set or group of yarn feed devices 70 received within the yarn feed unit. For example, in embodiments, such modules 75 can include 2, 4, 6, or more yarn feed devices 70 mounted in a replaceable module frame 75A that can include a face plate 77A and rear mounting plate 77B; with a series of openings 76 and recesses configured to receive the yarn feed devices therein, and with a wall or partition 77C separating the yarn feed devices 70.
In embodiments, each motor package 72 can include two or more motors 73, such as indicated in
In embodiments, as shown in
In some embodiments, the recesses 78 further can have an open ended construction with a rear side or portion thereof being open, or with an opening formed therethrough. This can enable receipt of a control cable 102 therethrough for connection to the integrated motor controller 80 of an associated motor package; and, in some embodiments, also can help promote air flow around and/or dissipation of heat from the motor packages.
In embodiments, each face plate 77A and mounting plate 77B can be formed from a metal such as aluminum or other lightweight, high strength material. Each of the openings 76 defined in the face plate further can be configured to enable a motor package to be slideably received therethrough. In some embodiments, a series of fasteners, such as bolts, screws, clips, or other similar removable fastening mechanisms, can be extended through the faceplate 77A and can engage corresponding fastener openings or apertures of the front plates 72A of the motor packages 72 for releasably securing the motor packages within the yarn feed unit.
As further illustrated in
In addition, each of the motor controllers 80 can be linked to the overall control system for the tufting machine, and can be configured to send position information for each of its associated motors to the system controller of 26 (
By linking the two or more motors 73 of each motor package to a single shared or integrated motor controller 80, a cost savings can be provided through sharing of the motor controller between at least two motors. In addition, in embodiments, the number of electrical connections (e.g., cables 102) that may be required to connect the motor controllers to the control system can be further reduced, enabling a more efficient and easier connection the motor controllers to the control system. For example, a single connection and/or cable can be connected to each motor package 72, enabling a reduction of up to ½ or more of such connections.
As additionally indicated in
In addition, as shown in
Each of the motors 73 further generally can comprise variable speed electric motors. For Servo motors, Stepper motors or other, similar motors, with a range of speeds of about 1000-5000 rpm or higher, and in embodiments, about 2000-4000 rpm. Each motor further can be of sufficient size and power that is generally sufficient to pull a constant force on a yarn or yarns Y being pulled and fed thereby. For example, in embodiments, the motors can be configured to be able to pull at least approximately 0.75-2.5 Nm peak torque, and in embodiments about 1.0-1.2 Nm peak torque. Preferably, the motors will have a motor power range of about 15 W to 100 W, sufficient to be able to provide yarn feed rates of up to 1500-1800 inches per minute. Other power ranges and yarn feed rates also can be provided.
However, it will be also understood that a variety of different type variable speed electric motors can be used for the motors 73 of the yarn feed units 70 in order to feed a range of yarn sizes (deniers) and materials that would or could be used in the tufting process, which motors are sufficiently compact in size for use in the yarn feed unit of the present disclosure. In embodiments, the motors can have a length of between approximately 5-12 inches (127 mm to 305 mm), and in embodiments, depending on the motors selected and the torque and/or pulling force required; and in some other can range between approximately 3-12 inches or less in length (76 mm to 305 mm); and in embodiments, can have a diameter or face size of approximately 1.0-3.0 inches (25.4 mm to 76 mm), although larger or smaller sized motors can be used, depending upon the application or system requirements. In embodiments, the motors 73 can include an internal encoder or similar feedback device for monitoring the position or speed of the motor. In addition, the motors can be selected for enhanced efficiency of the system for factors such as heat (power) management at the motor drive electronics and power supplies.
In embodiments, as indicated in
In embodiments, such as illustrated in
In embodiments, each of the cover plates 86 can have two or more groups of recesses 84, each of which can be configured to receive a corresponding set 79 of yarn feed rolls 83A-83C. In such a configuration, as illustrated in
The base and cover plates also can include yarn tube openings 89 configured to receive one or more yarn feed tubes 92 therethrough. The yarn feed tubes can be formed from a plastic or lightweight metal material, or can be formed from various other types of metals or synthetic materials having reduced frictional coefficients so as to reduce the drag exerted on the yarns passing therethrough. The yarn feed tubes can extend rearwardly through the base plate and along the motor package and connect to further yarn tubes 92A (
In embodiments, an indicator 100 further can be provided providing an indication of motor status or state of operation for each of the motors of each motor package. For example, in some embodiments the indicator can include a series of lights 101 arranged between the cover plate and the base plate. For example, in a non-limiting embodiment such as shown in
In embodiments, the indicator 100 can comprise a series of LED's, with the LED's being selectively illuminated by the motor controller 80 of the associated motor package 72 so as to generate an indication of operating conditions or a status of the motors of the motor package. When illuminated, the lights can be visible through the substantially clear, semi-transparent or translucent cover plate 86. In some embodiments, the LED's can be illuminated to provide different colors, such as yellow, green, red, or other colors, indicate normal operating conditions and/or fault conditions of the motors. For example, in some embodiments, a green light can be used to indicate the state of one or more of the motors. Alternatively, in embodiments, individual one's of the lights can be selectively illuminated to indicate various conditions relating to the operation of the yarn feed devices, e.g., a defect or stoppage of the operation of one or more motors, yarn breakage or mis-feeds, or other conditions that might require operator attention.
