A synergic weaving method, system and carpet for a multi-layer needle selection jacquard tufted carpet

Abstract

The application relates to a cooperative weaving method, system and carpet of a multi-layer needle selection jacquard tufted carpet, and relates to the technical field of textile machinery and carpet manufacturing. The method is based on a tufted weaving system, and through a computer control system, the action time of a clutch unit corresponding to each needle, the output characteristics of a servo yarn feeding motor and the angle of a main shaft are synchronously scheduled in real time according to a preset cooperative timing table; two cooperative modes of low-loop pile and high-loop pile are defined in the cooperative timing table, and the action time of the clutch units corresponding to the two modes is respectively locked in different preset intervals of the angle of the main shaft, and a free stroke protection area is arranged between the two preset intervals. The application can eliminate the transition section between high and low piles, realize the sharpness of the pile boundary, improve the stereoscopic feeling and fineness of a pattern, and improve the reliability of equipment operation.

Description

Technical Field

[0001] This application relates to the fields of textile machinery and carpet manufacturing technology, specifically to a collaborative weaving method, system, and carpet for multi-layer selective needle jacquard tufted carpet. Background Technology

[0002] Tufted carpets, widely used in home décor, commercial spaces, and vehicle interiors, are primarily manufactured using a tufting machine that inserts yarn into the base fabric to form pile. In traditional mid-to-high-end jacquard carpet production, to achieve a three-dimensional pattern, the depth of needle travel is typically controlled to create pile heights. Existing technologies often rely on mechanical cams driving the needle bar's overall movement, coupled with a servo motor controlling the yarn feed, or a single pneumatic needle selector mechanism to adjust the height of some needles. In these existing processes, a computer control system, based on preset pattern data, triggers needle selection when the spindle rotates to a specific angle, altering the needle's travel endpoint and simultaneously adjusting the yarn feed motor's speed to match the required pile height. This creates a staggered pile structure on the base fabric, achieving a layered pattern expression.

[0003] However, in existing technologies, due to the inertial delay of the mechanical transmission chain and the lack of high-precision timing coordination between the needle selection actuator and the main shaft movement, the knitting needles often experience uncontrollable intermediate states when switching from high-pile mode to low-pile mode or vice versa. This intermediate state creates a long transition slope area between adjacent pile heads of different heights, resulting in blurred pattern outlines and inability to clearly present the boundaries of fine structures, making it difficult to meet the stringent requirements of the high-end market for the sharpness and fine three-dimensionality of jacquard patterns. Summary of the Invention

[0004] This application provides a collaborative weaving method, system, and carpet for multi-layer jacquard tufted carpets, which can solve the technical problems in the traditional tufted carpet weaving process, such as the lack of coordination between the needle selection action and the main shaft movement, resulting in a blurred transition section between high and low pile heads and insufficient three-dimensionality and fineness of the pattern.

[0005] To achieve the above objectives, this application provides the following technical solution: The first aspect of this application provides a collaborative weaving method for a multi-layer jacquard tufted carpet, which is implemented based on a tufted weaving system. The system includes multiple needle assemblies, at least two layers of hooks, a clutch unit that independently controls the stroke of each needle assembly, a servo feed motor that independently controls the feed amount of each yarn, and a spindle drive unit. The computer control system performs real-time synchronous scheduling of the clutch unit action time, servo yarn feeding motor output characteristics, and spindle angle for each knitting needle according to the preset coordination timing table. The collaborative timing table defines at least a low loop pile weaving collaborative mode and a high loop pile weaving collaborative mode, and the clutch unit action time corresponding to the two modes is locked in different preset intervals of the spindle angle, with an empty travel protection zone between the two preset intervals.

[0006] In one alternative embodiment, the needle assembly includes a needle slide, a needle, an elongated groove disposed on the needle slide, a high-position fixing pin fixed to the frame, and a low-position coupling pin driven by the clutch unit; the needle slide is suspended by an elastic element to maintain its upper position.

[0007] In an optional embodiment, in the low loop pile weaving collaborative mode: the clutch unit disengages the low-position coupling pin from the long groove, the knitting needle is pushed down to the lower limit of the low loop position by the high-position fixing pin, the yarn is hooked by the upper layer hook plate, and the servo feeding motor outputs low pile yarn according to the first speed curve.

[0008] In an optional embodiment, in the high loop pile weaving collaborative mode: the clutch unit keeps the low-position coupling pin embedded in the long groove, the knitting needle is pushed down to the lower limit of the high loop position by the low-position coupling pin, the yarn is hooked by the lower layer hook plate, and the servo yarn feeding motor outputs high pile yarn according to the second speed curve, and the peak speed of the second speed curve is higher than that of the first speed curve.

[0009] In an optional embodiment, the coordinated timing table also defines an intermediate loop pile weaving mode: during the downward movement of the needle, the computer control system sends a pulse width modulation signal to the clutch unit within a preset spindle angle window, causing the needle stroke to stop at the intermediate hook layer.

[0010] In one optional embodiment, the computer control system receives real-time feedback from the spindle angle, clutch unit status, and servo yarn feeding motor to form a closed-loop control. When any feedback value deviates from the preset value of the coordination timing table by more than a threshold, the system immediately issues an emergency stop command and forces all knitting needles to return to the upper limit position.

[0011] In one optional embodiment, after the emergency stop command is issued, the computer control system also activates the backup air source to force all low-position coupling pins to disengage, and the total time from fault detection to the disengagement of all low-position coupling pins does not exceed 20 milliseconds.

[0012] In one optional embodiment, the tufting weaving system employs a needle pattern with a spacing selected from "1 / 10 inch", "1 / 8 inch", "5 / 32 inch", and "1 / 4 inch", and the yarn used is one or more twisted or network yarns selected from wool, polyester, and polypropylene.

[0013] A second aspect of this application provides a tufting weaving collaborative control system for implementing any of the foregoing methods, the system comprising: Spindle angle encoder; Multiple clutch unit status sensors; Multiple servo yarn feed motor encoders; The computer control system has the aforementioned coordinated timing table internally installed, and performs closed-loop correction and coordinated scheduling based on the feedback signals.

[0014] The third aspect of this application provides a multi-layer loop pile jacquard tufted carpet, woven using the method described in any of the preceding claims, wherein the carpet surface has at least two types of pile with different heights without transition sections, and the boundary between adjacent high and low piles is a vertical discontinuity.

[0015] This application provides a collaborative weaving method, system, and carpet for multi-layer jacquard tufted carpets. This solution strictly locks the clutch unit's operation within a specific preset range of the spindle angle and sets up idle travel protection zones between different mode ranges. This ensures that the downward movement of the needles is entirely dominated by a single driving force (high-position fixed pin or low-position coupling pin), avoiding the alternating action of two driving forces during the stroke. This completely eliminates the transition length between high and low pile ends, achieving a sharp pile boundary. Furthermore, a computer control system synchronously schedules the clutch unit, servo yarn feeding motor, and spindle angle in real time, ensuring precise matching between the yarn output characteristics and the moment the needles reach the lower limit. This ensures the yarn is in optimal tension at the moment of hooking, thereby guaranteeing the fullness and consistency of the pile formation. Simultaneously, a closed-loop feedback mechanism monitors the status of each actuator in real time. Once a deviation is detected, an emergency stop and reset logic is immediately triggered, effectively preventing mechanical damage or pattern misalignment caused by timing conflicts. Therefore, this solution effectively solves the problems of blurred pattern outlines and insufficient three-dimensionality in traditional technologies, and significantly improves the pattern fineness, layer richness, and reliability and safety of tufted carpets in the production process.

