Needle thread tensioning device

Abstract

A shifter adjustment assembly is configured to be coupled to a shifter of a tufting apparatus, the shifter having a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment. The shifter adjustment assembly includes a first body configured to be coupled to respective first ends of the first shaft segment and the third shaft segment. A second body is configured to be coupled to respective first ends of the second shaft segment and the fourth shaft segment. The assembly includes a coupling between the first body and the second body. The coupling is configured to releasably secure an axial position of the first body relative to the second body along a longitudinal dimension. The first body and the second body define respective complementary surfaces configured for sliding engagement such that movement between the first body and the second body is limited in a transverse dimension and allowed in the longitudinal dimension.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to and the benefit of the filing date of U.S. Provisional Application No. 63 / 015,849, filed April 27, 2020, the entire contents of which are hereby incorporated by reference herein. TECHNICAL FIELD

[0003] The disclosed invention relates to tufting machines, and in particular, to apparatuses and methods for adjusting needle bars of tufting machines. BACKGROUND

[0004] Tufting machines, such as conventional Card-Monroe tufting machines, include needle bars having a plurality of needles that reciprocally cut through a backing to produce a tufted product. A corresponding hook bar can include a plurality of hooks or “loopers” that engage yarn from the respective needles to form loops of yarn. A needle bar shifter assembly can be coupled to each needle bar to laterally shift the needle bar to moving yarn of the backing material so as to form a pattern in the tufted product. The needle bar shifter assembly can include a slide assembly coupled to a carriage assembly, and the needle bar in turn can be coupled to the carriage assembly. An actuator can laterally shift the slide assembly, thereby driving the carriage assembly laterally. One embodiment of a shifter assembly is disclosed in U.S. Patent No. 5,979,344 to William M. Christman, Jr., issued November 9, 1999, the entire contents of which are hereby incorporated by reference herein.

[0005] Conventional needle bar assemblies used in the shifter tufting process require periodic positional adjustment relative to the hook bar to maintain the selective positioning of the needles relative to the corresponding hooks. The desired spatial relationship between the needles and the corresponding hooks can vary based on the different types of yarn used.

[0006] While tufting machines generally have an adjustment (tensioning) system, a technician using a standard wrench can only access such a tensioning system from a protected area, thereby slowing the tensioning process. Further, technicians often use a hammer and / or a press or a special (crow’s foot) wrench to adjust the tension of the needle bar shifter assembly. However, the use of these tools creates additional safety concerns and damages the shifter shaft of the tufting machine. Further, conventional tensioning systems use a coarse pitch, so adjustments made by a conventional tensioner are correspondingly coarse. Thus, conventional tensioning systems lack precision. SUMMARY

[0007] In various aspects, described herein is a shifter adjustment assembly configured to be coupled to a shifter of a tufting apparatus. The shifter can have a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment. Each of the first shaft segment, the second shaft segment, the third shaft segment, and the fourth shaft segment can have respective first and second ends, the first and second shaft segments being aligned and spaced apart in a longitudinal dimension, the third and fourth shaft segments being aligned and spaced apart in the longitudinal dimension, the first ends of the first and second shaft segments facing one another, the first ends of the third and fourth shaft segments facing one another. The third and fourth shaft segments can be offset from the first and second shaft segments in a transverse dimension that is perpendicular to the longitudinal dimension. The shifter adjustment assembly can include a first body configured to be coupled to the first ends of the first and third shaft segments. A second body can be configured to be coupled to the first ends of the second and fourth shaft segments. The shifter adjustment assembly can include a coupling between the first body and the second body. The coupling can be configured to releasably secure an axial position of the first body relative to the second body in the longitudinal dimension. The first and second bodies can define respective complementary surfaces configured for sliding engagement such that movement between the first and second bodies in the transverse dimension is limited and movement between the first and second bodies in the longitudinal dimension is permitted.

[0008] The shifter adjustment assembly can further include an adjustment device configured to move the first body relative to the second body in the longitudinal dimension.

[0009] The first body can define a first bore extending through the first body in the longitudinal dimension. The second body can define a second bore extending through the second body in the longitudinal dimension. The first bore can define a right-hand thread. The second bore can define a left-hand thread. The adjustment device can include an elongate rod having a right-hand thread on a first end and a left-hand thread on a second end opposite the first end. The right-hand thread of the first end of the elongate rod can be engaged with the right-hand thread of the first bore, and the left-hand thread of the second end of the elongate rod can be engaged with the left-hand thread of the second bore.

[0010] The shifter adjustment assembly can further include a hex head coupled to the elongate rod.

[0011] The adjustment device can further include a lock nut threadably movable on the elongate rod and configured to be biased against one of the first body or the second body.

[0012] The first body can include a first portion and a second portion coupled to the first portion. The first portion of the first body can define the first bore defining the right hand thread. The second body can include a first portion and a second portion coupled to the first portion. The first portion of the second body can define the second bore defining the left hand thread.

[0013] The first portion of the first body can extend upwardly from the second portion of the first body. The first portion of the second body can extend upwardly from the second portion of the second body.

[0014] The coupling between the first body and the second body can include at least one fastener.

[0015] One of the first body and the second body can define at least one slot that is elongate in the longitudinal dimension, wherein each of the at least one fastener extends through a respective one of the at least one slot.