In embodiments, the roll support structure 82 (
In some embodiments, the roll support structures and/or the yarn feed rolls can be formed in varying sizes and/or configurations as needed to accommodate the feeding of various numbers and/or sizes of yarns as well as different types of yarns and/or other materials to be fed by the yarn feed rolls. In embodiments, the yarn feed roll assemblies can provide an easily replaceable yarn feed drive system and/or yarn feed device, that can be quickly changed or reconfigured with yarn feed rolls adapted or sized for feeding desired size and/or types of yarns or other materials, and which further can enable the formation of various standard yarn feed roll drive assembly or system designs or configurations. For example, in embodiments, the yarn feed rolls can be removed and replaced with their roll support structures as part of a substantially integrated drive system unit, or simply selected parts thereof, such as the yarn feed rolls, can be replaced as needed.
In the embodiments, such as shown in
As indicated in
The additional yarn feed rolls 83B and 83C of each set of yarn feed rolls each generally can be pivotally mounted within their recesses on bushings or shafts 113 received through openings formed therethrough, and will be driven by the engagement of their gear teeth with the gear teeth of the first driven yarn feed roll 83A as it is driven by the motor. The bushings can be coated with or manufactured from polytetrafluoride (e.g., Teflon®), an acetyl resin (e.g., Delrin®) or other, similar reduced friction material, and will support the additional, non-drive or idler yarn feed rolls 83B and 83C while enabling substantially free rotation of the drive rolls 83B and 83C thereabout.
In addition, in embodiments, the mounting arrangement of the yarn feed rolls, with their gear teeth engaged in an intermeshing relationship, can help maintain the yarn feed rolls with their forward ends 107 generally extended in a substantially parallel, spaced relationship. In addition, in embodiments the gear teeth/structures of the yarn feed rolls can be formed at a generally 1:1 ratio, while in other, alternative embodiments, the gear teeth can be formed at other, varying ratios such that one or more of the yarn feed rolls of each set can have different numbers of teeth. Such an arrangement can enable adjustment of roll surface speeds as needed to provide different levels of tension control of the yarns being fed by varying the ratios of the gear teeth, e.g., the first yarn feed roll can be driven at a first speed and the second and third yarn feed rolls driven at second and/or third, different rates.
In some embodiments, as shown in
The arrangement and configuration of the yarn feed rolls of the present yarn feed drive system 10, with the yarn feed rolls being geared together and the yarns entwined or fed thereabout, thus can enable tighter and/or more active, higher control of the feeding of the yarns wrapped and fed thereabout over multiple twist points of the yarns, helping maintain traction and reduce incidence of slipping of the yarns as the yarns are drawn thereabout. The yarn feed rolls also are provided with textured roll surfaces, which, in embodiments, can be applied as a replaceable covering or as a coating, or in other embodiments, can comprise texturing formed along their bodies. The textured surfaces generally will be configured to provide further increased or enhanced traction or grip of the yarns during pulling or feeding of the yarns by the yarn feed rolls.
In embodiments, various textured, tacky or enhanced grip materials also can be used to provide the textured surfaces to the yarn feed rolls. For example, an emery paper or similar abrasive/grit material carrier or sleeve can be applied about the body of each drive roll, and/or, in some embodiments, the drive rolls can be coated with metalized arc spray or thermal spray coating materials that provide a tacky feel or increased grip. Other materials and/or combinations of such textured, tacky or abrasive gripping materials also can be used, including the use of different materials on different ones of the yarn feed drive rolls.
In operation, in embodiments, as indicated in
As the yarn feed rolls become worn, or if there is a need to change out the yarn feed rolls to feed different yarns (i.e., yarns of a different size or type), the yarn feed rolls can be quickly and easily disengaged from the motor and the housing, and thereafter replaced with new yarn feed rolls. For example, in one embodiment, the yarn feed rolls can be directly removed from their associated housings and motors, such as with the removal of their fasteners and/or bushings, after which the yarn feed rolls, or possibly the forward body portions thereof, can be replaced with new yarn feed rolls, without necessarily having to remove the housing and/or motor (or the entire yarn feed device, in embodiments) from the yarn feed unit or pattern attachment.
Alternatively, in other embodiments, such as when the entire set of yarn feed rolls needs to be changed out to utilize other, different or varying size yarn feed rolls, the housing and yarn feed rolls can be removed from their associated motor, without having to necessarily remove the motor from the yarn feed attachment or unit housing for replacement of one or more of the yarn feed rolls. It will, however, also be understood that it may be possible to remove and replace the entire yarn feed devices, including the motor packages and the yarn feed roll assemblies thereof, as a unit. Still further, in embodiments, such as where a series of yarn feed devices are provided as a set or module having two of more yarn feed devices mounted together in a removable frame or package, such sets of yarn feed devices can be removed as a unit with the removal of their frame or package.