[0016] In summary, this application has formed a complete technical closed loop from hardware execution to software scheduling by constructing a mechanical-pneumatic coupled hierarchical needle selection structure and an intelligent control strategy based on a collaborative timing table. This not only achieves precise control of multi-level pile height, but also demonstrates systematic technical advantages in transition-free forming and safety collaborative protection. Attached Figure Description

[0017] Figure 1 A process flow diagram of a collaborative weaving method for a multi-layer jacquard tufted carpet provided in this application; Figure 2 This application provides an overall structural schematic diagram; Figure 3 This is a schematic diagram of the upward movement of the needle slide provided in this application; Figure 4 This is a schematic diagram of the downward movement of the needle slide provided in this application; Figure 5 A schematic diagram of the timing control for the intermediate loop pile weaving pattern provided in this application; Figure 6 The closed-loop control and emergency stop logic flowchart provided in this application; Figure 7 The diagram shows the collaborative control block diagram and timing representation of the computer control system and its execution units provided in this application. Figure 8 A schematic diagram illustrating the surface effect of a multi-layer loop pile carpet woven using the method of this invention, provided for this application.

[0018] Figure label: 10-Knitting needle assembly; 11-Needle slide; 12-Knitting needle; 13-Long groove; 14-High-position fixing pin; 15-Low-position coupling pin; 16-Elastic element; 20-Hook plate; 21-Upper layer hook plate; 22-Lower layer hook plate; 30-Clutch unit; 40-Servo yarn feeding motor; 50-Main shaft drive unit; 60-Computer control system; 70-Backup air source; S1-Low loop pile weaving collaborative mode; S2-High loop pile weaving collaborative mode; S3-Middle loop pile weaving mode. Detailed Implementation

[0019] The present application will now be described in further detail with reference to embodiments. It is to be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the scope of the application.

[0020] Example 1: Traditional tufted carpets often employ a single-needle height control method when weaving jacquard patterns, resulting in a limited range of pile height variation and difficulty in creating rich, clear layers, leading to insufficient three-dimensionality and detail. Some processes, aiming for a three-dimensional effect, use hand-punched or multi-layered weaving techniques reminiscent of handmade carpets. However, these methods rely on single-needle operation, are inefficient, and are prone to pattern misalignment and variation due to material deformation or needle displacement during multiple layering processes, resulting in significant post-processing repairs. Existing multi-pile, high-tufted carpet equipment often has excessively long transition sections between high and low pile, causing blurred pattern outlines and failing to reveal fine structures. The root cause lies in the fact that the downward movement of the needles is uniformly driven by a mechanical cam, unable to adjust the stroke endpoint according to the independent needs of each stitch. The so-called high and low pile are often merely created by differences in yarn feed, resulting in small actual pile height differences and blurred boundaries. Furthermore, traditional equipment lacks precise timing coordination between the solenoid valve action and the spindle movement, leading to uncontrollable intermediate states during the transition between high and low pile. In addition, the existing equipment has a simple linkage between the needle bar fixing component and the needle slide, and lacks a mechanical-pneumatic coupling structure for graded control of needle stroke, making it difficult to achieve precise needle selection.

[0021] Based on the above issues, please refer to Figure 1A flowchart illustrating a collaborative weaving method for a multi-layer jacquard tufted carpet, provided in this application embodiment, includes: Step 1: A collaborative weaving method for a multi-layer jacquard tufted carpet, the method being implemented based on a tufted weaving system, the system including multiple needle components 10, at least two layers of hooks 20, a clutch unit 30 for independently controlling the stroke of each needle component, a servo feed motor 40 for independently controlling the feed amount of each yarn, and a spindle drive unit 50. The tufting weaving system is the physical carrier for implementing this method. Multiple needle assemblies 10 are arranged in an array to carry yarn through the base fabric to form loops; at least two layers of hook plates 20 are staggered vertically to hook yarn at different depths to form pile heads of different heights; a clutch unit 30 independently corresponds to each needle assembly 30, independently controlling the endpoint of the needle's downward stroke; a servo feed motor 40 independently corresponds to each yarn path, used to precisely control the yarn output length and tension per unit time; and a spindle drive unit 50 provides the power source for the entire weaving cycle and establishes the time reference. Figure 1 As shown, the system integrates the aforementioned mechanical actuators and electrical drive components through a computer control system 60. The clutch unit 30 typically employs a solenoid valve-driven cylinder structure, using the extension and retraction of a push rod to couple or disengage with the long groove on the needle assembly. For example, when the pitch specification is 1 / 8 inch, the system can accommodate hundreds of independent needle assemblies 10, each equipped with an independent clutch unit 30 and a servo feed motor 40. Through this distributed control architecture, the system can independently determine the pile height attribute of each pixel on the carpet surface, providing a hardware foundation for achieving sharp boundaries without transition sections.

[0022] Step 2: The computer control system 60 performs real-time synchronous scheduling of the clutch unit action time, the output characteristics of the servo yarn feeding motor, and the spindle angle for each knitting needle according to the preset coordination timing table. The computer control system 60 is the core decision-making unit of this method, and it contains a built-in coordination timing table. This coordination timing table defines a strict mapping relationship between the spindle rotation angle and the action state of each actuator. The spindle angle serves as a global time reference, which is collected in real time by the spindle angle encoder and fed back to the computer control system. The clutch unit action time can refer to the specific spindle angle value at which the solenoid valve is energized or de-energized to drive the cylinder push rod. The output characteristics of the servo feed motor include the motor speed curve, rotation angle position, and start / stop time. Real-time synchronous scheduling means that the system ensures, with a response speed of milliseconds or even microseconds, that the corresponding clutch unit has completed the state switch and the servo motor has adjusted to the target speed the moment the spindle reaches a specific angle. For example, the coordination timing table can be set such that when the spindle angle is 30°, the corresponding clutch unit for knitting needles that need to weave low loop pile must disengage; while when the spindle angle is 210°, the corresponding clutch unit for knitting needles that need to weave high loop pile must remain coupled. This angle-based closed-loop synchronization mechanism eliminates the motion lag caused by backlash and inertia in traditional mechanical cam transmission, ensuring precise matching between yarn feed and needle depth. This allows the yarn to be in optimal tension at the moment the hook is picked up, preventing the pile from loosening or breaking.

[0023] Step 3: The collaborative timing table defines at least two collaborative modes: low loop pile weaving and high loop pile weaving. The clutch unit action times corresponding to the two modes are locked in different preset intervals of the spindle angle, and a no-travel protection zone is set between the two preset intervals.

[0024] Among them, the low-loop pile weaving collaborative mode and the high-loop pile weaving collaborative mode are two core working states defined in the collaborative timing table. In the low-loop pile weaving collaborative mode, the clutch unit's action time is locked in the first preset interval. At this time, the clutch unit drives the coupling pin to disengage from the needle assembly, so that the needle is only pushed down to a shallower lower limit position by the high-position fixed pin, and cooperates with the upper hook plate to hook a small amount of yarn. In the high-loop pile weaving collaborative mode, the clutch unit's action time is locked in the second preset interval. At this time, the clutch unit keeps the coupling pin embedded in the needle assembly, so that the needle is pushed down to a deeper lower limit position by the low-position coupling pin, and cooperates with the lower hook plate to hook a large amount of yarn. The key is that the first preset interval and the second preset interval do not overlap on the spindle angle axis, and there is a free travel protection zone between them. This free travel protection zone is a range of spindle rotation angles within which no mode switching command is triggered. It is specifically used to reserve mechanical response time and gas pressure build-up / depressurization time for the clutch unit (such as solenoid valves and cylinders). For example, if the first preset interval ends at a spindle angle of 60° and the second preset interval begins at a spindle angle of 210°, then the area between 60° and 210° includes a free travel protection zone. This ensures that when switching from a low loop mode to a high loop mode (or vice versa), the cylinder push rod has sufficient time to complete its full extension or retraction, avoiding a semi-coupled intermediate state during the needle's descent. Figure 1 As shown in branches S1 and S2, this interval locking and protection zone design fundamentally eliminates the phenomenon of needle collision or hooking due to timing conflicts, ensuring that the needle is dominated by a single driving force throughout its downward movement, thereby completely eliminating the transition slope between high and low pile heads and realizing the vertical discontinuity shape of the pile head boundary.

