Tufting machine needle drive system

Abstract

A tufting machine is disclosed that includes a drive system for driving the reciprocating motion of one or more needle bars carrying a series of needles. A backing material is fed through a tufting zone of the tufting machine, and the needles will penetrate in and out of the backing material as the drive system reciprocates the needle bars to form tufts of yarn in the backing material at an increased production rate. In one embodiment, the tufting machine includes a machine frame, at least one needle bar, and a drive system. The at least one needle bar has a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns.

Description

[Technical field]

[0001] (Related Applications) This patent application claims the benefit of pending U.S. Provisional Patent Application No. 63 / 321,944, filed March 21, 2022. (Incorporated by reference)

[0002] The present disclosure and figures made in U.S. Provisional Patent Application No. 63 / 321,944, filed March 21, 2022, are specifically incorporated by reference into this specification as if set forth in their entirety. (Technical field)

[0003] The present disclosure relates to tufting machines, and more particularly to a tufting machine needle drive system for driving one or more needle bars of a tufting machine, enabling increased operating speeds, improved maintenance efficiencies, and other improvements. [Background technology]

[0004] The use of tufting machines to produce tufted articles, such as tufted carpets, is well known in the art. A conventional tufting machine may have a drive system for driving the reciprocating movement of a needle bar carrying multiple needles into and out of a backing material that passes laterally under the needle bar. As the needles penetrate the backing material, they carry a yarn into the backing material where it is captured by a looper to produce a loop pile tuft, or by a hook or level cut loop looper and cut with a knife to produce a cut pile tuft. Typically, as the main drive shaft of the tufting machine rotates, the needle bar is reciprocated toward and away from the backing material. However, such a drive system may have disadvantages in terms of maintainability. For example, some drive systems utilize a series of individual drive assemblies that are mounted along the tufting machine and tied to the main drive shaft of the tufting machine, and some drive systems may also include belt-driven gear arrangements that drive push rods coupled to the needle bars to reciprocate the needle bars. However, when the belts of such drive assemblies wear and / or break and require replacement, the entire drive system often must be substantially disassembled to allow access to the belt. Additionally, the operating speeds of many conventional tufting machine drive systems are often limited, especially for cut pile tufting machines.

[0005] What is needed, therefore, is an improved drive system for a tufting machine that addresses the foregoing problems and other related and unrelated problems in the art, including, but not limited to, a needle drive system for driving the reciprocating motion of needles in a cut pile tufting machine at operating speeds similar to those of loop pile machines, and that provides an apparatus that is efficient and easy to maintain, durable and rugged. Summary of the Invention [Problem to be solved by the invention]

[0006] Briefly, the present disclosure generally relates to a tufting machine and a tufting method. In an embodiment, such a tufting machine may include a drive system for driving the reciprocating motion of one or more needle bars thereof, the drive system being configured to drive the reciprocating motion of one or more needle bars to provide an improvement in forming tufts of twisted yarn in a backing material at an increased production rate. The drive system may be used for forming loop pile tufts, cut pile tufts, and / or combinations thereof, and the production rate for a tufted article formed using cut pile tufts may be substantially comparable to the production rate for a similarly formed tufted article formed using loop pile tufts. Such tufted articles may include, for example, but are not limited to, carpets, artificial turf, and other tufted articles or materials. [Means for solving the problem]

[0007] In embodiments, the tufting machine may include one or more needle bars having a series of needles mounted therealong. The needles may be arranged in a straight line, staggered, or other arrangement along the one or more needle bars. The backing material may be fed through a tufting zone of the tufting machine, and the needles may penetrate into and out of the backing material as the drive system reciprocates the needle bars. The twist may be introduced into the backing material as the needles are reciprocated in and out of the backing material. In some embodiments, a shifting mechanism may be provided to shift one or more needle bars laterally across the tufting zone. In other embodiments, multiple shifting mechanisms may be utilized, as desired.

[0008] Tufting machines generally may further include at least one yarn feed mechanism or pattern attachment to control the feeding of yarns to their respective needles. In embodiments, such yarn feed mechanisms or pattern attachments may include, but are not limited to, various roll, scroll, servo scroll, single end, double end, or multi-end yarn feed attachments. For example, in embodiments, Yarntronics TM , Infinity TM , or Infinity IIE TM The yarn feed mechanism or pattern attachment is manufactured by Card-Monroe Corp. Other types of yarn feed mechanisms can also be used.

[0009] In an embodiment, the shift mechanism and at least one yarn feed mechanism or pattern attachment may generally be in communication with a control system for the tufting machine. For example, the shift mechanism may receive commands or communications from a control system for the tufting machine to advance (or shift) at least one needle bar laterally across the backing material according to a pattern shift step programmed and / or designed for the pattern being tufted to thereby provide a yarn that is delivered to a tuft or stitch location along / across the backing. In an embodiment, at least one yarn feed mechanism may also be operated to selectively control the feeding of yarn to their associated needles to form tufts of yarn, which may include forming tufts having a selected pile height and / or no tufts to generate a desired pattern appearance.

[0010] In addition, the tufting machine can include a gauge component assembly mounted below the backing, which in embodiments can include a series of gauge components that can include, for example, but not limited to, loop pile loopers, cut pile hooks, level cut loop loopers, cut / loop clips, knives, and the like. The gauge components can be reciprocated to engage the needles as they penetrate the backing material and pick up loops of yarn therefrom. In embodiments, the height or location of the gauge components below the backing material, and in some embodiments, the stroke or penetration depth of the needles through the backing, can be varied by adjusting the stroke or penetration depth of the needles through the backing material to form varying loops of yarn of varying pile heights in the backing material (including forming different pile height loops). Yarn feed control can also be used to control pile height, for example, by leaving substantially no or completely pulling out loops of yarn in the backing. In embodiments, various configurations and / or combinations of loop pile loopers, cut pile hooks, cut / loop hooks, level cut loopers or hooks, and / or other gauge components may also be used.

[0011] In an embodiment, the drive system for driving the reciprocating motion of the needles of the tufting machine can include first and second spaced apart drive shafts disposed within the head of the tufting machine, the drive shafts extending generally parallel to one another along the head of the tufting machine and laterally across the backing material being fed through the tufting machine. The first and second drive shafts can include exposed ends projecting through side plates on opposite sides of the tufting machine frame, the exposed ends being located outside the frame and projecting away from the exterior surfaces of the side plates. In an embodiment, the exposed ends of the first and second drive shafts include shaft drive gears mounted thereon and coupled to motor drive gears, pulleys, or sprockets of one or more main motors to drive the first and second drive shafts.

[0012] The drive system may further include a series of needle stroke or drive assemblies located along the head of the tufting machine, with the drive shaft extending therethrough. In an embodiment, each of the needle stroke assemblies may include a series of needle stroke drive gears connected to and driven by a drive member coupled to the drive shaft. In an embodiment, the drive member may include a chain driven by alternating ones of the drive shafts such that the needle stroke drive gears of alternating ones of the needle stroke assemblies, e.g., odd needle stroke assemblies may be rotated in one rotational direction while the even needle stroke assemblies may be rotated in the opposite direction. By rotating the drive shafts in opposite directions, a series of connecting rods may connect the needle stroke drive gears to a series of push rods coupled to at least one needle bar, driven in a generally vertical direction or travel path to transfer the rotary motion of the first and second drive shafts to the push rods to drive the push rods in a linear reciprocating motion, the opposite rotational direction may allow the weight of the connecting rods to substantially counter such motion, in an embodiment, the opposite rotation of the first and second drive shafts. In an embodiment, counterweights may also be mounted on the first and second drive shafts to help balance the drive system and reduce / control vibrations thereof as the needles are reciprocated in and out of the backing material.