[0016] The first body can define a first longitudinally extending through hole for receiving the first shaft segment. The first body can define a second longitudinally extending through hole for receiving the third shaft segment.

[0017] The first body can define a first slot extending between a first side of the first body and the first longitudinally extending through hole. The first body can define a second slot extending between a second side of the first body and the second longitudinally extending through hole. The shifter adjustment assembly can include at least one threaded fastener extending across the first slot of the first body. The at least one threaded fastener extending across the first slot of the first body can be threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the first body tightens the first longitudinally extending through hole against the first shaft segment. The shifter adjustment assembly can include at least one threaded fastener extending across the second slot of the first body. The at least one threaded fastener extending across the second slot of the first body can be threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the first body tightens the second longitudinally extending through hole against the third shaft segment.

[0018] The second body can define a first longitudinally extending through hole for receiving the second shaft segment. The second body can define a second longitudinally extending through hole for receiving the fourth shaft segment.

[0019] The second body can define a first slot extending between a first side of the second body and the first longitudinally extending through hole. The second body can define a second slot extending between a first edge of the second body and the second longitudinally extending through hole. The shifter adjustment assembly can include at least one threaded fastener extending across the first slot of the second body. The at least one threaded fastener extending across the first slot of the second body can be threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the second body tightens the first longitudinally extending through hole against the second shaft segment. The shifter adjustment assembly can include at least one threaded fastener extending across the second slot of the second body. The at least one threaded fastener extending across the second slot of the second body can be threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the second body tightens the second longitudinally extending through hole against the fourth shaft segment.

[0020] The first body can define one of a tongue or a groove, and the second body can define the other of the tongue and the groove. The tongue can be received into the groove with a gap between the groove and the tongue in the lateral dimension, which inhibits lateral movement between the tongue and the groove.

[0021] The tongue can define first and second longitudinally extending outer edges. The groove can define corresponding first and second longitudinally extending inner edges that are outside respective ones of the first and second outer edges of the tongue with respect to the lateral dimension. The first and second outer edges of the groove can slidingly engage the first and second inner edges of the tongue, respectively, to thereby limit movement between the first body and the second body in the lateral dimension.

[0022] The shifter adjustment assembly can further include a linear position sensor configured to detect at least one of a distance or a change in distance between the first body and the second body with respect to the longitudinal dimension.

[0023] Additional advantages of the application will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following and / or can be learned by practice of the application. The advantages of the application will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. BRIEF DESCRIPTION OF DRAWINGS

[0024] These and other features of the preferred embodiments of the present application will become more apparent from the following detailed description, from the claims, when taken in conjunction with the accompanying drawings.

[0025] Figure 1 is a perspective view of a shifter adjustment apparatus according to embodiments disclosed herein.

[0026] Figure 2 is a perspective view of a shifter adjustment apparatus of Figure 1

[0027] Figure 3 is a side view of a shifter adjustment apparatus of Figure 1

[0028] Figure 4 is a rear view of a shifter adjustment apparatus of Figure 1

[0029] Figure 5 is​​​Figure 1 The top view of the shifter adjustment device.

[0030] Figure 6 yes Figure 1 Top view of the first body of the shifter adjustment device.

[0031] Figure 7 yes Figure 1 The front view of the first main body of the shifter adjustment device.

[0032] Figure 8 yes Figure 1 Top view of the second body of the shifter adjustment device.

[0033] Figure 9 yes Figure 1 Rear view of the second body of the shifter adjustment device.

[0034] Figure 10 yes Figure 1 Side view of the slender rod of the shifter adjustment device.

[0035] Figure 11 yes Figure 1 A perspective view of a portion of a needle bar shifter assembly with shifter adjustment device.

[0036] Figure 12 This is a perspective view of another part of the needle bar shifter assembly with shifter adjustment device.

[0037] Figure 13 This is a front view of a part of the needle bar shifter assembly.

[0038] Figure 14 This is a bottom side view of the needle bar shifter assembly, which shows the shifter adjustment device. Detailed Implementation

[0039] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Throughout the text, similar reference numerals refer to similar elements. It should be understood that the invention is not limited to the specific methods and solutions described, as these can vary. It should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention.

[0040] Many modifications and other embodiments of the applications set forth herein will come to mind to one skilled in the art to which these applications pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the applications are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

[0041] As used herein, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. For example, the use of the term "a screw" can refer to one or more screws, and the like.

[0042] Unless specifically defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these applications belong.

[0043] In this document, ranges are presented as "from about" one particular value and / or "to about" another particular value. When such a range is recited, another aspect includes from the one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation, it should be understood that the particular value is formed by the use of the antecedent "about." It is further understood that the endpoints of each range are effective as if individually presented with the other aspect related to the other endpoint, as well as independent of the other endpoint. Optionally, in some aspects, when a value is approximated by the use of the antecedent "about," it is contemplated that values within at most 15%, at most 10%, at most 5%, or at most 1% (higher or lower) of that specifically recited value can be included within the scope of the aspects. Similarly, in some optional aspects, when a value is approximated by the use of the terms "substantially" or "generally," it is contemplated that values within at most 15%, at most 10%, at most 5%, or at most 1% (higher or lower) of that specifically recited value can be included within the scope of the aspects. "Substantially" or "generally," when used in relation to an identified property or circumstance, can refer to a degree of deviation from the identified property or circumstance that is small enough to not deviate from the property or circumstance in a measurement, and the exact degree of deviation allowed can depend on the specific context in some cases.