[0025] This application achieves high-precision weaving of multi-layer jacquard tufted carpets through the synergistic effect of the aforementioned technical features. The computer control system, based on a preset timing table, synchronizes the mechanical actions of the clutch unit, the material output of the servo yarn feeding motor, and the motion trajectory of the main shaft drive unit in three dimensions in real time. Specifically, by strictly locking the clutch unit actions in both low-loop and high-loop modes within different preset ranges of the main shaft angle, and by using a free travel protection zone to isolate the switching process between the two modes, it ensures that the source of the downward driving force for the knitting needles is unique and deterministic at any given time (either entirely driven by the high-position fixed pin or entirely driven by the low-position coupling pin). This deterministic driving force transmission mechanism, combined with the precise speed-changing output of the servo yarn feeding motor at a specific main shaft angle, creates a strict linear or non-linear matching relationship between the yarn feed rate and the needle piercing depth. Therefore, the system can eliminate the intermediate transition pile height caused by the alternation of driving force or the lag in timing in traditional processes when operating at high speed, so that a clear vertical discontinuity boundary is formed between adjacent high and low pile heads, which significantly improves the three-dimensionality and fineness of the carpet pattern. At the same time, the setting of the empty travel protection zone effectively avoids the interference of mechanical parts, greatly improving the reliability and safety of equipment operation.

[0026] Example 2: In one embodiment, this application also provides a specific structural implementation of the knitting needle assembly described in the above embodiments.

[0027] Step 1: The needle assembly 10 includes a needle slide 11, a needle 12, an elongated groove 13 disposed on the needle slide 11, a high-position fixing pin 14 fixed to the frame, and a low-position coupling pin 15 driven by the clutch unit 30. The needle slide 11 is the core sliding component that carries the knitting needle and performs reciprocating lifting and lowering motion. Its material is typically high-strength alloy steel or engineering plastic to ensure no deformation during high-speed reciprocating motion. The knitting needle is fixed to the lower end of the needle slide and performs the actions of piercing the base fabric and retracting synchronously with the displacement of the needle slide. A long groove is formed on the side wall or inside of the needle slide, forming a vertically extending strip structure. Its length determines the maximum theoretical stroke range of the knitting needle. This long groove provides a track for the high-position fixing pin and the low-position coupling pin to bear force. The high-position fixing pin is rigidly fixed to the frame of the tufting machine by bolts or welding. Its position remains stationary relative to the frame and is used as a drive source in low loop pile mode to contact the lower plane of the long groove to limit the downward depth of the knitting needle. The low-position coupling pin is connected to the output end of the clutch unit and can extend and retract horizontally under the drive of the clutch unit, thereby selectively engaging or disengaging from the long groove to determine whether to transmit the driving force of the clutch unit to the needle slide. Figure 2 As shown, Figure 2This is a schematic diagram of the knitting needle assembly provided in this application. The diagram details the spatial layout and connection relationship of the needle slide 11, knitting needle 12, long groove 13, high-position fixing pin 14, and low-position coupling pin 15. The high-position fixing pin 14 is always located within the path of the long groove 13, while the low-position coupling pin 15, in its extended state, extends into the long groove 13 to form a mechanical lock. For example, when the depth of the long groove is set to 20mm, the high-position fixing pin can be positioned 8mm from the upper limit, so that when driven solely by the high-position fixing pin, the needle's downward movement of 8mm is blocked; while if the low-position coupling pin is fully embedded and moves downward with the clutch unit to the bottom, it can push the knitting needle downward by 18mm. Through this dual-pin and single-groove cooperative structure, the end point of the knitting needle's stroke can be controlled in stages by switching the drive source without changing the physical dimensions of the needle slide.

[0028] Step 2: The needle slide is suspended by an elastic element to maintain its upper limit position.

[0029] The elastic element can refer to an elastic body with a reset function, specifically including a tension spring, a compression spring, or an elastic rubber block; in this embodiment, a tension spring is preferred. One end of the elastic element is connected to a fixed support point of the frame, and the other end is connected to the upper part or side of the needle slide. The function of this elastic element is to provide an upward pulling force when the needle assembly is not subjected to a downward driving force from the high-position fixing pin or the low-position coupling pin, thus maintaining the needle slide at a preset upper limit position. This suspension holding mechanism ensures that the starting height of all needles is strictly consistent at the beginning of each weaving cycle, eliminating initial position deviations caused by gravity or inertia, thereby ensuring the uniformity of the blanket pile height. At the same time, the elastic element can also absorb the lateral vibration generated by the needles during high-speed operation, improving the stability of the weaving process. Figure 2 As shown in the figure, the elastic element 16 is clearly connected above the needle slide 11 and is in a stretched state to balance the weight of the needle slide and the knitting needle. For example, using a tension spring with a stiffness coefficient of 5 N / mm, when the total weight of the needle slide assembly is 0.5 kg, the spring pre-tension is approximately 10 mm, at which point the needle slide is stably stopped at the upper limit stop. When the knitting needle needs to move downwards, the thrust applied by the drive pin must first overcome the preload of the spring before it can push the needle slide downwards. Through the coordinated operation of the elastic element and the double-pin structure, not only is precise graded control of the knitting needle stroke achieved, but also the static stability of the needle slide in the non-working state and its rapid dynamic response reset capability are ensured.

[0030] This application, through the structural design of the aforementioned needle assembly, utilizes a long groove as a universal force transmission medium, combining a stationary high-position fixing pin with a movable low-position coupling pin to construct a flexible mechanical hierarchical drive foundation. The introduction of elastic elements further establishes a stable reference zero point, enabling the computer control system to physically lock the needle's movement path—whether it is constrained by the high-position fixing pin or follows the low-position coupling pin—by ​​controlling a single action (coupling or disengaging) of the clutch unit. This provides reliable hardware support for subsequent seamless high-low pile switching.

[0031] Example 3: In one embodiment, such as Figure 3 The diagram shown is a schematic representation of the operating principle of a low-loop pile weaving collaborative mode according to an embodiment of this application. The method further includes the following specific steps: Step 1: The clutch unit disengages the low-position coupling pin from the long groove; The clutch unit can refer to a pneumatic or electromagnetic drive device that independently controls the stroke of each needle assembly. Its function is to drive the low-position coupling pin to switch between the coupling and disengagement positions. The low-position coupling pin is a pin structure installed at the end of the clutch unit push rod, used to engage or disengage from the long groove on the needle slide to transmit driving force. The long groove is a longitudinal guide groove set on the side of the needle slide, and its length determines the maximum potential stroke of the needle. In this step, when the computer control system determines that the current needle needs to perform low loop pile knitting, it will issue a first command to the corresponding clutch unit at the moment the spindle angle enters the first preset range (e.g., 31°). This command drives the push rod of the clutch unit to retract, causing the low-position coupling pin to completely disengage from the long groove, so that the low-position coupling pin and the long groove are physically separated. At this time, the low-position coupling pin no longer has the ability to push the needle slide downward, thus releasing its interference with the needle stroke. For example, if the clutch unit is a small cylinder, the solenoid valve is energized, causing the cylinder piston rod to retract to the return position. The low-position coupling pin then exits the long groove by approximately 2-3 mm, ensuring that it does not rub against or interfere with the groove wall during subsequent downward movement. This disengagement action ensures that the downward driving force of the knitting needle is singular, avoiding stroke uncertainty caused by conflict between dual driving sources.