[0013] In an embodiment, each drive member of the needle stroke assembly can be configured as a double strand roller chain that includes two paired rows or strands that extend in a looped path around a first needle stroke drive gear attached to one of the drive shafts and around a second needle stroke drive gear attached to a secondary drive shaft. Other drive members can also be used.

[0014] In embodiments, the secondary shaft can be further coupled to the connecting rod to drive the connecting rod in an up and down motion as the crankshaft rotates. For example, in some embodiments, the secondary drive shaft can have a series of cam members mounted thereon in an offset arrangement, the cam members coupled to the connecting rod to drive the reciprocating movement of the connecting rod and thus the push rod and needle bar. In some embodiments, the secondary drive shaft can include a crankshaft coupled to the connecting rod to drive its reciprocating motion. Additionally, in embodiments, the drive chain can be configured to increase shaft horsepower and for easier repair and / or replacement that does not require removal of the first and second drive shafts from the needle stroke assembly.

[0015] In an embodiment, the drive system may further include a drive belt configured to encircle and extend in a serpentine path around a motor drive gear mounted on a motor shaft of one or more drive motors and a shaft drive gear mounted on an end of the drive shaft of the drive system. In an embodiment, the drive belt and the motor drive gear and the drive shaft gear may comprise a high torque drive arrangement configured to enable the motor to drive the first and second drive shafts with increased horsepower and torque. The drive gear and drive belt are mounted from outside the tufting machine, for example, on the outside of the end box and along an exterior surface of the tufting machine, further providing ease of maintenance. As the motor drive gear is driven by the motor, the drive belt drives the shaft drive gear to rotate the first drive shaft in one direction and rotate the second drive shaft in the opposite or counter direction to the first drive shaft.

[0016] In embodiments, the drive belt may comprise a toothed timing belt having a series of spaced apart teeth, which in embodiments may include a series of curvilinear teeth. In some embodiments, the drive belt may comprise a double-sided curvilinear toothed timing belt. In other embodiments, the drive belt may comprise a double-sided high torque belt having a series of spaced apart teeth therealong, which in embodiments may include a plurality of curvilinear teeth.

[0017] In an embodiment, the drive belt can be extended around a tension adjustment gear located on an adjustable support, which can be movable along a side plate of the frame to which it is mounted to move the tension adjustment gear relative to the drive belt to adjust the tension therein, for example to take up slack in the drive belt.

[0018] In some aspects of the disclosure, a tufting machine is provided that includes a frame having a base, spaced side portions, an end box, and a head extending between the side portions, at least one needle bar having a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns and being moved in a reciprocating motion toward and away from the backing material as the backing material moves through the tufting machine such that the needles penetrate the backing material and form tufts of the yarns in the backing material, and a drive system. In an embodiment, the drive system includes at least one motor mounted along at least one of the sides of the frame and having a motor drive shaft with a motor gear coupled thereto, first and second drive shafts extending along the head of the tufting machine, each having an exposed end extending through the side of the frame to project away from the exterior surface of the frame, and a plurality of needle stroke assemblies located within the head of the frame and positioned at spaced locations along the first and second drive shafts, each needle stroke assembly including a plurality of needle stroke drive gears. The plurality of needle stroke drive gears may include a series of first needle stroke drive gears coupled to and driven by one of the first or second drive shafts, and a series of second needle stroke drive gears coupled to and driven by the first needle stroke gears by a drive member. Rotation of the first and second drive shafts may cause rotation of the needle stroke drive gears of alternating needle stroke assemblies in opposite directions. A plurality of push rods may be coupled to the at least one needle bar and needle stroke drive gear for converting rotation of the first and second drive shafts into linear reciprocating motion of the at least one needle bar.The drive system may further include first and second shaft drive gears mounted on exposed ends of the first and second drive shafts, the first and second drive gears located along an exterior surface of the side portion of the frame and outside of an end box of the frame; a tension adjustment gear located along the exterior surface of the side portion of the frame; a drive belt extending around the motor drive gear, the first and second shaft drive gears, and the tension adjustment gears; and an adjustable support on which the tension adjustment gear is mounted, the support configured to move along the exterior surface of the side portion of the frame to adjust the position of the tension adjustment gear relative to the first and second drive gears to maintain a selected tension in the drive belt.

[0019] In an embodiment of the tufting machine, the drive member comprises a double strand size #60 roller chain. In some embodiments, each of the needle stroke assemblies further comprises a mounting platform attached to the head of the frame and through which the drive shaft extends.

[0020] In some embodiments of the tufting machine, the first needle stroke drive gear can be coupled to the first and second drive shafts in an alternating arrangement. For example, in an embodiment, the first needle stroke drive gear of one of the needle stroke assemblies can be coupled to the first drive shaft and the next first needle stroke drive gear of the next needle stroke assembly can be coupled to the second drive shaft in the alternating arrangement.

[0021] In some embodiments of the tufting machine, the drive belt comprises a double sided modified curvilinear tooth timing belt, hi embodiments, the drive belt has a width of at least about 2 inches to about 4 inches.

[0022] In an embodiment of the tufting machine, the drive members comprise twin strand roller chains, each having a master connection linkage configured to be removable from the twin strand roller chain to enable removal of the drive members from the needle stroke drive gear.

[0023] In some embodiments, the tufting machine further comprises a plurality of gauge elements positioned below the backing material and configured to engage the needles and pull loops of yarn therefrom. In embodiments, the gauge elements can comprise cut pile hooks and knives for forming cut pile tufts of yarn in the backing material. In some embodiments, the gauge elements can comprise hooks, loopers, level cut loop loopers, or combinations thereof.

[0024] In some embodiments, the operating speed of the tufting machine to form the cut pile tufts can be at least about 1,800 RPM.

[0025] Additionally, in embodiments, the drive belt comprises a double-sided modified curvilinear tooth timing belt having a width of at least about 2 inches, and in embodiments may include a multi-chain drive belt.

[0026] The present disclosure therefore provides a tufting machine and a drive system for a tufting machine that allows for operating speeds at increased rates, including operation of the tufting machine to form cut pile tufts at similar operating speeds as a loop pile tufting machine. In embodiments, the drive system can be further configured such that worn parts of the drive system can be easily and simply replaced and the drive and timing mechanisms can be easily adjusted.

[0027] Various other objects, features and advantages of the present disclosure will become apparent from the following description when considered in conjunction with the accompanying drawings, in which like reference characters refer to corresponding parts throughout the several views. [Brief description of the drawings]

[0028] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of the present disclosure in more detail than may be required for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced. Those skilled in the art will further recognize and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and the dimensions of the various features and elements of the drawings may be expanded or reduced in order to more clearly illustrate the embodiments of the present disclosure described herein.