[0044] As used herein, the term "optional" or "optionally" means that the subsequently described event or circumstance can or can not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[0045] As used herein, the term "at least one of' is intended to be synonymous with "one or more of' Examples include only A, only B, only C, and combinations of each.

[0046] The word “or” as used herein means any one member of a particular list and also

[0047] It should be understood that any of the methods outlined herein are not intended to require their steps to be performed in a particular order, unless otherwise explicitly stated, and are not intended to require that any particular order be adhered to unless explicitly stated. Unless specifically stated, it is intended that the order of steps in any of the methods that can be claimed be the reverse of the stated order, or that steps can be performed at the same time. This applies to any possible non- express basis of interpretation, including, among others, commonly assigned matters concerning the arrangement of steps or the

[0048] The following description provides specific details for a thorough understanding. However, a skilled person will understand that the devices, systems, and associated methods of using the devices can be practiced without employing these specific details. Indeed, the devices, systems, and associated methods can be practiced by modifying the devices, systems, and associated methods illustrated and described, and can employ any other apparatuses and techniques conventionally used in the industry.

[0049] In various aspects and with reference to Figures 11-14 A shifter adjustment assembly 100 for use with a needle bar shifter assembly 10 (referred to herein as “shifter”) is disclosed herein. The shifter 10 can include a first shaft segment 12 having a first end 14 and an opposite second end 16, a second shaft segment 18 having a first end 20 and an opposite second end 22, a third shaft segment 24 having a first end 26 and an opposite second end 28, and a fourth shaft segment 30 having a first end 32 and an opposite second end 34. The first and second shaft segments can be aligned and spaced apart in a longitudinal dimension 36, and the first end 14 of the first segment 12 can face the first end 20 of the second shaft segment 18. The third and fourth shaft segments can be aligned and spaced apart in the longitudinal dimension 36, and the first end 26 of the third segment 24 can face the first end 32 of the fourth shaft segment 30. The first and second shaft segments can be offset from the third and fourth shaft segments in a transverse dimension 38 that is perpendicular to the longitudinal dimension 36. Optionally, the transverse dimension 38 can be horizontal.

[0050] As explained further below, it is contemplated that the disclosed shifter adjuster assembly can allow for faster, safer, and more precise tensioning adjustments as compared to conventional methods. More specifically, the disclosed shifter adjuster assembly can be located below the head of a tufting machine such that the adjustment location is easily and safely accessible without requiring entry into a protected area or use of a tool that damages the shifter shaft. Optionally, the disclosed shifter adjuster assembly can use fine threads, which allows for more precise tensioning adjustments.

[0051] Also referring to Figure 1 and 2 , the shifter adjustment assembly 100 can include a first body 102 that can be coupled to the first end 14 of the first shaft segment 12 and the first end 26 of the third shaft segment 24. The shifter adjustment assembly 100 can further include a second body 104 that can be coupled to the first end 20 of the second shaft segment 18 and the first end 32 of the fourth shaft segment 30. For example, each of the first body 100 and the second body 104 can define a first through hole and a second through hole 108 located on opposite sides. Each of the first body and the second body 110 can have a first side 113a and a second side 113b. A slot 110 can extend inwardly from the respective side (e.g., the first side 113a or the second side 113b) of the respective body to the respective through hole 108. One or more fasteners 112 (e.g., screws) can extend through a through hole 114 located on a first (e.g., upper) side of the slot 110 and engage a threaded hole 116 located on an opposite second (e.g., lower) side of the slot 110. In this way, tightening the fasteners 112 in the threaded holes can compress the bodies close to the slot, thereby reducing the inner diameter of the through holes 108 and frictionally engaging the respective shaft segments.

[0052] Referring to Figures 1-2And 6-9, the first body 102 and the second body 104 can be slidingly coupled such that movement between the first body 102 and the second body 104 in the lateral dimension 38 is restricted and movement between the first body 102 and the second body 104 in the longitudinal dimension 36 is permitted. For example, the first body 102 can define a tongue 120 that can have a first longitudinally extending outer edge 122 and a second longitudinally extending outer edge 124 that is spaced apart from the first longitudinally extending outer edge 122 in the lateral dimension 38. The second body 104 can define a groove 126 having a first longitudinally extending inner edge 128 and a second longitudinally extending inner edge 130. The tongue 120 can be received into the groove 126 in the lateral dimension with a small gap between the groove 126 and the tongue 120 to inhibit lateral movement between the tongue and the groove that is greater than the small gap. The first outer edge 122 of the tongue 120 can slidingly engage the first inner edge 128 of the groove 126 and the second outer edge 124 of the tongue 120 can slidingly engage the second inner edge 130 of the groove. Thus, the first inner edge 128 of the groove 126 can restrict movement of the tongue in a first direction relative to the lateral dimension and the second inner edge 130 of the groove 126 can restrict movement of the tongue in a second, opposite direction relative to the lateral dimension, while the first and second inner edges can guide longitudinal movement of the tongue 120 and thereby the first body 102.