[0032] like Figure 3 As shown, Figure 3 This diagram illustrates the operating principle of the low loop pile weaving cooperative mode. It shows in detail the state in which the clutch unit 30 drives the low-position coupling pin 15 to exit the long groove 13 on the needle slide 11 in the S1 low loop pile weaving cooperative mode. The low-position coupling pin 15 is located outside the long groove 13, and a clear gap is formed between the two, indicating that the power transmission chain has been cut off.

[0033] This step aims to eliminate the potential driving interference of the low-position coupling pin on the downward movement of the knitting needle, creating the preconditions for the high-position fixing pin to take over control, thereby ensuring the consistency of the low loop pile height.

[0034] Step 2: The knitting needle is pushed down by the high-position fixing pin to the lower limit of the low loop position; The high-position fixing pin is a stationary pin component fixed to the frame. Its position is fixed relative to the base fabric plane and always lies within the movement path of the long groove. The knitting needle is fixed to the lower end of the needle slide and moves synchronously with it. In this step, after the low-position coupling pin disengages, the main shaft drive unit drives the needle bar and needle bar fixing component downwards. Since the low-position coupling pin has disengaged, the downward movement of the needle slide is entirely achieved by the cooperation of the high-position fixing pin and the long groove. Specifically, as the needle bar fixing component moves downwards, the high-position fixing pin, fixed to the frame, contacts and abuts against the lower plane (or lower limit step) of the long groove, forcibly pushing the needle slide and the knitting needle downwards. When the needle slide descends to the preset lower limit of the low loop position, the high-position fixing pin reaches its end point of travel, and the knitting needle stops descending. The height of this lower limit of the low loop position is determined by the installation position of the high-position fixing pin and the effective working length of the long groove, and usually corresponds to the hooking depth of the upper hook plate. For example, if the vertical distance between the high-position fixing pin and the upper limit is set to 8mm, the needle will be precisely pushed to the low loop position at that depth of 8mm, instead of continuing to descend to a deeper 15mm as in the high loop mode. The rigid limiting effect of the high-position fixing pin achieves graded cutoff of the needle travel, ensuring that all low loop piles have a uniform short pile height.

[0035] This step utilizes a high-position fixed pin as the sole active drive source, locking the needle travel at a shorter low loop level. This effectively avoids pile height fluctuations caused by accumulated mechanical errors, laying a mechanical foundation for forming sharp pile height boundaries.

[0036] Step 3: Hook the yarn from the upper hook plate; The upper hook plate is the higher of at least two hook plates, and its hook tip height matches the lower limit of the low loop position. In this step, when the needle descends to the lower limit of the low loop position, the needle tip passes through the base fabric and reaches the lowest point. At this moment, the hook tip of the upper hook plate moves precisely to the preset hooking position next to the needle tip. As the spindle continues to rotate, the upper hook plate performs the hooking action, catching the yarn loop brought down by the needle. Because the needle only descends to the low loop position, the yarn loop is short, resulting in a lower pile height. For example, if the hooking height of the upper hook plate is set to 4mm from the base fabric surface, the pile height of the hooked yarn loop will remain around 4mm after cutting or retaining the loop. The precise matching of the upper hook plate and the lower limit of the low loop position ensures that the yarn is only introduced into the base fabric within a short stroke range, preventing waste of excess yarn and uncontrollable growth in pile height.

[0037] This step transforms short-stroke mechanical motion into a specific low-loop pile shape through the hooking action of the upper hook plate at a specific depth, thus achieving a fine expression of the dark or background areas in the pattern.

[0038] Step 4: The servo feed motor outputs low-fiber yarn according to the first speed curve; The servo feed motor is an actuator that independently controls the feed amount of each yarn. The first speed curve is a motor control strategy preset in the computer control system's timing table, characterized by a low peak speed and a smooth acceleration process. Low-pile yarn refers to a shorter yarn output per unit time to match the formation requirements of low-loop pile. In this step, when the computer control system detects that the knitting needle has reached the lower limit of the low loop position (or the upper hook plate begins to hook), it immediately sends a second command to the corresponding servo feed motor, controlling the motor to operate according to the first speed curve. This curve is typically designed to provide a moderate instantaneous speed at the moment of hooking, followed by rapid deceleration to ensure that the total output yarn amount is just enough to form a tight low-loop pile, and that the yarn tension remains constant. For example, the peak speed of the first speed curve is set to 300 rpm for 50 ms, with a total output yarn length of 12 mm; in contrast, the high-loop mode may require 600 rpm and an output of 25 mm. This low-speed, short-time control avoids loosening, collapsing, or pilling of the low loop pile due to excessive yarn feeding, while also preventing yarn breakage or tightening of the base fabric due to insufficient yarn feeding.

[0039] This step ensures a perfect match between the yarn supply and the pile head space requirements by synchronizing the low pile feeding with the low loop position and the upper hook plate hooking at the millisecond level, which significantly improves the flatness and density of the blanket surface in the low loop area.

[0040] Example 4: In one embodiment, such as Figure 4 The diagram shown is a schematic representation of the operating principle of a high-loop pile weaving collaborative mode according to an embodiment of this application. The method further includes the following specific steps: Step 1: The clutch unit keeps the low-position coupling pin embedded in the long groove; The "retaining embeddedness" refers to the computer control system controlling the clutch unit to be in a driven state before entering the preset spindle angle range of the high-loop pile weaving collaborative mode. This ensures that the low-position coupling pin is fully extended and locked into the long groove on the needle slide. Specifically, the low-position coupling pin is driven by the clutch unit (such as a small cylinder push rod), and its extension length is sufficient to cover the effective stroke section of the long groove, thereby establishing a rigid mechanical connection between the needle slide and the drive source. This connection method ensures that the needle slide will not slide or decouple relative to the low-position coupling pin during subsequent downward movement. For example, when the system determines that the current needle position needs to perform high-loop pile weaving, the clutch unit is instructed to remain in the extended position before the spindle angle reaches 210°. At this time, the front end of the low-position coupling pin penetrates deep into the bottom of the long groove, forming a stable coupling interface. Through this pre-locking mechanism, the stroke lag caused by mechanical backlash in traditional equipment is eliminated, ensuring that the needle can accurately respond to the command for deep downward movement.

[0041] Step 2: The knitting needle is pushed down by the low-position coupling pin to the lower limit of the high loop position; The lower limit of the high loop position refers to the knitting needle, under the direct push of the low coupling pin, overcoming the tension of the elastic element, descending to a deeper limit position than the low loop position. Specifically, since the low coupling pin is rigidly coupled to the long groove, when the main shaft drive unit drives the needle bar and fixing parts downward, the power is directly transmitted to the needle slide through the low coupling pin, thereby driving the knitting needle downward. During this process, although the high fixing pin is still located on the path of the long groove, because the pushing stroke of the low coupling pin exceeds the point of action of the high fixing pin, the knitting needle will continue to descend beyond the low loop position until it reaches the preset lower limit of the high loop position. Figure 4 As shown in the diagram, this figure details the movement trajectory of each component in the high loop pile weaving mode. The low-position coupling pin 15 is tightly embedded in the long groove 13, pushing the needle slide 11 and the knitting needle 12 down the path indicated by the arrow to the deepest point. At this point, the lower hook plate 22 is in the hooking position. For example, if the lower limit of the low loop position is 8mm from the upper limit, the lower limit of the high loop position can be set to 12mm. This additional 4mm of travel relies entirely on the low-position coupling pin's dominant push on the long groove throughout its travel. Thus, the knitting needle can accurately reach the deep hooking point, providing the necessary spatial foundation for forming a towering pile.