[0029] [Figure 1A] 1A-1B are perspective views of an upper portion of a tufting machine with parts separated and diagrammatically illustrate an embodiment of the tufting machine with a drive system for driving the reciprocating motion of needles of the tufting machine in accordance with the principles of the present disclosure. [Figure 1B] 1A-1B are perspective views of an upper portion of a tufting machine with parts separated and diagrammatically illustrate an embodiment of the tufting machine with a drive system for driving the reciprocating motion of needles of the tufting machine in accordance with the principles of the present disclosure.

[0030] [Diagram 2] FIG. 2 is a perspective view of a drive system for a tufting machine as depicted in FIGS. 1A-1B.

[0031] [Diagram 3] FIG. 3 is a vertical end view of the tufting machine drive system as illustrated in FIG. 1A-2.

[0032] [Figure 4] FIG. 4 is a schematic side elevational view of the tufting machine drive system as illustrated in FIG. 1A-2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Referring now in detail to the embodiments selected for purposes of illustrating the present disclosure, FIGS. 1A-4 generally illustrate an embodiment of a tufting machine 10 having a drive system 5 for forming a patterned tufted article in accordance with the principles of the present disclosure, in which stitches or tufts of twisted yarn Y (FIG. 1A) can be inserted or placed at desired locations within backing material B, which moves along a travel path 6 through the tufting machine beneath the needles of the tufting machine by the action of backing feed rolls 7.

[0034] Such tufts or stitches can be formed with a variety of patterns, including having a multi-pile height tufted appearance. For example, tufted articles can be formed with tufts of yarn formed to varying pile heights to provide a sculpted look, and can be formed with different colors or types of yarn for the formation of multi-color patterns of various geometric and / or free-flowing designs. In addition, it will be appreciated that various numbers of different types and / or colors of yarn (i.e., two colors, three colors, five colors, six colors, etc.) can be used to form multi-pile height patterned tufted articles according to the principles of the present disclosure.

[0035] As illustrated in FIG. 1A, the number 10 generally designates a tufting machine including a frame 11 having a base 12 and a bed plate 13 extending laterally across the machine over which a backing material B is moved. The tufting machine 10 also includes a head 14 extending laterally across the frame of the tufting machine spaced above the bed plate 13. The frame 11 further has a pair of opposing, vertically disposed, spaced apart parallel sides 16 (only one of which is shown in FIG. 1A) having a side plate 17 with an exposed side surface 17A, and an upper surface or portion 18, with motor supports or plates 19 mounted adjacent one another on the upper surface or portion 18. As further shown in FIG. 1A, an end box 21 is formed along at least one side 16 of the frame. The end box 21 generally defines a chamber in which lubricant is applied to the first and second drive shafts 25A / 25B of the drive system 5 and other operating components of the tufting machine (e.g., needle bar shifter connections, etc.), such as by applying an oil bath thereto inside the end box chamber.

[0036] 1A-2 and 4, the tufting machine 10 further includes one or more needle bars 30 coupled to a series of needle strokes or drive assemblies 28 of a drive system 5 by a push rod 81 that reciprocates at least one needle bar 30 toward and away from the backing material B in the direction of arrows 32 / 32'. A plurality of needles 31 are mounted along the one or more needle bars and are typically spaced at selected gauge increments, e.g., 1 / 8 inch, 1 / 10 inch, 5 / 16 inch, etc. The needles 31 are moved linearly by the push rod 81 and are carried with the at least one needle bar 30 to reciprocate and move up and down (as indicated by arrows 32 / 32') such that the needles penetrate in and out of the backing material B and carry or insert the yarn Y into the backing to form tufts in the backing material B. Loop pile tufts, cut pile tufts, or a combination of loop and cut pile tufts can be formed in the backing material.

[0037] At least one needle bar 30 may further be shiftable laterally across the width of the backing material to shift or advance the needles 31 in a direction transverse or generally perpendicular to the machine path of travel 6 through the tufting machine. For example, a shifting mechanism may be coupled to one or more needle bars to shift at least one needle bar laterally across the backing material. The shifting mechanism may be a Smart Step tufting mechanism such as those manufactured by Card-Monroe Corp. TM The needle bar shifter may include a type shifter, or alternatively may include various other types of shifting mechanisms including servo motor or hydraulically controlled shifters, and / or pattern cam shifters as are conventionally used. Additional shifting mechanisms may also be used, including backing material or jute shifters operable separately or in conjunction with the needle bar shifter to laterally shift the backing material relative to the needles.

[0038] In embodiments, the needles 31 can be arranged in a single linear row along one or more needle bars 30. In other embodiments, the needles 31 can be mounted in a staggered arrangement along a single needle bar or along a pair of needle bars, with rows of offset needles spaced laterally along the length of each needle bar and staggered across the tufting zone of the tufting machine. Thus, while one exemplary embodiment including a single needle bar 30 (with a linear row of needles 31 arranged along the single needle bar 30) may be generally shown in FIGS. 1A-1B, the present disclosure is not limited to the use of a single needle bar or a particular configuration of needles. It will be understood by those skilled in the art that additional arrangements of one or more needle bars having linear, or spaced rows of needles that may be arranged in a staggered or offset configuration (both of which rows may be further shifted) may also be utilized within a tufting machine 10 incorporating a system according to the present disclosure.

[0039] Each of the needles generally includes a shank or body terminating in a point and including an extraction point or area where a gauge part 35 (FIGS. 1B and 4) of a gauge part assembly may engage the yarns Y and pick them up from the needle. As the needles are reciprocated in a generally vertical motion in the direction of arrows 32 and 32' (FIG. 2), the needles will penetrate in and out of the backing material B along the stroke to a desired or predetermined penetration depth, carrying the yarns Y with the needles and being selectively engaged by the gauge part 35 of the gauge part assembly to pick up loops of yarn from the needles.

[0040] It will be understood by those skilled in the art that in various embodiments, the gauge components 35 can include loopers, hooks, level cut loop loopers, knives, and other types of gauge components. For example, in this embodiment, the gauge components can include a series of cut pile hooks and knives to form cut pile tufts in the backing material. Other gauge components, including loop pile loopers and level cut loop loopers, can also be used to form loop pile tufts, and / or loop and cut pile tufts, loop pile loopers.

[0041] The gauge member is generally disposed below the bed plate and is reciprocated toward and away from the needle to engage and pick up the yarn inserted through the backing material (not shown) as the needle penetrates the backing material. The gauge member may further be located at a fixed height to protrude through the loop sewn by the needle and capture and temporarily hold the loop of yarn when the needle is at approximately bottom dead center.

[0042] For example, the gauge members 35 can be mounted below the bed of the tufting machine 10 and spaced at a desired or selected distance to engage the needles 31 at a selected needle stroke or penetration depth. As the needles 31 penetrate the backing material, the needles 31 are engaged by the gauge components 35 of the gauge component assembly to pick up and form loops of yarn Y to form tufts of a selected color or type of yarn with a selected length or pile height in the backing material.

[0043] In embodiments, at least some of the gauge components 35 may be slidably mounted within a gauge module, gauge block, or other holder that may be mounted along with a gauge bar or similar mount or attachment that couples the gauge components to a drive mechanism that drives the reciprocating movement of the gauge components in directions toward and away from the needle. Additionally, it will be understood by those skilled in the art that various types of gauge components may also be used, including cut pile hooks, loop pile loopers, level cut loop loopers, cut / loop clips, or other gauge components.