[0053] It is further contemplated that many alternative structures known to those skilled in the art can slidingly couple the first body to the second body, for example, a dowel pin that is fixedly coupled to the first body and slidingly received within a bore of the second body.

[0054] Reference Figures 1-2Coupling 140 between first body 102 and second body 104 can secure the position of first body relative to second body. For example, in some aspects, coupling 140 can include one or more fasteners 142 (e.g., screws or bolts) and, optionally, washers 143. In some optional aspects, tongue 120 of first body 102 can define one or more slots 144 that are elongated in the longitudinal dimension 36. Second body 104 can define corresponding holes 146 (optionally threaded holes) that are aligned in the transverse dimension relative to slots 144 along a portion of the longitudinal travel of first body 102 relative to second body 104. In some aspects, fasteners 142 can threadably engage holes 146. In further aspects (not shown), fasteners 142 can be bolts that are bolted into corresponding nuts through holes 146. Upon loosening of fasteners 142, first body 102 can be slid along the longitudinal dimension relative to second body 104, which is optionally limited by the length of the slots in the longitudinal dimension. Upon tightening of fasteners 142, first body 102 can be held in a fixed position relative to second body.

[0055] Referring to Figures 1-3 In some aspects, shifter adjustment assembly 100 can include adjustment device 150. In some aspects, first body can define first bore 152 that extends through first body in the longitudinal dimension. First bore 152 can define at least one right-handed thread. Second body 104 can include second bore 154. Second bore 154 can define at least one left-handed thread. Elongate rod 156 can have a length, a first end 158, and an opposite second end 160. Elongate rod 156 can define right-handed thread 162 on first end and extending along a portion of the length of elongate rod 150. Elongate rod 156 can define left-handed thread 164 on second end 160 and extending along a portion of the length of elongate rod 150. Elongate rod can be threadably coupled to first body 102 and second body 104 and extend therebetween. Right-handed thread 162 of elongate rod 156 can threadably screw into first bore 152 of first body, and left-handed thread 164 of elongate rod can threadably screw into second bore 154 of second body.

[0056] Rotation of the elongated rod in a first direction can cause the first body to move away from the second body in the longitudinal dimension, and rotation of the elongated rod in a second direction opposite the first direction can cause the first body to move toward the second body. Optionally, the elongated rod can define one or more gripping features, e.g., a hex head 166, for facilitating rotation of the elongated rod. For example, a nut can be threaded into one of the ends of the elongated rod 156 and then attached to the end by a weld. Optionally, a locking nut 168 can be threaded into one of the ends of the elongated rod. The locking nut can be tightened down against a face of the respective one of the first and second bodies that shares the same thread as the locking nut 168 to inhibit further rotation of the elongated rod relative to the first or second body.

[0057] It is contemplated that in some cases the spacing between the first body 102 and the second body 104 can be extremely important. Thus, the gap between the threads of the first bore 152 and the right-handed threads 162 and the gap between the threads of the second bore 154 and the left-handed threads 164 can be minimized such that no (substantial) longitudinal movement between the elongated rod and the first and second bodies is allowed. For example, the first and second bores 152, 154 can define unified thread grade 3A threads, and the right- and left-handed threads 162, 164 can define unified thread grade 2B threads. In further aspects, all of the threads can be grade 3A. In this way, the exact spacing between the first and second bodies can be selected.

[0058] In some optional aspects, the first body 102 can include a first portion 170 and a second portion 172 that can be coupled to the first portion, e.g., by screws 176. The first portion can define the bore 152. The first portion 170 of the first body 102 can extend perpendicularly or substantially perpendicularly from the second portion 172, e.g., vertically upward from an upper face of the second portion 172. Likewise, the second body 104 can include a first portion 178 and a second portion 180 that can be coupled to the first portion, e.g., by screws 176. The first portion 178 of the first body 102 can extend perpendicularly or substantially perpendicularly from the second portion 180, e.g., vertically upward from an upper face of the second portion 180.

[0059] Reference Figure 1Optionally, a linear position sensor 182 (e.g., a linear potentiometer) can be coupled between the first body 102 and the second body 104 such that the position of the linear position sensor 182 in the longitudinal dimension relative to one another can be known. For example, a first end of the linear position sensor 182 can be coupled to the first body 102 and a second end of the linear position sensor can be coupled to the second body 104. Optionally, the linear position sensor can be a capacitance gauge having a resolution of, for example, 0.0005 inches. The linear position sensor can be in communication with a computing device (e.g., a desktop computer, a laptop computer, a smartphone, a tablet, etc.), a small LED display, or other output device to communicate the position sensed by the linear position sensor to an operator.

[0060] While the description and drawings describe certain features on the first body 102 and complementary features on the second body 104, it should be understood that the features can be reversed unless specifically provided for in the claims. For example, it should be understood that in some alternative aspects, the first body can define the groove 126 and the second body can include the tongue 120. In further alternative aspects, the first body 102 can define the left-hand thread 164 and the second body 104 can define the right-hand thread 162. Accordingly, any features provided for in the claims should not be limited to their association with the first body or the second body unless the claims specifically so provide.