[0042] Step 3: Hook the yarn from the lower hook plate; The lower hook plate refers to a hooking component positioned below the needle plate of the tufting machine, lower than the upper hook plate, specifically designed to capture yarn loops extending into the deeper layers of the high loop pile weaving pattern. Specifically, as the lower hook plate rotates to its highest point with the main shaft and begins to fall, its hook tip precisely passes through the yarn loop brought to its lowest point by the knitting needle. Since the knitting needle has been pushed to the lower limit of the high loop position by the low coupling pin, the length of the yarn loop increases significantly, allowing the lower hook plate to stably hook this long yarn loop and pull it across the base fabric. For example, at the instant the lower hook plate 22 rises to its apex and begins to descend, its hook tip accurately hooks the extended yarn loop released by the knitting needle 12. As the base fabric moves forward, this yarn loop is fixed to the back of the blanket, forming a high loop structure. Through the precise coordination between the lower hook plate and the deep needle position, the forming stability of the high loop pile is ensured, avoiding missed hooks or uneven pile height caused by insufficient needle positions.

[0043] Step 4: The servo feeding motor outputs high-fiber yarn according to the second speed curve, and the peak speed of the second speed curve is higher than that of the first speed curve; The second speed curve is a servo motor speed-time function pre-set by the computer control system for the needs of high-loop pile weaving. Its characteristic is that the yarn length output per unit time is significantly greater than that of the first speed curve in low-loop mode. Specifically, the peak speed of the second speed curve is set higher than that of the first speed curve to quickly release sufficient yarn to fill the space required for the high-loop pile within the short time window of the needle descending to the hook point. The rising edge of this curve is usually steeper to ensure that the yarn reaches maximum tension matching at the moment of hooking, preventing pile collapse or yarn breakage due to insufficient yarn supply. For example, if the peak speed of the first speed curve is 300 rpm, used to output 5mm long low-loop yarn, then the peak speed of the second speed curve can be set to 450 rpm to output 8mm or even longer high-loop yarn within the same time period. Figure 4 As shown, the servo feed motor 40, according to the instructions of the coordination timing table, accelerates strictly according to the second speed curve before and after the knitting needle reaches the lower limit of the high loop position. Its output characteristics are strictly synchronized with the action time of the lower layer hook plate 22. Through this differentiated control of the peak speed, not only are the physical requirements of the high loop pile for yarn consumption met, but the tension consistency of the yarn is also ensured during the high-speed weaving process, thereby forming a full, fluffy and uniformly high loop pile.

[0044] This application achieves refined weaving of high-loop pile through the synergistic effect of the aforementioned technical features. Specifically, the clutch unit keeps the low-position coupling pin embedded in the long groove, establishing a rigid transmission chain from the drive source to the knitting needle, ensuring that the knitting needle can overcome the low-loop limitation and descend to the high-loop position. On this basis, the lower layer hook plate precisely hooks the deep needle position, while the servo yarn feeding motor instantaneously supplies sufficient yarn at a higher peak speed (second speed curve). A tight spatiotemporal coupling relationship is formed among these three: rigid transmission ensures depth, dedicated hook plate ensures capture, and high peak yarn feeding ensures fullness. In particular, the setting of the peak speed of the second speed curve being higher than that of the first speed curve directly solves the problem of yarn supply lag that easily occurs in high-loop pile due to its long stroke and large yarn requirement. With the deep synergy of this mechanical coupling and electrical control, this method can present piles with significant height differences without transition on the same carpet surface, effectively eliminating the blurred transition zone in traditional processes and greatly improving the three-dimensionality and pattern clarity of jacquard carpets.

[0045] Example 5: In one embodiment, such as Figure 5 The diagram shown is a timing diagram of a middle loop pile weaving mode control provided in an embodiment of this application. The method also includes a specific step of defining the middle loop pile weaving mode in the coordination timing table.

[0046] Step 1: During the downward movement of the knitting needle, the computer control system sends a pulse width modulation signal to the clutch unit within the preset spindle angle window; The preset spindle angle window refers to a specific angle range within the spindle rotation cycle, after the needle assembly has started its downward movement but before reaching the lower limit of the high loop position. The starting angle of this window is typically set after the high loop mode drive command is issued, and between the end of the idle travel protection zone and the arrival of the high loop lower limit. The pulse width modulation (PWM) signal is a variable duty cycle electrical signal used to control the solenoid valve in the clutch unit to perform high-frequency on / off or short-term pressure relief operations. Specifically, when the needle moves downward under the push of the low-position coupling pin, the computer control system monitors the real-time feedback from the spindle angle encoder. Once it enters the preset window, it immediately triggers the PWM signal output. The pulse width of this signal determines the duration of the clutch unit's action, and thus the displacement amount of the interrupted needle travel. For example, if the preset window is 212° to 240°, the system can issue a pulse signal with a pulse width of 5ms at 225°; if a smaller intermediate pile height is required, the pulse width can be adjusted to 3ms. By dynamically adjusting the pulse width, the response time of the clutch unit can be precisely controlled, enabling microsecond-level intervention during the needle's downward movement.

[0047] Step 2: Stop the knitting needle's travel at the middle hook layer; The intermediate hook layer can refer to a virtual stop position between the lower limit of the low loop position corresponding to the upper hook layer and the lower limit of the high loop position corresponding to the lower hook layer. This position is formed as follows: when the clutch unit receives a pulse width modulation (PWM) signal, it drives the low-position coupling pin to perform a controllable slip-re-entry action. Specifically, the PWM signal causes the cylinder push rod driving the low-position coupling pin to depressurize instantaneously, causing the low-position coupling pin to briefly disengage from the long groove of the needle slide or undergo a slight displacement. At this time, the knitting needle loses the downward thrust from the low-position coupling pin and is only affected by its own gravity and frictional resistance, resulting in a sharp decrease in its downward speed or a temporary halt. Subsequently, after the PWM signal ends, the cylinder quickly restores pressure, and the low-position coupling pin re-enters the long groove and resumes its coupling state. Due to this brief disengagement process, the knitting needle fails to complete the originally set full-stroke downward movement, and its final stop position is locked at an intermediate height, higher than the lower limit of the high loop position and lower than the lower limit of the low loop position. Figure 5 As shown, curve S3 illustrates the decreasing trend of needle displacement relative to the standard high loop pattern (S2) after applying a PWM signal within the spindle angle window, forming a stable intermediate pile height level. This mechanism allows multiple virtual pile height levels to be generated through software algorithms without increasing the number of physical hook layers (e.g., without needing to specifically set a third hook layer). For example, by setting different pulse width values ​​(3ms, 5ms, 8ms), stroke shortening of 0.15mm, 0.3mm, and 0.5mm can be achieved respectively, thus presenting rich multi-layered three-dimensional patterns on the same carpet surface.

[0048] This application introduces a center loop pile weaving mode and utilizes pulse width modulation (PWM) signals to precisely control the clutch unit, achieving dynamic variability of the needle stroke. The close coordination between the computer control system and the clutch unit allows the needle to precisely brake and stop at any preset intermediate position during its descent. This electromechanical synergy not only avoids the increased complexity and cost of equipment structure caused by adding mechanical hook layers but also greatly expands the design freedom of jacquard patterns. With the flexible adjustment of the PWM signal, the system can generate clear, seamless height differences in real time according to pattern requirements, significantly improving the visual depth and refinement of tufted carpets and effectively solving the technical challenge of traditional equipment failing to reproduce subtle variations in pile height.

[0049] Example 6: In one alternative implementation, such as Figure 6 The diagram shown is a closed-loop control and emergency stop logic flowchart provided in an embodiment of this application. The method also includes a collaborative interruption and protection step based on real-time feedback.