[0044] One or more yarn feed mechanisms or pattern attachments 40 (FIGS. 1A, 2, and 4) may further be mounted to the frame 11 of the tufting machine 10 for controlling the feeding of the yarn Y to each of the needles during operation of the tufting machine. In various embodiments, a variety of yarn feed mechanisms or pattern attachments may be used, including, but not limited to, a roll or scroll pattern attachment having one or more yarn feed rolls extending at least partially along the tufting machine and driven by a motor under the direction of a tufting machine control system, for example as shown diagrammatically in FIGS. 1A and 2.

[0045] In embodiments, other pattern twist feed mechanisms or attachments having multiple twist feed drives can be used, including the use of individual twist feed devices to control the feeding of a single twist (or end) or multiple ends of a twist (i.e., 2-4 or more twists) to needles 31, as shown in FIG. 4, each of the multiple twist feed drives may include a motor and feed roll for feeding the twist to a selected needle. For example, in some embodiments, the Infinity 1000 series, such as those manufactured by Card-Monroe Corp. TM and Infinity IIE TMSingle-ended and / or multi-ended yarn feed mechanisms of pattern attachments such as systems can be used. Additionally, in embodiments, multiple yarn feed mechanisms or pattern attachments can be mounted on one or both sides of the tufting machine to feed yarn to the needles of one or more needle bars 30.

[0046] The tufting machine will further include a control system configured to control the operation of the tufting machine 10, including generally controlling the backing feed, controlling the feeding of the yarn through the yarn feeding attachment or mechanism, and controlling the drive / operation speed of the main drive shaft, e.g., one or more motor drive shafts 45 (FIGS. 1A-4) of one or more motors 46 of the drive system 5. For example, the control system may include programming configured to cooperate with other operating systems of the tufting machine to control the yarn feeding mechanisms or pattern attachments (including the backing feed, shifting of the needle bars, and operation of the gauge component assemblies) to selectively feed the yarns to their respective needles. In an embodiment, the control system may control the provision of several different colors or types of yarns into the backing material, and the selective pick-up and retention of loops of selected yarns (e.g., yarns selected to appear in the face of the finished patterned article) to form tufts of such yarns with a selected or desired pile height and / or other texture effect across the width of the backing material.

[0047] In embodiments, the control system may comprise a tufting machine controller, generally including a computer / processor or system controller and an operator interface, such as a touch screen, keyboard, mouse, etc., through which an operator can input patterns, make adjustments, etc. In some embodiments, the control system may comprise or include a stitch distribution control system, where the control system controller further includes programming for a control methodology for forming tufted patterns, including carved patterns having tufts formed at multiple pile heights, multi-color patterns, etc. Additionally, one or more encoders, motor controls, and / or other similar sensors adapted to monitor rotation of the motor drive shaft and report the position of the motor drive shaft to the control system may also be provided for control of the operation of the tufting machine 10.

[0048] As illustrated in Figures 1-4, the drive system 5 generally includes at least one drive motor 46 for driving the movement of the multiple needle stroke assembly 28. In the illustrated embodiment, a pair of motors 46 mounted on opposite sides of the tufting machine frame are shown in Figure 4, by way of example and not limitation. The motor 46 may generally include a 20 horsepower (Hp) AC motor, and may include a servo motor, stepper motor, or other type of drive motor. Other types of motors and different horsepower motors may also be used.

[0049] In an embodiment, the motors may be mounted on opposite sides of the tufting machine frame and, as shown, may be mounted on a support plate or platform 19 attached to an upper portion 18 of the tufting machine frame on each side 16 thereof, as shown in FIGS. 1A, 3, and 4. Each motor would further include a motor drive shaft 47 and a motor drive gear 48 mounted distally thereto. In an embodiment, the motor drive gear 48 may include a gear, pulley, or sprocket. The motor 46 would be operated under the control of the control system during the tufting operation to drive the needle stroke assembly 28 of the drive system 5, causing reciprocating motion of the needle bar 30. As will be appreciated, the term "gear" may include gears, sprockets, pulleys, cogs, wheels, or other similar transmission elements.

[0050] 1A and 2, in an embodiment, the drive system 5 further includes first and second drive shafts 25a and 25b extending generally across the tufting machine, the first and second drive shafts generally being located along the head 14 of the frame 11 and extending laterally across the backing material B being fed through the tufting machine. Each of the first and second drive shafts may extend through a side 16 of the tufting machine frame 11 (through an end box 21 and through a side plate 17 mounted along an exterior-facing surface of the side 16 of the frame). The first and second drive shafts 25A / 25B terminate in opposite exposed ends 26A / 26B that project away from the exterior surface of the side plate 17 and are located outside the tufting machine frame.

[0051] In an embodiment, a shaft drive gear 49 is mounted to each of the exposed ends 26A / 26B of the first and second drive shafts, as shown in FIG. 1A-3. The shaft drive gear 49 may include a gear, a sprocket, or a pulley. As further shown in FIG. 1A-2 and 4, the first and second drive shafts extend through each of the multiple needle stroke assemblies 28, which are mounted at spaced locations along the head 14 of the tufting machine frame 11.

[0052] In an embodiment, each of the needle stroke assemblies 28 can include a generally L-shaped frame 51 including a base portion 52 mounted to the head 14 of the tufting machine frame 11, such as by bolts or other fasteners, and an upright shaft support section 53. Each of the shaft support sections 53 can include a bearing or bushing 54 located adjacent a lower end of each shaft support section and through which the first and second drive shafts 25A / 25B extend, generally as shown in FIGS. 1A-2. In an embodiment, these bearings or bushings 54 can rotatably support the first and second drive shafts extending through the shaft support sections, allowing the drive shafts to rotate therein.

[0053] A secondary drive shaft 56 or stud shaft may be rotatably received in each shaft support segment 53 by and may project through a bearing or bushing 57 mounted within the shaft support segment adjacent the shaft support segment's upper end 53A. In an embodiment, the secondary drive shaft projects in a first direction through the shaft support segment and includes a proximal end 58 attached to a rotatable cam member 59, and a distal end 61 which projects in an opposite direction through the support segment and is engaged for rotatable support by a bearing 62 in a stub shaft support 63 which may be formed with or attached to the support framework 51.

[0054] In embodiments, each needle stroke assembly 28 may further include a plurality or set of needle stroke drive gears 70. For example, in some embodiments, the needle stroke drive gears may include a first one of the needle stroke drive gears 71 and a second one of the needle stroke drive gears of each needle stroke assembly 28 that may be mounted along one of the first or second drive shafts 25A / 25B, with the second one being mounted on the secondary drive shaft 56 adjacent its proximal end. In embodiments, a rotatable cam member 59 may be further connected to the secondary drive shaft 56, as shown in FIGS. 1A-B. The first and second needle stroke drive gears 71 and 72 of each needle support assembly 28 may be further coupled together in driving relationship by a drive member 75.

[0055] 1A-1B, the drive member 75 can include a belt and / or chain, such as in some embodiments a double strand roller chain 76. By way of example, and not limitation, the drive member can include a double strand size #60 drive chain. Each of the double strand drive chains 76 can include two rows or strands of chain links in a substantially endless looped path, with a master connection linkage 77 connecting strands that can be disengaged, allowing each drive chain to be released and removed from engagement with the first and second needle stroke drive gears 71 and 72.