As indicated in
As additionally shown in
In some embodiments, it further can be possible to replace the CAN bus communication system line or cable with other high speed fieldbus communications network connection or bus communication systems, such as an Ethernet, Firewire, USB or other, similar high speed network connection or system. Thus, a single cable can be used to provide instructions from the system controller to the yarn feed controllers of the yarn feed system, and to the motor controllers for control of each motor of their motor package to drive rotation of the yarn feed rolls connected to each motor at different rates (including slowing or potentially stopping rotation of the yarn feed rolls) to feed varying amounts of yarns controlled thereby to the needles associated therewith to form high or low pile tufts or to pull back certain yarns as needed to form various tufted patterns yarn or yarns being fed thereby according to programmed pattern instructions, as well as providing real-time feedback from each motor of the pair or set of the motors of each motor package via their motor controllers.
In embodiments, each motor controller can monitor and communicate real-time feedback information regarding the position of both of its associated motors directly to the control system, which is further receiving feedback regarding other operating systems of the tufting machine, including the position and/or speed of the main shaft, the operation of the backing feed, etc. In response to such feedback information, the system controller of the control system can calculate new motor positions and/or speeds and send updated calculated individual motor position instructions for each motor of the motor package to each of the motor controllers thereof to adjust the operation of each motor individually, e.g., increase or decrease the operating speed thereof, for a desired or prescribed time period of operation of each motor, to accordingly adjust the feed rate of the yarn or yarns being fed by the motors according to the programmed tuft pattern which adjustments can be made substantially in real-time.
The system controller of the control system generally can communicate with each of the yarn feed controllers of the yarn feed devices, with feedback reports being provided from the motor controllers to the system controller. For example, in embodiments, such feedback or other operational information can be provided over a real-time network so as to provide a substantially constant stream of information/feedback regarding the motors. Pattern instructions or motor position information for causing the motor controllers to increase or decrease the rate of operation of the motors and thus change the rate of feed of the yarns as needed to produce the desired pattern step(s) can be provided from the control system.
In addition, in embodiments, the motors can be electronically geared to the main shaft of the tufting machine, e.g., in embodiments, at desired buffered gear ratios that vary depending upon the yarns being fed and the rates of feed of such yarns. The control system can process the feedback information from the tufting machine and from the motor controllers of each motor package, and will issue motor control position instructions or commands to the motor controllers. In response, the motor controllers can control their associated motors for varying the feeding of the individual yarns to each of the respective needles as needed, depending upon the pattern, step, or sequence being run.
The present disclosure accordingly provides a yarn feed roll drive system or assembly that can enable the efficient and easy change out or removal of yarn feed devices, including yarn feed rolls and motors thereof as needed from a pattern attachment or yarn feed unit of a tufting machine. The yarn feed roll drive system further enables the control of individual or single ends of yarns to each of the needles of a tufting machine to enable enhanced control of the feeding of the yarns so as to provide greater precision and to enable a greater varicty and variation in designing and producing carpet patterns.
The yarn feed control system of the present disclosure further enables the manufacture of substantially standardized yarn feed units or attachments that can be constructed with a desired number of yarn feed devices that can be manufactured and tested separately from a tufting machine. In embodiments, such yarn feed units or attachments can be maintained in inventory for mounting on a tufting machine as needed, without requiring a custom manufacture of the yarn feed units. Multiple yarn feed units can be selected from inventory and mounted on a tufting machine and connected to a to the system controller of the control system 25 without requiring extensive cabling to be run and electrical connections made and tested in the field.
Additionally, in embodiments, the yarn feed devices can be constructed as substantially integrated units comprising a motor package of two or more yarn feed motors directly connected/mounted to and linked with one shared or integrated yarn feed controller, and which can be provided in a common housing or package, and with a yarn feed roll assembly having sets of yarn feed rolls being coupled to the motor package to form such substantially integrated yarn feed device.
The construction of the yarn feed units of the present disclosure, including the use of the integrated yarn feed devices, accordingly can help improve reliability and efficiency of manufacture and installation of such units on a tufting machine, further helping to improve the efficiencies in the manufacture and set-up of the tufting machines in the field. The design of the yarn feed control system of the present disclosure further enables relatively quick and efficient expansion and removal and replacement of yarn feed devices or other operative components as needed for ease of manufacturing and maintaining the system.
It will be further understood by those skilled in the art that while the present disclosure has been described above with reference to preferred embodiments, numerous variations, modifications, and additions can be made thereto without departing from the spirit and scope of the present disclosure as set forth in the following claims.
The present Patent application claims the benefit of U.S. Provisional Patent Application No. 63/432,717, filed Dec. 15, 2022.
| Number | Date | Country | |
|---|---|---|---|
| 63432717 | Dec 2022 | US |