[0061] Conventionally, the two original shafts of a shogger of a tufting machine extend along the longitudinal length of the tufting machine. Accordingly, to attach the shogger adjustment assembly 100, it is contemplated that the shafts can be cut to provide a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment. It is further contemplated that the original shafts can be removed and replaced with shorter segments (i.e., the first shaft segment, the second shaft segment, the third shaft segment, and the fourth shaft segment) that provide the same length or substantially the same length as the original shafts of the shogger assembly when coupled to the shogger adjustment assembly 100. The first shaft segment and the third shaft segment can be inserted into the respective through holes 108 of the first body and the fasteners 112 can be tightened downward. Likewise, the second shaft segment and the fourth shaft segment can be inserted into the respective through holes 108 of the second body and the fasteners 112 can be tightened downward.

[0062] To adjust the needle tension with the shogger adjustment assembly, an operator can first verify that the needles are in an upward position and are not passing through any hooks of the tufting machine. It can be desirable that the cradle is not under tension or compression during the adjustment. The tufting machine can be locked for safety.

[0063] The lock nut 168 can be loosened from against the first or second body, and the slide fastener 142 can be loosened to enable movement between the first and second bodies. Using a wrench, an operator can rotate the tension adjustment nut to adjust the position of the first body relative to the second body in the longitudinal dimension. For example, to increase the tension on the needle, the first and second bodies can be moved toward one another. To decrease the tension, the first and second bodies can be moved away from one another. The adjustment between the first and second bodies can displace the needle bar relative to the hook bar, thereby adjusting the position of the needle relative to its corresponding hook. Optionally, a linear position sensor can output a reading, and an operator can select the relative position between the first and second bodies based on a desired reading from the linear position sensor.

[0064] Once the selected position is achieved, the lock nut can be tightened against the respective body. The fastener 142 can be tightened down (e.g., to about 60 ft-lbs) to hold the first and second bodies in their respective positions. The tufting machine can be locked out to return the machine to production.

[0065] Exemplary Aspects

[0066] In view of the described products, systems, and methods, and variations thereof, certain more particular descriptions of aspects of the application described herein follow. However, these specifically described aspects should not be construed as limiting in any way on any differing claim contained herein that incorporates by reference the more general teachings set forth herein, or on the inherent inventive

[0067] Aspect 1 : A shifter adjustment assembly configured to couple to a shifter of a tufting apparatus, the shifter having a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment, each of the first, second, third, and fourth shaft segments having respective first and second ends, the first and second shaft segments being aligned and spaced apart in a longitudinal dimension, the third and fourth shaft segments being aligned and spaced apart in the longitudinal dimension, the first ends of the first and second shaft segments facing one another, the first ends of the third and fourth shaft segments facing one another, the third and fourth shaft segments being offset from the first and second shaft segments in a transverse dimension perpendicular to the longitudinal dimension, the shifter adjustment assembly comprising: a first body configured to couple to the first ends of the first and third shaft segments; a second body configured to couple to the first ends of the second and fourth shaft segments; and a coupling between the first and second bodies, wherein the coupling is configured to releasably secure an axial position of the first body relative to the second body in the longitudinal dimension, wherein the first and second bodies define respective complementary surfaces configured for sliding engagement such that: movement between the first and second bodies in the transverse dimension is limited; and movement between the first and second bodies in the longitudinal dimension is permitted.

[0068] Aspect 2: The shifter adjustment assembly of aspect 1, further comprising an adjustment device configured to move the first body relative to the second body in the longitudinal dimension.

[0069] Aspect 3: The shifter adjustment assembly of aspect 2, wherein the first body defines a first bore extending through the first body in the longitudinal dimension, wherein the second body defines a second bore extending through the second body in the longitudinal dimension, wherein the first bore defines a right-hand thread, wherein the second bore defines a left-hand thread, wherein the adjustment device comprises an elongate rod having a right-hand thread on a first end and a left-hand thread on a second end opposite the first end, wherein the right-hand thread of the first end of the elongate rod is engaged with the right-hand thread of the first body and the left-hand thread of the second end of the elongate rod is engaged with the left-hand thread of the second body.

[0070] Aspect 4: The shifter adjustment assembly of aspect 3, further comprising a hex head coupled to the elongate rod.

[0071] Aspect 5: The shifter adjustment assembly of either Aspect 3 or Aspect 4, wherein the adjustment device further comprises a lock nut threadably movable on the elongate rod and configured to be biased against one of the first body or the second body.

[0072] Aspect 6: The shifter adjustment assembly of any one of Aspects 3-5, wherein the first body comprises a first portion and a second portion coupled to the first portion, wherein the first portion of the first body defines the first bore defining the right-hand thread, wherein the second body comprises a first portion and a second portion coupled to the first portion, wherein the first portion of the second body defines the second bore defining the left-hand thread.

[0073] Aspect 7: The shifter adjustment assembly of Aspect 6, wherein the first portion of the first body extends upward from the second portion of the first body, wherein the first portion of the second body extends upward from the second portion of the second body.

[0074] Aspect 8: The shifter adjustment assembly of any one of the preceding Aspects, wherein the coupling between the first body and the second body comprises at least one fastener.