[0056] In addition to providing or enabling a significant increase in horsepower to drive the reciprocating motion of at least one needle bar, the drive chain can be further configured to promote efficiency in maintenance and repair of the drive system 5 by allowing the drive chain to be disassembled and easily removed for repair and / or replacement of the drive chain, needle stroke drive gear, secondary drive shaft, and / or other components of the needle stroke assembly 28, but not requiring removal of the first and / or second drive shafts 25A / 25B.

[0057] In an embodiment, the drive member 75, e.g., a drive chain, belt, or other similar drive member, will be sized and configured to handle an increase in horsepower (HP) up to about 2-3 times that of a conventional cut pile tufting machine. For example, in an embodiment, the drive member can have a horsepower rating sufficient to withstand an increase in horsepower driving the rotation of the first and second drive shafts of the needle drive system from 30 HP to about 60 HP, up to 90 HP.

[0058] Enabling the use of drive members configured to accommodate such increases in horsepower can in turn enable the drive system to drive at least one needle bar 30 at increased speeds. For example, in embodiments featuring a cut pile tufting machine, the drive system 5 can be operable to drive the reciprocating motion of at least one needle bar at speeds approximately comparable to those obtainable with a loop pile tufting machine, e.g., up to about 1,500 rpm to about 2,000 rpm. In embodiments, speeds of 1,500 rpm to 1,900 rpm, 1,500 rpm to 1,800 rpm, 1,500 rpm to 1,700 rpm, 1,500 rpm to 1,600 rpm, 1,600 rpm to 2,000 rpm, 1,600 rpm to 1,900 rpm, 1,600 rpm to 1,800 rpm, 1,600 rpm to 1,700 rpm, 1,700 rpm to 2,000 rpm, 1,700 rpm to 1,900 rpm, 1,700 rpm to 1,800 rpm, 1,800 rpm to 2,000 rpm, 1,800 rpm to 1,900 rpm, and 1,900 rpm to 2,000 rpm can be achieved, although higher speeds are also contemplated.

[0059] 1A-2, in an embodiment, alternating needle stroke assemblies 28 of the drive system 5 can be coupled to opposite ones of the first and second drive shafts 25A / 25B. For example, the first needle stroke drive gear 71 of each odd needle stroke assembly can be coupled or mounted along the first drive shaft 25A, and the drive member of such needle support assembly couples their first needle stroke drive gears 71 to their second needle stroke drive gears 72 so as to drive the rotation of the secondary drive shaft 56 of the odd needle stroke assembly in a first direction by rotation of the first drive shaft 25A. The first needle stroke drive gear 71 of the even needle stroke assembly 28 may similarly be coupled or mounted along the second drive shaft 25B, and the drive chain 76 of the even needle stroke assembly couples the second drive shaft 25B to its second needle stroke drive gear 72 for driving the rotation of the respective secondary drive shaft 56 of the even needle stroke assembly in the opposite reverse direction upon rotation of the second drive shaft 25B.

[0060] In an embodiment, each of the needle stroke assemblies 28 may further include a cam arm 80 having a first or upper end attached to the rotatable cam member 59 and a second distal end connected by a connecting rod 81 to one of the push rods 33, which in turn is connected to at least one needle bar 30. As the first and second drive shafts 25A / 25B are rotated, their rotation is transmitted through the needle stroke assembly's respective needle stroke drive gear and drive member to the secondary drive shaft 56 of each needle stroke assembly, which in turn rotates the rotatable cam member 59 attached thereto. As the rotatable cam member 59 is driven with the rotation of the first and second drive shafts 25A / 25B, the cam arm 80 is driven in a reciprocating up and down linear motion. This up and down motion is transmitted via connecting rod 81 to push rod 33, which may be coupled to at least one needle bar 30 by a support bracket or foot 82, whereby the at least one needle bar is caused to reciprocate up and down in the direction of arrows 32 and 32' to reciprocate needles 31 carried by the at least one needle bar 30 in and out of the backing material B passing beneath it.

[0061] 1A, 1B, and 3, in an embodiment, the drive belt 85 encircles (or extends) in a substantially serpentine path around the motor drive gears 48 and around the shaft drive gears 49 attached to the exposed ends 26A / 26B of the first and second drive shafts 25A / 25B. In an embodiment, the drive belt and the motor drive gears and drive shaft gears can comprise a high torque drive arrangement configured to enable the motor to drive the first and second drive shafts with increased horsepower and torque.

[0062] In embodiments, the drive belt 85 may generally comprise a double sided modified curvilinear toothed timing belt, which in some embodiments may include a multi-chain belt. In embodiments, the drive belt may have an expanded width of about 3-4 inches, and in some embodiments may have widths of about 2 inches to 6 inches, 2 inches to 5 inches, 2 inches to 4 inches, 2 inches to 3 inches, 3 inches to 6 inches, 3 inches to 5 inches, 4 inches to 6 inches, 4 inches to 5 inches, and 5 inches to 6 inches. Other widths may also be used.

[0063] Additionally, in embodiments, the drive belt may comprise a toothed timing belt having a series of spaced apart teeth, which in embodiments may include a series of curvilinear teeth. In some embodiments, the drive belt may comprise a double-sided curvilinear toothed timing belt. In other embodiments, the drive belt may comprise a double-sided high torque belt having a series of teeth spaced apart therealong, which in embodiments may include a plurality of curvilinear teeth.

[0064] As shown in FIG. 3, the motor drive gear 48 and the shaft drive gear 49 would be along the exterior exposed, or outer, surface along the side 16 of the tufting machine frame 11. In this configuration, the drive belt 85 is not exposed to lubricating materials (e.g., oil or other materials) that may deteriorate the drive belt, as may occur in previous drive systems where the drive belt and drive connections to the drive shafts are contained within the end boxes 21 of the tufting machine frame. As shown, the drive belt extends around the motor drive gear 48 and around the shaft drive gear 49 attached to the exposed ends 26A / 26B of the first and second drive shafts 25A / 25B in a serpentine arrangement configured such that rotation of the drive motor causes rotation of the first drive shaft and rotation of the second drive shaft in opposite opposite directions.

[0065] Additionally, as shown and illustrated in Figures 1A, 1B, and 3, in an embodiment, a tension adjustment or idler gear 90 may be located along an exposed surface of the side plate 17 on each side 16 of the tufting machine frame 11, generally located adjacent the drive shaft gears of the first and second drive shafts. In an embodiment, the tension adjustment gear 90 may be mounted generally in a lower position relative to the drive shaft gears 49 of the first and second drive shafts 25A / 25B, with the drive belt 85 further extending around (or wrapped around) the tension adjustment gear 90. In an embodiment, the tension adjustment gear 90 may further be mounted along or on an adjustable support 91 movably attached to or mounted along the side plate 17 of the tufting machine frame, as illustrated in Figures 1A and 3.

[0066] In an embodiment, the support 91 is vertically adjustable or movable along the side plate 17 of the tufting machine frame to allow adjustment in the tension applied to the drive belt, for example, to remove or take up slack in the drive belt that may be created over time during operation of the drive belt. In an embodiment, the support 91 may be mounted on a rail 92 along a slide, track, and / or other guide member, as shown in FIG. 1A, to guide the support along a generally linear path of movement relative to the drive belt along the side plate 17. In an embodiment, the movement of the support 91, and thus the tension adjustment gear 90, may be controlled by actuators such as servo motors, cylinders, etc., operated under control of the tufting machine control system (and / or manually controlled by an operator). For example, in an embodiment, sensors or detectors may be provided positioned along one or more of the shaft gears and / or tension adjustment gears to detect slippage, slack, or loss of tension in the drive belt and provide an indication thereof to a controller of the control system and / or signal such a condition by indicators such as lights, gauges, etc.