[0050] Step 1: The computer control system receives real-time feedback from the spindle angle, clutch unit status, and servo yarn feeding motor to form a closed-loop control. Closed-loop control refers to the process by which the system continuously collects the actual operating parameters of the actuators through a multi-source sensor network and dynamically compares them with a preset coordination timing table. Specifically, the spindle angle feedback comes from a high-precision angle encoder installed at the end of the spindle drive unit, which is used to monitor the rotation phase of the spindle in real time with a resolution of up to 0.1 degrees, ensuring accurate positioning of the needle's descent. The clutch unit status feedback comes from displacement sensors or Hall switches set at the extreme positions of each independent clutch unit (such as a small cylinder driven by a solenoid valve), used to determine in real time whether the low-position coupling pin is in a coupled state embedded in the long groove or in a disengaged state. The servo yarn feeding motor feedback comes from a rotary encoder integrated inside the servo motor, used to calculate and feedback the actual output length and instantaneous speed of the yarn in real time. The computer control system, as the core processing unit, reads the above three feedback signals at millisecond intervals, constructing a closed-loop circuit of instruction-execution-feedback-correction. For example, in low-loop pile weaving mode, when the timing table indicates that the spindle angle has entered the first preset range, the system will simultaneously check whether the clutch unit feedback has changed to a disengaged state. If the feedback still shows coupling, it is determined to be a lag in action. Through this multi-dimensional real-time data interaction, the system can instantly perceive any minor abnormalities in the mechanical transmission chain, such as cylinder response delay, spindle step loss, or yarn slippage, thereby providing accurate data support for subsequent fault decision-making.

[0051] Step 2: When any feedback value deviates from the preset value of the collaborative timing table by more than the threshold, the system immediately issues an emergency stop command and forces all knitting needles to return to the upper limit position.

[0052] The threshold is a safety tolerance range pre-stored in the computer control system, used to define the boundary between normal system fluctuations and fault states. For the spindle angle, the threshold can be set to ±2 degrees. If the actual angle lags behind the commanded angle by more than this range, it means that the spindle drive has lost synchronization. For the clutch unit status, the threshold is reflected in a time window. If no status switching signal is received within the specific angle window of the spindle, it is considered that the deviation exceeds the limit. For the servo yarn feeding motor, the threshold can be set to ±5% of the theoretical yarn feeding amount. Exceeding this range indicates abnormal yarn tension or motor stall. Once any feedback value is detected to exceed the preset threshold, the computer control system will immediately trigger the highest priority emergency stop logic: first, an emergency braking signal is sent to the spindle drive unit to cut off the power output to prevent mechanical collision; then, the system starts the backup air source or executes a forced reset procedure, sending a unified command to all clutch units to force all low-position coupling pins to quickly disengage from the coupling connection with the long groove of the needle slide. During this process, since the needle assembly is usually suspended and held at the upper limit by elastic elements (such as tension springs), when the low-position coupling pins are disengaged, the needle will instantly and automatically spring back to the mechanical upper limit under the action of elastic restoring force. For example, if the clutch unit corresponding to a certain needle fails to switch to the extended state at a spindle angle of 211° (deviation exceeding the time threshold), the system issues an emergency stop command within 5 milliseconds and then uses high-pressure gas to force all cylinders to retract within the following 15 milliseconds, ensuring that all hundreds of needles on the entire fabric width safely return to their upper limit position within a total time of 20 milliseconds. This mechanism effectively blocks the spread of fault signals and avoids hook plate collisions, needle breakage, or large-scale misalignment of carpet patterns caused by single needle movement errors.

[0053] This application constructs a highly robust closed-loop control system by introducing a triple real-time feedback mechanism involving the spindle angle, clutch unit status, and servo yarn feeding motor. By frequently comparing the real-time acquired multi-dimensional data with the theoretical model of the collaborative timing table, the system can identify potential risks such as spindle loss of synchronization, cylinder jamming, or abnormal yarn feeding at the nascent stage of a fault. Once the monitored data deviates from the preset safety threshold, an emergency stop command and a forced reset action are triggered in tandem. Utilizing the reset characteristics of the elastic element and the rapid pneumatic response capability, all moving parts are locked to a safe upper limit state in a very short time. This synergistic effect of real-time monitoring, threshold determination, and rapid reset not only fundamentally eliminates the possibility of mechanical damage to the entire machine caused by the failure of a partial actuator, but also maximizes the protection of high-value carpet semi-finished products in the process of weaving, significantly improving the continuity and safety of the tufting weaving process.

[0054] Example 7: In one embodiment, this application also provides a specific implementation method for forcibly disengaging all low-position coupling pins quickly using a backup air source after an emergency stop command is issued.

[0055] Step 1: After the emergency stop command is issued, the computer control system also starts the backup air source to force all low-position coupling pins to disengage. The backup air source can refer to a high-pressure air storage device independent of the main air supply system, which pre-stores compressed gas at a pressure higher than the normal operating pressure. When the computer control system determines that any feedback value deviates from the preset value of the coordination timing table by more than a threshold and issues an emergency stop command, the system immediately triggers the release valve of the backup air source. Specifically, high-pressure gas is directly injected into the back pressure chamber or reset chamber of all clutch units through a dedicated fast-response air path, generating a strong reverse thrust. This thrust acts on the drive push rod of the low-position coupling pin, overcoming mechanical friction and residual air pressure, forcing the push rod to retract instantaneously to the return position, thereby physically separating the low-position coupling pin from the long groove on the needle slide. The air path connection between the backup air source 70 and the clutch units 30 in the multiple knitting needle assemblies 10; at the instant the emergency stop signal is triggered, the high-pressure airflow output by the backup air source 70 directly acts on the drive end of the low-position coupling pin 15, forcing the low-position coupling pin 15, which may have been in an embedded state, to quickly exit the long groove 13, cutting off the connection between the needle slide 11 and the downward driving force. For example, with the main gas source pressure at 0.6 MPa, the backup gas source can be pre-charged to 0.8 MPa-1.0 MPa. Utilizing the pressure difference advantage, it ensures that even in extreme failures such as main gas line blockage or solenoid valve jamming, the decoupling action can still be forcibly completed through physical high pressure. This independent and redundant gas source design eliminates the dependence on the original sequential operation of the solenoid valves, ensuring the absolute reliability and priority of the decoupling action.

[0056] Step 2: The total time from fault detection to the complete disengagement of all low-level coupling pins shall not exceed 20 milliseconds; The total timeout refers to the entire time interval from the moment the computer control system collects the abnormal signal and confirms the fault, to the moment the last low-position coupling pin completely exits the long groove and reaches the safe return position. This time indicator encompasses signal processing delay, valve opening response time, gas transmission time, and the movement time of the mechanical actuator. To meet this stringent timing requirement, the system employs a high-speed hardware interrupt mechanism to process fault signals, skipping the conventional software polling cycle and directly triggering the backup gas source valve within microseconds. Simultaneously, the gas pipeline adopts a large-diameter, short-path design to reduce gas transmission lag, and the drive push rod of the low-position coupling pin uses lightweight materials to reduce motion inertia. For example, when the spindle angle encoder detects an angle deviation exceeding 2° (T0), the computer control system completes the logical judgment and outputs a high-level signal within 1ms (T1), the backup gas source solenoid valve opens within 2ms (T2), high-pressure gas fills the back pressure chambers of each cylinder within 5ms, and pushes all low-position coupling pins to complete their mechanical stroke within the subsequent 12ms, ensuring that the total timeout T_total ≤ 20ms. This millisecond-level response speed ensures that within a very small range of angles that the spindle continues to rotate due to inertia, all knitting needles have been released from the downward driving force and are ready to reset, thus avoiding rigid collisions between the knitting needles and the hook during high-speed movement.

[0057] This application constructs a multi-layered safety protection system by introducing a backup air source and an ultra-fast response mechanism. Utilizing the independent high-pressure power provided by the backup air source, the system overcomes the physical bottlenecks in response speed and reliability of conventional electromagnetic control circuits. Through tight timing locking between fault detection and mechanical execution, the overall decoupling process is compressed to within 20 milliseconds. This synergistic effect not only solves the problem of sudden stoppage caused by the failure of a single air source or control, but also fundamentally eliminates needle collisions or carpet tearing accidents caused by individual needles failing to reset in time, greatly improving the fault tolerance and safety of the tufted weaving system under high-speed operating conditions.