[0075] Aspect 9: The shifter adjustment assembly of Aspect 9, wherein one of the first body and the second body defines a respective slot that is elongate in the longitudinal dimension, wherein each of the at least one fastener extends through the respective slot.

[0076] Aspect 10: The shifter adjustment assembly of any one of the preceding Aspects, wherein the first body defines a first longitudinally extending through hole for receiving the first shaft segment, and wherein the first body defines a second longitudinally extending through hole for receiving the second shaft segment.

[0077] Aspect 11 : The shifter adjustment assembly of Aspect 10, wherein the first body defines a first slot extending between a first side of the first body and the first longitudinally extending through hole, wherein the first body defines a second slot extending between a second side of the first body and the second longitudinally extending through hole, wherein the shifter adjustment assembly includes at least one threaded fastener extending across the first slot of the first body, wherein the at least one threaded fastener extending across the first slot of the first body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the first body tightens the first longitudinally extending through hole against the first shaft segment, and wherein the shifter adjustment assembly includes at least one threaded fastener extending across the second slot of the first body, wherein the at least one threaded fastener extending across the second slot of the first body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the first body tightens the second longitudinally extending through hole against the third shaft segment.

[0078] Aspect 12: The shifter adjustment assembly of any of the preceding aspects, wherein the second body defines a first longitudinally extending through hole for receiving the second shaft segment, and wherein the second body defines a second longitudinally extending through hole for receiving the fourth shaft segment.

[0079] Aspect 13: The shifter adjustment assembly of Aspect 12, wherein the second body defines a first slot extending between a first side of the second body and the first longitudinally extending through hole, wherein the second body defines a second slot extending between a second side of the second body and the second longitudinally extending through hole, wherein the shifter adjustment assembly includes at least one threaded fastener extending across the first slot of the second body, wherein the at least one threaded fastener extending across the first slot of the second body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the second body tightens the first longitudinally extending through hole against the second shaft segment, and wherein the shifter adjustment assembly includes at least one threaded fastener extending across the second slot of the second body, wherein the at least one threaded fastener extending across the second slot of the second body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the second body tightens the second longitudinally extending through hole against the fourth shaft segment.

[0080] Aspect 14: The shifter adjustment assembly of any of the preceding aspects, wherein the first body defines one of a tongue or a groove, and the second body defines the other of the tongue and the groove, wherein the tongue is receivable in the groove with a gap therebetween in the lateral dimension, which inhibits lateral movement between the tongue and the groove.

[0081] Aspect 15: The shifter adjustment assembly of aspect 14, wherein the tongue defines first and second longitudinally extending outer edges, and wherein the groove defines corresponding first and second longitudinally extending inner edges that are outside respective ones of the first and second outer edges of the tongue with respect to the lateral dimension, wherein the first and second outer edges of the groove slidingly engage the first and second inner edges of the tongue, respectively, to thereby limit movement between the first and second bodies in the lateral dimension.

[0082] Aspect 16: The shifter adjustment assembly of any of the preceding aspects, further comprising a linear position sensor configured to detect at least one of a distance or a change in distance between the first and second bodies with respect to the longitudinal dimension.

[0083] Aspect 17: A method of coupling a shifter adjustment assembly according to any of the preceding aspects to a tufting machine having a longitudinal dimension that is perpendicular to a lateral dimension, the tufting machine including a shifter having a first end and a second end, the shifter including: a first continuous shaft extending between the first and second ends of the shifter, and a second continuous shaft extending between the first and second ends of the shifter, the method comprising: modifying or replacing the first continuous shaft of the shifter to provide a first shaft segment and a second shaft segment; modifying or replacing the second continuous shaft of the shifter to provide a third shaft segment and a fourth shaft segment; and coupling the shifter adjustment assembly to the first, second, third, and fourth shaft segments.

[0084] Aspect 18: The method of aspect 17, wherein the first continuous shaft is removed and replaced with the first and second shaft segments, and wherein the second continuous shaft is removed and replaced with the third and fourth shaft segments.

[0085] Aspect 19: The method of Aspect 17, wherein the first continuous shaft is cut to produce the first shaft segment and the second shaft segment, and wherein the second continuous shaft is cut to produce the third shaft segment and the fourth shaft segment.

[0086] Aspect 20: A method of adjusting a shifter adjustment assembly using the shifter adjustment assembly of one of Aspects 2-16, the method comprising: adjusting the position of the first body relative to the second body; and securing the position of the first body relative to the second body.

[0087] Aspect 21 : The method of Aspect 20, wherein the shifter adjustment assembly is the shifter adjustment assembly of any one of Aspects 3-16, wherein adjusting the position of the first body relative to the second body comprises rotating the elongate rod to adjust the position of the first body relative to the second body.

[0088] Aspect 22: The method of Aspect 20 or Aspect 21, wherein the shifter adjustment assembly is the shifter adjustment assembly of any one of Aspects 8-16, wherein securing the position of the first body relative to the second body comprises tightening each fastener (e.g., threaded fastener) that couples (e.g., fixedly couples) the first body to the second body.