[0067] The drive belt 85 communicates or transmits the rotation of the motor drive shaft 48 to the shaft drive gear 49 to rotate each of the first and second drive shafts in synchronized, opposite, counter directions. As the first and second drive shafts 25A / 25B are rotated, the drive member 75 of each of the needle stroke assemblies 28 transmits such rotation to the secondary drive shaft 56 which in turn drives the eccentric movement of a cam arm 80 attached to a rotatable cam member 59 such that the cam arm is moved in a reciprocating up and down movement. In an embodiment, the timing of the movement of each of the cam arms can be arranged such that the movement of each of the cam arms of the needle stroke assemblies can stop at approximately the same time at a top dead center position and at approximately the same time at bottom dead center.

[0068] Additionally, in some embodiments, the connecting rod 81 or push rod 33 coupling the cam arm 80 to at least one needle bar 30 can be replaced to position the needle bar at a predefined location relative to the backing material to allow for variation in the depth of penetration or stroke of the needle 31 into the backing material without necessarily varying the height of the bed plate. Alternatively, in embodiments, the bed plate and / or gauge components are movable to allow adjustment in the pile height of the tufting of the yarn formed in the backing material.

[0069] In general, the timing of the strokes of the alternating cam arms 80 and connecting rods 81 of the needle stroke assembly 28 can be selected to be approximately 180° out of phase with one another, so that the needle 31 is fully raised when the cam arms are at top dead center and fully lowered when the cam arms are at bottom dead center. The counter-rotating drive shafts 25A / 25B thus rotate the secondary drive shafts 56 of the alternating needle stroke assemblies in counter-rotating directions, whereby the eccentric mounting of the cam arms on the rotatable cam members drives the cam arms, and thus the connecting rods and push rods coupled thereto, in synchronized, dynamically counterbalanced motions during movement of the needle bar 30 in the upward / downward directions.

[0070] To further provide dynamic counterbalance, in some embodiments, the first and second drive shafts 25A / 25B can include counterbalance weights 95 (FIGS. 1A-2) that can rotate with the first and second drive shafts. Such counterbalance weights would be selected and / or configured to counterbalance the rotation of the first and second drive shafts and help substantially damp or cancel normal forces generated by the reciprocating motion of at least one needle bar 30.

[0071] In an embodiment, the counterweights 95 can include one or more pairs of opposing rectangular clamping blocks 96 that can grip the first and second drive shafts 25A / 25B from opposite sides, causing the counterweights 95 to surround and clamp to the first and second drive shafts. The exterior surfaces of the clamping blocks can be configured to receive or attach to an appropriately sized offset weight. In an embodiment, the counterweights can be positioned adjacent the cam arm 80 and the connecting rod 81, respectively, and can be positioned approximately 180° out of phase with each other.

[0072] With such an arrangement, the tufting machine 10 of the present disclosure is substantially balanced during operation and the tufting machines (including cut pile tufting machines) can be configured to operate at speeds generally comparable to the operating speeds of loop pile tufting machines. In embodiments, cut pile tufting machines can be provided that can operate at speeds of 1,500 RPM to 2,000 RPM or greater.

[0073] The tufting machine of the present disclosure further exhibits little vibration transmitted to the floor on which the machine 10 is mounted and / or to any yarn feed mechanisms that may be associated with the machine. Additionally, machine noise is reduced, thereby causing less of an environmental impact when the machine 10 is operating than prior art machines.

[0074] In addition to the embodiments described above, embodiments of the present disclosure further relate to one or more of the following examples of drive systems according to the principles of the present disclosure, which examples can include combinations of various embodiment features or elements and / or feature steps or elements as disclosed herein. The following disclosed examples should not be construed as limiting the scope of the present disclosure and any of the embodiments. Example 1

[0075] A tufting machine, comprising: a machine frame having sides and a head extending between the sides; at least one needle bar having a plurality of spaced needles mounted therealong, the needles configured to move in a reciprocating motion toward and away from the backing material moving through the tufting machine to penetrate the backing material to form tufts of the yarn in the backing material; A drive system, comprising: at least one motor mounted along at least one of the sides of the frame and having a motor drive shaft with a motor gear coupled thereto; first and second drive shafts extending along the head of the tufting machine, each having an exposed end extending through a side of the frame; a plurality of needle stroke assemblies disposed at spaced locations along the first and second drive shafts, each needle stroke assembly comprising: a pair of needle stroke drive gears, each including one needle stroke drive gear coupled to and driven by one of the first and second drive shafts and another needle stroke drive gear coupled to the one needle stroke drive gear to a secondary drive shaft; a drive member extending between and connecting the needle stroke drive gears of each pair of needle stroke drive gears such that the secondary drive shaft is rotated with rotation of the first and second drive shafts; a plurality of push rods coupled to at least one of the needle bars and to a secondary drive shaft, such that when the secondary drive shaft is rotated with the rotation of the first and second drive shafts, the plurality of push rods are driven in a linear motion to reciprocate the needles toward and away from the backing material; a needle stroke assembly comprising: first and second shaft drive gears mounted on exposed ends of the first and second drive shafts outside the end boxes of the frame; a tension adjustment gear located adjacent to the first and second drive gears; a drive belt extending around the motor drive gear, the first and second shaft drive gears, and the tension adjustment gear; an adjustable support positioned along an exterior surface of a side of the frame and having a tension adjustment gear mounted thereon; and wherein the support is configured to move along a lateral exterior surface of the frame to adjust the position of the tension adjustment gear relative to the first and second drive gears to maintain a selected tension in the drive belt. A tufting machine equipped with:

[0076] The tufting machine of Example 1 of paragraph (0072), wherein the drive belt comprises a double-sided curvilinear toothed timing belt.

[0077] The tufting machine of Example 1 of paragraph (0072), wherein the drive member includes a double-strand drive chain having at least one connecting link configured to disengage to enable removal of the drive chain from around the needle stroke drive gear and the respective push rod gear.

[0078] The tufting machine of Example 1 of paragraph (0072), further comprising a plurality of gauge elements positioned below the backing material and configured to engage the needles and pick up loops of yarn therefrom.

[0079] The tufting machine of Example 1 of paragraph (0075), wherein the gauge assembly includes a cut pile hook and a knife for forming cut pile tufts of twisted yarn in the backing material.

[0080] The tufting machine of Example 1 of paragraph (0076), wherein the operating speed of the tufting machine to form the cut pile tufts is at least about 1,800 RPM.

[0081] The tufting machine of embodiment 1 of paragraph (0072), wherein the drive belt comprises a multi-chain double-sided curvilinear toothed timing belt having a width of at least about 2 inches to about 6 inches.