[0058] Example 8: In another embodiment, the method further includes adaptively setting the hardware configuration parameters and raw material specifications of the tufted weaving system to match the production needs of different application scenarios.

[0059] Step 1: The tufting weaving system uses a needle pattern array with a spacing specification selected from 1 / 10 inch, 1 / 8 inch, 5 / 32 inch, and 1 / 4 inch; The stitch spacing specification refers to the horizontal distance between the center lines of two adjacent needles on the needle plate of the tufting machine. This parameter directly determines the stitch density and pattern fineness of the finished carpet. Based on a preset production task, the system mechanically installs the corresponding needle plate assembly, or locks the stitch spacing to one of the four standard specifications mentioned above on an adjustable needle plate. When using a 1 / 10-inch stitch spacing, the needle pattern arrangement is high-density, suitable for scenarios with extremely high requirements for pattern detail, such as automotive interior carpets or aviation carpets; when using a 1 / 8-inch stitch spacing, it is suitable for regular household wall-to-wall carpets, balancing production efficiency and carpet texture; when using a 5 / 32-inch or 1 / 4-inch stitch spacing, the stitch spacing is wider, suitable for the rapid weaving of commercial area rugs or large-patterned decorative carpets. After reading the current stitch spacing configuration parameters, the computer control system automatically adjusts the spindle angle window width and the base fabric step in the coordination timing table to ensure that the clutch unit's action timing and the hook plate's hooking position remain precisely synchronized under different needle densities. For example, when switching to a 1 / 10-inch high-density layout, the system compresses the spindle movement range of the low-loop pile weaving cooperative mode to accommodate shorter mechanical response times and prevent interference risks caused by excessively dense stitch spacing. This flexible spacing configuration allows the system to be compatible with a wide range of products, from ultra-fine jacquard to coarse textures, significantly improving the equipment's versatility.

[0060] Step 2: The yarn used is one or more twisted or network yarns of wool, polyester, and polypropylene. Yarn is the core material for forming carpet pile, and its material properties and structural form directly affect the stability of the weaving process and the physical properties of the final carpet surface. Wool yarn provides a natural feel and high-end luster, suitable for high-end home environments; polyester (PET) yarn has excellent color fastness and abrasion resistance, and rich color expression; polypropylene (PP) yarn has the advantages of being lightweight, hydrophobic, and low-cost, and is often used in commercial settings. To adapt to the dynamic environment of high-speed hooking of multiple layers and frequent needle lifting and lowering in this method, the selected yarn must be twisted or networked. Twisted yarn is formed by twisting multiple single yarns axially, increasing the yarn's cohesion and tensile strength; networked yarn uses high-pressure airflow to make the filaments intertwine to form nodes, which also enhances the bundled properties. During the weaving process, when the servo feed motor outputs yarn at high speed according to the first or second speed curve, the twisting or network structure can effectively prevent the yarn from loosening, pilling, or breaking under sudden tension changes. For example, when using twisted polyester yarn for high-loop pile weaving, even with a high peak speed of the servo motor, the yarn maintains its complete cylindrical shape and is accurately hooked by the lower hook plates, avoiding hooking failures or carpet defects caused by filament unraveling. Furthermore, the computer control system can fine-tune the torque output parameters of the yarn feeding motor based on differences in the friction coefficient of the yarn material, further optimizing yarn tension control. This synergistic selection of materials and processes ensures continuous operation and finished product quality under high-density, high-pile weaving conditions.

[0061] This application achieves broad applicability and high reliability of the technical solution in various industrial scenarios by limiting specific spacing specifications and yarn types. By selecting standard spacing from 1 / 10 inch to 1 / 4 inch, the system can flexibly meet diverse needs, ranging from precision instrument mats to large-area commercial floor coverings. Furthermore, the computer control system can automatically optimize timing parameters based on spacing changes, ensuring the precision of mechanical actions. Simultaneously, limiting the use of twisted or network yarns made of wool, polyester, or polypropylene leverages the high cohesion and strength of these yarns, effectively overcoming the breakage and pilling problems easily caused by high-speed hooking in traditional tufting processes. The established spacing specifications provide a spatial basis for the stable operation of the mechanical structure, while the specific yarn structure provides material assurance for high-speed dynamic weaving. The combination of these two aspects allows this method to significantly improve weaving efficiency and product yield while maintaining pattern three-dimensionality and edge sharpness, meeting the stringent requirements of industrialized production of mid-to-high-end tufted carpets.

[0062] Example 9: The following is for reference. Figure 7 It shows a schematic diagram of the structure of a computer system suitable for implementing the embodiments of this application.

[0063] like Figure 7As shown, the computer system includes a central processing unit (CPU) 801, which can perform various appropriate actions and processes based on programs stored in read-only memory (ROM) 802 or programs loaded from storage section 808 into random access memory (RAM) 803. RAM 803 also stores various programs and data required for the operation of system 800. CPU 801, ROM 802, and RAM 803 are interconnected via bus 804. Input / output (I / O) interface 805 is also connected to bus 804.

[0064] The following components are connected to I / O interface 807: an input section 806 including a keyboard, mouse, etc.; an output section 807 including a cathode ray tube (CRT), liquid crystal display (LCD), etc., and speakers, etc.; a storage section 808 including a hard disk, etc.; and a communication section 809 including a network interface card such as a LAN card, modem, etc. The communication section 809 performs communication processing via a network such as the Internet. Drive 810 is also connected to I / O interface 805 as needed. Removable media 811, such as a disk, optical disk, magneto-optical disk, semiconductor memory, etc., are installed on drive 810 as needed so that computer programs read from them can be installed into storage section 808 as needed.

[0065] Example 10: Traditional tufted carpets, when weaving jacquard patterns, are often limited by a single needle height control method or a uniform mechanical cam drive mode, resulting in a limited range of variations in pile height and making it difficult to construct rich and clear layered structures. In existing technologies, to achieve a three-dimensional effect, some processes employ hand-punching or multi-layered weaving, but this is not only inefficient but also prone to pattern misalignment due to material deformation or needle displacement. A more common problem is that in existing mechanized production equipment, the switching between high and low pile heights often involves uncontrollable intermediate states, resulting in long transition slopes between pile heights. This blurs the pattern outlines, fails to sharply reveal fine structures, and severely affects the carpet's visual detail and tactile texture. Therefore, how to obtain a multi-layered loop pile jacquard carpet with excellent visual effects and tactile texture, overcoming the defects of blurred patterns and weak three-dimensionality, is a technical problem urgently needing to be solved in this field.

[0066] To address the aforementioned issues, this application provides a multi-layer loop pile jacquard tufted carpet, which is prepared using the aforementioned collaborative weaving method. This method fundamentally eliminates the transition section between high and low pile, achieving a sharpening of the pile height boundary.

[0067] like Figure 8As shown, the multi-layer loop pile jacquard tufted carpet provided in this application has at least two types of pile with varying heights and no transition sections, and the boundary between adjacent high and low piles is a vertical discontinuity. This carpet is a product woven using any one of the multi-layer selective needle jacquard tufted carpet co-weaving methods described in embodiments 8 above.

[0068] Among them, at least two types of pile with no transition section can refer to areas of pile with significantly different heights existing simultaneously on the same surface of the carpet, such as low loop pile 10 and high loop pile 11. The height difference between these two piles is not formed by a small adjustment of the yarn stack amount, but is achieved through substantial graded control of the downward stroke of the knitting needle. In the scheme of this application, low loop pile 10 corresponds to the pile formed when the knitting needle assembly 10 is disengaged from the long groove 13 and is pushed down to the lower limit of the low loop position by the high fixed pin 14; while high loop pile 11 corresponds to the pile formed when the low coupling pin 15 is kept embedded in the long groove 13 and the knitting needle assembly 10 is directly pushed down to the lower limit of the high loop position by the low coupling pin 15. Because the driving force for the downward movement of the needles in the two modes comes from different sources (high-position fixed pin 14 and low-position coupling pin 15, respectively), and the movement time is locked within different preset ranges of the spindle angle, the lower limit position reached by the needles has a clear step-like nature and there is no intermediate gradual stroke, thus ensuring the transition-free characteristics of the pile height in the physical structure.