[0089] Aspect 23: A tufting device having a longitudinal dimension that is perpendicular to a lateral dimension, the tufting device comprising: a shifter comprising: a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment, each of the first shaft segment, the second shaft segment, the third shaft segment, and the fourth shaft segment having a respective first end and a second end, wherein the first shaft segment and the second shaft segment are aligned and spaced apart in the longitudinal dimension, wherein the third shaft segment and the fourth shaft segment are aligned and spaced apart in the longitudinal dimension, wherein the first ends of the first shaft segment and the second shaft segment face each other, wherein the first ends of the third shaft segment and the fourth shaft segment face each other, wherein the third shaft segment and the fourth shaft segment are offset from the first shaft segment and the second shaft segment in a lateral dimension that is perpendicular to the longitudinal dimension; and the shifter adjustment assembly of any one of Aspects 1-16, wherein the first body is coupled to the first ends of the first shaft segment and the third shaft segment, and wherein the second body is coupled to the first ends of the second shaft segment and the fourth shaft segment.

[0090] While the foregoing application has been described in some detail for the purposes of clarity and understanding, it will be appreciated that certain changes and modifications can be practiced within the scope of the appended claims.

Claims

1. A shifter adjustment assembly configured to be coupled to a shifter of a tufting apparatus, the shifter having a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment, each of the first, second, third, and fourth shaft segments having respective first and second ends, the first and second shaft segments being aligned and spaced apart in a longitudinal dimension, the third and fourth shaft segments being aligned and spaced apart in the longitudinal dimension, the first ends of the first and second shaft segments facing one another, the first ends of the third and fourth shaft segments facing one another, the third and fourth shaft segments being offset from the first and second shaft segments in a transverse dimension that is perpendicular to the longitudinal dimension, the shifter adjustment assembly comprising: a first body configured to be coupled to the first ends of the first and third shaft segments; a second body configured to be coupled to the first ends of the second and fourth shaft segments; and a coupling between the first and second bodies, wherein the coupling is configured to releasably secure an axial position of the first body relative to the second body along the longitudinal dimension, wherein the first and second bodies define respective complementary surfaces configured for sliding engagement, such that: movement between the first and second bodies in the transverse dimension is limited; and movement between the first and second bodies in the longitudinal dimension is permitted; and wherein adjustment between the first and second bodies enables shifting of a needle strip of the tufting apparatus relative to a hook strip of the tufting apparatus, thereby adjusting a position of needles of the needle strip relative to hooks of the respective hook strip.

2. The shifter adjustment assembly of claim 1, further comprising an adjustment device configured to move the first body relative to the second body in the longitudinal dimension.

3. The shifter adjustment assembly of claim 2, wherein the first body defines a first bore extending through the first body in the longitudinal dimension, wherein the second body defines a second bore extending through the second body in the longitudinal dimension, wherein the first bore defines a right-hand thread, wherein the second bore defines a left-hand thread, wherein the adjustment device comprises an elongate rod having a right-hand thread on a first end and a left-hand thread on a second end opposite the first end, wherein the right-hand thread of the first end of the elongate rod is engaged with the right-hand thread of the first bore and the left-hand thread of the second end of the elongate rod is engaged with the left-hand thread of the second bore.

4. The shifter adjustment assembly of claim 3, further comprising a hex head coupled to the elongate rod.

5. The shifter adjustment assembly of claim 3, wherein the adjustment device further comprises a lock nut threadably movable on the elongate rod and configured to be biased against one of the first body or the second body.

6. The shifter adjustment assembly of claim 3, wherein the first body comprises a first portion and a second portion coupled to the first portion, wherein the first portion of the first body defines the first bore defining the right-hand thread, wherein the second body comprises a first portion and a second portion coupled to the first portion, wherein the first portion of the second body defines the second bore defining the left-hand thread.

7. The shifter adjustment assembly of claim 6, wherein the first portion of the first body extends upward from the second portion of the first body, wherein the first portion of the second body extends upward from the second portion of the second body.

8. The shifter adjustment assembly of claim 1, wherein the coupling between the first body and the second body comprises at least one fastener.

9. The shifter adjustment assembly of claim 8, wherein one of the first body and the second body defines at least one slot that is elongate in the longitudinal dimension, wherein each of the at least one fastener extends through a respective one of the at least one slot.

10. The shifter adjustment assembly of claim 1: wherein the first body defines a first longitudinally extending through hole for receiving the first shaft segment, wherein the first body defines a second longitudinally extending through hole for receiving the third shaft segment, wherein the second body defines a first longitudinally extending through hole for receiving the second shaft segment, and wherein the second body defines a second longitudinally extending through hole for receiving the fourth shaft segment.

11. The shifter adjustment assembly of claim 10: wherein the first body defines a first slot extending between a first side of the first body and the first longitudinally extending through hole, wherein the first body defines a second slot extending between a second side of the first body and the second longitudinally extending through hole, wherein the shifter adjustment assembly comprises at least one threaded fastener extending across the first slot of the first body, wherein the at least one threaded fastener extending across the first slot of the first body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the first body tightens the first longitudinally extending through hole against the first shaft segment, and wherein the shifter adjustment assembly comprises at least one threaded fastener extending across the second slot of the first body, wherein the at least one threaded fastener extending across the second slot of the first body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the first body tightens the second longitudinally extending through hole against the third shaft segment. wherein the shifter adjustment assembly includes at least one threaded fastener extending across the second slot of the first body, wherein the at least one threaded fastener extending across the second slot of the first body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the first body tightens the second longitudinally extending through hole against the third shaft segment.