[0082] The tufting machine of Example 1 of paragraph (0072), wherein each needle stroke assembly further comprises a frame attached to the head of the machine frame, a pair of lower bearings in which the first and second drive shafts are received, and at least one upper bearing in which the secondary drive shaft is received. Example 2

[0083] A tufting machine, comprising: A frame, at least one needle bar having a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns; a plurality of gauge elements configured to pick up loops of yarn from the needles; a drive system coupled to the at least one needle bar; The drive system includes: at least one motor mounted along the frame, the at least one motor including a motor drive shaft with a motor gear coupled thereto; first and second drive shafts extending across a frame of the tufting machine, each of the drive shafts extending through a side of the frame and having at least one exposed end projecting outwardly from an exterior surface of the side of the frame; a plurality of needle stroke assemblies disposed at spaced locations along the first and second drive shafts, each needle stroke assembly comprising: a plurality of needle stroke drive gears including at least one drive needle stroke gear coupled to one of the first and second drive shafts and at least one needle stroke drive gear coupled to a secondary drive shaft; at least one drive member extending between the needle stroke drive gear and the needle stroke drive gear coupled to the secondary drive shaft; at least one push rod coupled to the at least one needle bar and operably connected to the secondary drive shaft and configured to translate rotation of the first and second drive shafts into reciprocating motion of the at least one needle bar; a needle stroke assembly comprising: first and second shaft drive gears mounted on exposed ends of the first and second drive shafts, the first and second drive gears positioned outside of the end boxes of the frame along an exterior surface of a side of the frame; a tension adjustment gear positioned adjacent to at least one of the first and second drive gears; a drive belt extending around the motor drive gear, the first and second shaft drive gears, and the tension adjustment gear to drive rotation of the first and second drive shafts; Equipped with as the first and second drive shafts are rotated, the at least one needle bar is moved in a reciprocating motion toward and away from the backing material as the backing material moves through the tufting machine such that the needles penetrate the backing material and form tufts of yarn in the backing material; A tufting machine, wherein the tension adjustment gear is mounted on an adjustable support configured to move along a lateral exterior surface of the frame to adjust the position of the tension adjustment gear relative to the first and second drive gears to maintain a selected tension in the drive belt.

[0084] The tufting machine of Example 2 of paragraph (0080), further comprising one or more counterweights attached to at least one of the first and second drive shafts, the counterweights configured to substantially dampen normal forces resulting from the reciprocating motion of the at least one needle bar.

[0085] The tufting machine of Example 2 of paragraph (0080), wherein each of the drive members includes at least one connecting link configured to be disengaged to enable removal of the drive member from around the needle stroke drive gear and the respective push rod gear.

[0086] The tufting machine of Example 2 of paragraph (0080), wherein the gauge component includes a cut pile hook and a knife for forming cut pile tufts of twisted yarn in the backing material.

[0087] The tufting machine of Example 2 of paragraph (0080), wherein the operating speed of the tufting machine for forming cut pile tufts in the backing material is at least about 1,800 RPM.

[0088] The tufting machine of embodiment 2 of paragraph (0080), wherein the drive belt comprises a multi-chain double-sided modified curvilinear toothed timing belt having a width of at least about 2 inches to about 5 inches. Example 3

[0089] A tufting machine, comprising: A frame, at least one needle bar having a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns; a plurality of gauge elements configured to pick up loops of yarn from the needles; a drive system coupled to the at least one needle bar; The drive system includes: at least one motor mounted along the frame; first and second drive shafts extending across a frame of the tufting machine, each having at least one exposed end extending beyond a periphery of the frame; a plurality of needle stroke assemblies positioned along the first and second drive shafts, each needle stroke assembly comprising: at least one drive member coupled thereto; a rotatable cam member operatively connected to the at least one drive member and configured to translate rotation of the first or second drive shaft into reciprocating motion of the at least one needle bar; a needle stroke assembly comprising: a tension adjustment gear mounted on an adjustable support adjacent an exposed end of at least one of the first and second drive shafts; a drive belt coupled to the motor, the first and second drive shafts, and a tension adjustment gear to drive rotation of the first and second drive shafts; and wherein as the first and second drive shafts are rotated, at least one needle bar is moved in a reciprocating motion toward and away from the backing material as the backing material moves through a tufting zone of the tufting machine such that the needles penetrate the backing material and form tufts of twisted yarn in the backing material.

[0090] The tufting machine of Example 3 of paragraph (0086), wherein the drive system further includes a secondary drive shaft coupled to at least one of the first needle stroke drive gear and the second needle stroke drive gear such that the secondary drive shaft is rotated in conjunction with rotation of the first and second drive shafts.

[0091] The tufting machine of Example 3 of paragraph (0086), wherein the needle stroke assembly further comprises a plurality of needle stroke drive gears including a first drive needle stroke gear coupled to one of the first and second drive shafts and a second needle stroke drive gear coupled to the secondary drive shaft, and the drive member extends around and connects the first and second needle stroke drive gears.

[0092] The tufting machine of Example 3 of paragraph (0086), further comprising first and second drive gears mounted on exposed ends of the first and second drive shafts, the drive belt extending around the first and second drive gears in a generally serpentine path such that the first and second drive shafts rotate in opposite directions.

[0093] The tufting machine of Example 3 of paragraph (0086), further comprising one or more counterweights attached to at least one of the first and second drive shafts, the counterweights configured to substantially dampen normal forces resulting from the reciprocating motion of the at least one needle bar.

[0094] In one or more embodiments, the counterweight comprises one or more pairs of opposing rectangular clamp blocks positioned to grip the first and second drive shafts from opposite sides.

[0095] In the drawings and specification, embodiments of a drive system for driving a needle bar or bars of a tufting machine are disclosed and, although specific terms are employed, such terms are used in a descriptive sense only and not for purposes of limitation. In addition, although embodiments of the drive system and its method of operation have been described in detail with specific reference to the illustrated embodiments, it will be understood by those skilled in the art that various changes and modifications can be made to the above-discussed structures of the present disclosure without departing from the spirit and scope of the present disclosure as disclosed herein, and it is intended that all matter contained in the above description or shown in the accompanying drawings should be construed as illustrative and not taken in a limiting sense.

[0096] Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc. to the embodiments described above, which shall be considered to be within the scope of the present disclosure. Thus, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure, and numerous variations, modifications, and additions may further be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

Claims

1. A tufting machine, comprising: a machine frame having sides and a head extending between the sides; at least one needle bar having a plurality of spaced needles mounted therealong, the at least one needle bar configured to move in a reciprocating motion toward and away from a backing material moving through the tufting machine, whereby the needles penetrate the backing material to form tufts of yarn in the backing material; Drive system and Equipped with The drive system comprises: at least one motor mounted along at least one of the sides of the frame, the at least one motor having a motor drive shaft with a motor gear coupled thereto; first and second drive shafts extending along the head of the tufting machine, each of the first and second drive shafts having an exposed end extending through the side of the frame; a plurality of needle stroke assemblies disposed at spaced locations along the first and second drive shafts, each needle stroke assembly comprising: a plurality of pairs of needle stroke drive gears, each pair including one needle stroke drive gear coupled to and driven by one of said first and second drive shafts and another needle stroke drive gear coupled to said one needle stroke drive gear for a secondary drive shaft; a drive member extending between and connecting the needle stroke drive gears of each pair of needle stroke drive gears, whereby the secondary drive shaft is caused to rotate with rotation of the first and second drive shafts; a plurality of push rods coupled to the at least one needle bar and the secondary drive shaft; a needle stroke assembly comprising: when the secondary drive shaft is rotated with rotation of the first and second drive shafts, the plurality of push rods are driven in a linear motion to reciprocate the needles toward and away from the backing material; first and second shaft drive gears mounted on the exposed ends of the first and second drive shafts outside of the end boxes of the frame; a tension adjustment gear located adjacent to the first and second drive gears; a drive belt extending around the motor drive gear, the first and second shaft drive gears, and the tension adjustment gear; an adjustable support positioned along an exterior surface of the side of the frame, the tension adjustment gear being mounted on the adjustable support; Equipped with the support is configured to move along the exterior surface of the side of the frame to adjust the position of the tension adjustment gear relative to the first and second drive gears to maintain a selected tension in the drive belt.