[0069] The vertical discontinuity between adjacent high and low pile ends refers to the fact that, on the carpet surface, the change in pile height from a low-pile area to a high-pile area appears as a near-vertical step on a microscale, rather than a sloping surface. This discontinuity relies on the precise synchronization of the clutch unit 30's movement with the angle of the main shaft drive unit 50 by the computer control system 60. Specifically, when the weaving pattern switches from low to high (or vice versa), the system utilizes a no-travel protection zone to ensure that the clutch unit 30 completes the state switch (i.e., the extension or retraction of the low-position coupling pin 15), avoiding interference or alternating action between the two drive mechanisms during the stroke. Therefore, in each reciprocating motion, each needle 12 is either completely limited in its stroke by the high-position fixing pin 14 or completely limited in its stroke by the low-position coupling pin 15, without any partial stroke. This mechanism ensures that even if one yarn is low-pile and the other high-pile, their landing heights on the backing fabric are drastically different, thus creating a clear vertical discontinuity on a macroscopic scale.

[0070] In the fabrication process of this multi-layered loop pile jacquard tufted carpet, the output characteristics of the servo yarn feeding motor 40 are strictly matched with the needle stroke. When forming the low loop pile 10, the servo yarn feeding motor 40 outputs low pile yarn according to the first speed curve, which is then hooked by the upper hook plate 21. When forming the high loop pile 11, the servo yarn feeding motor 40 outputs high pile yarn according to the second speed curve, which is then hooked by the lower hook plate 22. This synergy between the yarn supply and the needle penetration depth further consolidates the morphological stability of the high and low piles, prevents pile collapse or stretching caused by uneven yarn tension, and ensures the durability of the vertical discontinuity morphology.

[0071] Specifically, the carpet of this application, in its practical implementation, can be produced based on a tufted weaving system with a pitch of 1 / 10 inch, 1 / 8 inch, 5 / 32 inch, or 1 / 4 inch. The yarn material used can be set according to actual needs, for example, it can be one or more twisted or mesh yarns of wool, polyester, and polypropylene. In a preferred embodiment, when the carpet is used to represent fine text or geometric patterns, a 1 / 8-inch pitch is used, and the clutch unit 30 of each row of needles assembly 10 is independently controlled by a computer control system 60. In areas where the edges of the pattern need to be formed, adjacent needles respectively execute a low loop pile weaving cooperative mode S1 and a high loop pile weaving cooperative mode S2. Since the end points of the two modes are rigidly limited to different horizontal planes by the mechanical structure, and there is no intermediate state in the switching process, the final result on the carpet surface is as shown in the attached image. Figure 8 The clear boundary is shown: one side is short pile, the other side is long pile, and there is no obvious slope at the junction, giving it a distinct stepped feel. In another embodiment, if it is necessary to increase the richness of the layers, a middle loop pile weaving mode S3 can be introduced. The clutch unit 30 is controlled by a pulse width modulation signal to generate a controllable slip-re-entry action, causing the knitting needle to stop at the middle hook layer, thereby forming an additional virtual pile layer between the low and high loops, but the boundary between adjacent layers still maintains a vertical discontinuity.

[0072] Through the above technical solution, this application achieves a multi-layered loop pile jacquard tufted carpet with the following beneficial effects: Due to the adoption of independent needle selection control based on a collaborative timing table and a mechanical-pneumatic coupling drive structure, the blurring phenomenon in the transition zone between high and low pile in traditional carpets is completely eliminated, resulting in extremely clear carpet pattern outlines, especially suitable for depicting small text or sharp-angled graphics; the vertically discontinuous pile distribution brings a strong visual impact and a unique tactile sense of layering, significantly enhancing the carpet's artistic expression and high-end quality; simultaneously, as a direct product of the aforementioned method, this product verifies the feasibility of eliminating mechanical transition errors through precise timing control, providing a new product form for the industrial production of high-quality jacquard carpets.

[0073] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A method for the collaborative weaving of a multi-layer jacquard tufted carpet, characterized in that, This method is implemented based on a tufted weaving system, which includes multiple needle assemblies, at least two layers of hook plates, a clutch unit that independently controls the stroke of each needle assembly, a servo feed motor that independently controls the feed amount of each yarn, a spindle drive unit, and a computer control system. The computer control system performs real-time synchronous scheduling of the clutch unit action time, servo yarn feeding motor output characteristics, and spindle angle for each knitting needle according to the preset coordination timing table. The collaborative timing table defines at least a low loop pile weaving collaborative mode and a high loop pile weaving collaborative mode, and the clutch unit action time corresponding to the two modes is locked in different preset intervals of the spindle angle, with an empty travel protection zone between the two preset intervals.

2. The method according to claim 1, characterized in that, The needle assembly includes a needle slide, a needle, an elongated groove on the needle slide, a high-position fixing pin fixed to the frame, and a low-position coupling pin driven by the clutch unit; the needle slide is suspended by an elastic element to maintain its upper position.

3. The method according to claim 2, characterized in that, In the low loop pile weaving collaborative mode: the clutch unit disengages the low-position coupling pin from the long groove, the knitting needle is pushed down to the lower limit of the low loop position by the high-position fixing pin, the yarn is hooked by the upper layer hook plate, and the servo feeding motor outputs low pile yarn according to the first speed curve.

4. The method according to claim 2, characterized in that, In the high loop pile weaving collaborative mode: the clutch unit keeps the low-position coupling pin embedded in the long groove, the knitting needle is pushed down to the lower limit of the high loop position by the low-position coupling pin, the yarn is hooked by the lower layer hook plate, and the servo yarn feeding motor outputs high pile yarn according to the second speed curve, and the peak speed of the second speed curve is higher than that of the first speed curve.

5. The method according to claim 1, characterized in that, The collaborative timing table also defines an intermediate loop pile weaving mode: during the downward movement of the needle, the computer control system sends a pulse width modulation signal to the clutch unit within a preset spindle angle window, causing the needle stroke to stop at the intermediate hook layer.

6. The method according to claim 1, characterized in that, The computer control system receives real-time feedback from the spindle angle, clutch unit status, and servo yarn feeding motor to form a closed-loop control. When any feedback value deviates from the preset value of the coordination timing table by more than a threshold, the system immediately issues an emergency stop command and forces all knitting needles to return to the upper limit position.

7. The method according to claim 6, characterized in that, After the emergency stop command is issued, the computer control system also activates the backup air source to force all low-position coupling pins to disengage. The total time from fault detection to the disengagement of all low-position coupling pins does not exceed 20 milliseconds.

8. The method according to claim 1, characterized in that, The tufted weaving system uses a needle pattern with a spacing of 1 / 10 inch, 1 / 8 inch, 5 / 32 inch, or 1 / 4 inch, and the yarn used is one or more twisted or network yarns of wool, polyester, or polypropylene.

9. A tufting weaving collaborative control system for implementing the method according to any one of claims 1 to 8, characterized in that, The system includes: Spindle angle encoder; Multiple clutch unit status sensors; Multiple servo yarn feed motor encoders; The computer control system has the aforementioned coordinated timing table internally installed, and performs closed-loop correction and coordinated scheduling based on the feedback signals.

10. A multi-layered loop pile jacquard tufted carpet, characterized in that, The blanket is woven using the method described in any one of claims 1 to 8, and its surface has at least two types of pile with different heights without transition sections, and the boundary between adjacent high and low piles is a vertical discontinuity.

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