12. The shifter adjustment assembly of claim 10: wherein the second body defines a first slot extending between a first side of the second body and the first longitudinally extending through hole, wherein the second body defines a second slot extending between a second side of the second body and the second longitudinally extending through hole, wherein the shifter adjustment assembly includes at least one threaded fastener extending across the first slot of the second body, wherein the at least one threaded fastener extending across the first slot of the second body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the first slot of the second body tightens the first longitudinally extending through hole against the second shaft segment, and wherein the shifter adjustment assembly includes at least one threaded fastener extending across the second slot of the second body, wherein the at least one threaded fastener extending across the second slot of the second body is threadably coupled to the first body such that tightening of the at least one threaded fastener extending across the second slot of the second body tightens the second longitudinally extending through hole against the fourth shaft segment.

13. The shifter adjustment assembly of claim 1, wherein the first body defines one of a tongue or a groove and the second body defines the other of the tongue and the groove, wherein the tongue is receivable in the groove with a gap therebetween in the lateral dimension that inhibits lateral movement between the tongue and the groove.

14. The shifter adjustment assembly of claim 13, wherein the tongue defines first and second longitudinally extending outer edges, wherein the groove defines corresponding first and second longitudinally extending inner edges that are exterior to the respective outer edges of the first and second longitudinally extending outer edges of the tongue with respect to the lateral dimension, wherein the first and second longitudinally extending inner edges of the groove slidingly engage the first and second longitudinally extending outer edges of the tongue, respectively, to thereby limit movement between the first and second bodies in the lateral dimension.

15. The shifter adjustment assembly of claim 1, further comprising a linear position sensor configured to detect at least one of a distance or a change in distance between the first body and the second body with respect to the longitudinal dimension.

16. A method of coupling a shifter adjustment assembly according to any one of claims 1-15 to a tufting machine having a longitudinal dimension that is perpendicular to a lateral dimension, the tufting machine comprising a shifter having a first end and a second end, the shifter comprising a first continuous shaft extending between the first end and the second end of the shifter and a second continuous shaft extending between the first end and the second end of the shifter, the method comprising: modifying or replacing the first continuous shaft of the shifter to provide a first shaft segment and a second shaft segment; modifying or replacing the second continuous shaft of the shifter to provide a third shaft segment and a fourth shaft segment; and coupling the shifter adjustment assembly to the first shaft segment, the second shaft segment, the third shaft segment, and the fourth shaft segment.

17. The method of claim 16, wherein the first continuous shaft is removed and replaced with the first shaft segment and the second shaft segment, and wherein the second continuous shaft is removed and replaced with the third shaft segment and the fourth shaft segment.

18. The method of claim 16, wherein the first continuous shaft is cut to produce the first shaft segment and the second shaft segment, and wherein the second continuous shaft is cut to produce the third shaft segment and the fourth shaft segment.

19. A tufting apparatus having a longitudinal dimension and a lateral dimension, the tufting apparatus comprising: a shifter, the shifter comprising: a first shaft segment, a second shaft segment, a third shaft segment, and a fourth shaft segment, each of the first shaft segment, the second shaft segment, the third shaft segment, and the fourth shaft segment having a respective first end and second end, wherein the first shaft segment and the second shaft segment are aligned and spaced apart in the longitudinal dimension, wherein the third shaft segment and the fourth shaft segment are aligned and spaced apart in the longitudinal dimension, wherein the first ends of the first shaft segment and the second shaft segment face each other, wherein the first ends of the third shaft segment and the fourth shaft segment face each other, wherein the third shaft segment and the fourth shaft segment are offset from the first shaft segment and the second shaft segment in a lateral dimension that is perpendicular to the longitudinal dimension; and a shifter adjustment assembly according to any one of claims 1-15.

20. A method of using a shifter adjustment assembly according to one of claims 1-15, wherein the shifter adjustment assembly comprises an adjustment device configured to move the first body relative to the second body in the longitudinal dimension, the method comprising: adjusting the position of the first body relative to the second body; and fixing the position of the first body relative to the second body. ​ 21. The method of claim 20, wherein the shifter adjustment assembly is a shifter adjustment assembly, wherein the first body defines a first bore extending through the first body in the longitudinal dimension, wherein the second body defines a second bore extending through the second body in the longitudinal dimension, wherein the first bore defines right-handed threads, wherein the second bore defines left-handed threads, wherein the adjustment device comprises an elongate rod having right-handed threads on a first end and left-handed threads on a second end opposite the first end, wherein the right-handed threads of the first end of the elongate rod are engaged with the right-handed threads of the first bore and the left-handed threads of the second end of the elongate rod are engaged with the left-handed threads of the second bore, and wherein adjusting the position of the first body relative to the second body comprises rotating the elongate rod to adjust the position of the first body relative to the second body.

22. The method of claim 20, wherein the coupling between the first body and the second body of the shifter adjustment assembly comprises at least one threaded fastener, and wherein securing the position of the first body relative to the second body comprises tightening each threaded fastener coupling the first body to the second body.

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