2. 2. The tufting machine of claim 1, wherein said drive belt comprises a double sided curvilinear tooth timing belt.

3. 2. The tufting machine of claim 1, wherein the drive members comprise double strand drive chains, each of the drive chains having at least one connecting link configured to be disengaged to permit removal of the drive chain from around the needle stroke drive gear and a respective push rod gear.

4. The tufting machine of claim 1 , further comprising a plurality of gauge elements positioned below the backing material and configured to engage the needles and pick up loops of yarn from the needles.

5. 5. The tufting machine of claim 4, wherein said gauge assembly includes cut pile hooks and knives for forming cut pile tufts of yarn in said backing material.

6. 6. The tufting machine of claim 5, wherein the operating speed of said tufting machine to form cut pile tufts is at least about 1,800 RPM.

7. 10. The tufting machine of claim 1, wherein said drive belt comprises a multi-chain double-sided curvilinear tooth timing belt having a width of at least about 2 inches to about 6 inches.

8. 2. The tufting machine of claim 1, wherein each needle stroke assembly further comprises a frame attached to the head of the machine frame, a pair of lower bearings in which the first and second drive shafts are received, and at least one upper bearing in which the secondary drive shaft is received.

9. A tufting machine, comprising: A frame, at least one needle bar having a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns; a plurality of gauge elements configured to pick up loops of yarn from the needles; a drive system coupled to the at least one needle bar; Equipped with The drive system comprises: at least one motor mounted along the frame, the at least one motor including a motor drive shaft with a motor gear coupled thereto; first and second drive shafts extending across the frame of the tufting machine, each of the first and second drive shafts extending through the side of the frame and having at least one exposed end projecting outwardly from an exterior surface of the side of the frame; a plurality of needle stroke assemblies disposed at spaced locations along the first and second drive shafts, each needle stroke assembly comprising: a plurality of needle stroke drive gears, the plurality of needle stroke drive gears including at least one drive needle stroke gear coupled to one of the first and second drive shafts and at least one needle stroke drive gear coupled to a secondary drive shaft; at least one drive member extending between the needle stroke drive gear and the needle stroke drive gear coupled to the secondary drive shaft; at least one push rod coupled to the at least one needle bar and operably connected to the secondary drive shaft; a needle stroke assembly comprising: the at least one push rod configured to translate rotation of the first and second drive shafts into reciprocating motion of the at least one needle bar; first and second shaft drive gears mounted on the exposed ends of the first and second drive shafts, the first and second drive gears positioned outside an end box of the frame along the exterior surface of the side of the frame; a tension adjustment gear positioned adjacent to at least one of the first and second drive gears; a drive belt extending around the motor drive gear, the first and second shaft drive gears, and the tension adjustment gear for driving rotation of the first and second drive shafts; Equipped with as the first and second drive shafts are rotated, the at least one needle bar is moved in a reciprocating motion toward and away from the backing material as the backing material moves through the tufting machine, whereby the needles penetrate the backing material and form tufts of the yarn in the backing material; the tension adjustment gear is mounted on an adjustable support configured to move along the exterior surface of the side of the frame to adjust the position of the tension adjustment gear relative to the first and second drive gears to maintain a selected tension in the drive belt.

10. 10. The tufting machine of claim 9, further comprising one or more counterweights attached to at least one of the first and second drive shafts, the counterweights configured to substantially damp normal forces resulting from the reciprocating motion of the at least one needle bar.

11. 10. The tufting machine of claim 9, wherein each of the drive members includes at least one connecting link configured to be disengaged to permit removal of the drive member from around the needle stroke drive gear and respective push rod gear.

12. 10. The tufting machine of claim 9, wherein the gauge assembly includes cut pile hooks and knives for forming cut pile tufts of yarn in the backing material.

13. 10. The tufting machine of claim 9, wherein the operating speed of the tufting machine for forming cut pile tufts in the backing material is at least about 1,800 RPM.

14. 10. The tufting machine of claim 9, wherein said drive belt comprises a multi-chain double-sided modified curvilinear tooth timing belt having a width of at least about 2 inches to about 5 inches.

15. A tufting machine, comprising: A frame, at least one needle bar having a plurality of spaced needles mounted therealong, the needles carrying a plurality of yarns; a plurality of gauge elements configured to pick up loops of yarn from the needles; a drive system coupled to the at least one needle bar; Equipped with The drive system comprises: at least one motor mounted along the frame; first and second drive shafts extending across the frame of the tufting machine, each of the first and second drive shafts having at least one exposed end extending beyond a periphery of the frame; a plurality of multi-needle stroke assemblies positioned along the first and second drive shafts, each multi-needle stroke assembly comprising: at least one drive member coupled thereto; a rotatable cam member operatively connected to the at least one drive member and configured to translate rotation of the first or second drive shaft into reciprocating motion of the at least one needle bar; a needle stroke assembly comprising: a tension adjustment gear mounted on an adjustable support adjacent an exposed end of at least one of the first and second drive shafts; a drive belt coupled to the motor, the first and second drive shafts, and the tension adjustment gear for driving rotation of the first and second drive shafts; Equipped with As the first and second drive shafts are rotated, the at least one needle bar is moved in a reciprocating motion toward and away from the backing material as the backing material moves through a tufting zone of the tufting machine, whereby the needles penetrate the backing material and form tufts of the yarn in the backing material.

16. 16. The tufting machine of claim 15, wherein the drive system further comprises a secondary drive shaft, the secondary drive shaft coupled to at least one of the first needle stroke drive gear and the second needle stroke drive gear, whereby the secondary drive shaft is rotated with rotation of the first and second drive shafts.

17. 16. The tufting machine of claim 15, wherein the needle stroke assembly further comprises a plurality of needle stroke drive gears including a first drive needle stroke gear coupled to one of the first and second drive shafts and a second needle stroke drive gear coupled to a secondary drive shaft, the drive member extending around and connecting the first and second needle stroke drive gears.

18. 16. The tufting machine of claim 15, further comprising first and second drive gears mounted on the exposed ends of the first and second drive shafts, the drive belt extending around the first and second drive gears in a generally serpentine path whereby the first and second drive shafts rotate in opposite directions.

19. 16. The tufting machine of claim 15, further comprising one or more counterweights attached to at least one of the first and second drive shafts, the counterweights configured to substantially dampen normal forces resulting from the reciprocating motion of the at least one needle bar.

20. 20. The tufting machine of claim 19, wherein the one or more counterweights comprise one or more pairs of opposed rectangular clamp blocks positioned to grip the first and second drive shafts from opposite sides.

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