Tufting machine and tufting method

Abstract

A tufting machine for selectively forming tufts of yarn containing different colors or types of yarn to form a patterned tufted article such as a carpet. A series of needles are reciprocated in and out of a backing fed through the tufting machine and engaged by a series of gauge elements to pick up loops of yarn from the needles. The gauge elements are selectively controlled by an actuator to extend or retract the gauge elements to a position or height sufficient to pick up or not pick up loops of yarn from the needles. The feed of yarn to the needles can be further controlled in conjunction with the movement of the gauge elements, but the backing feed can also be controlled, allowing the formation of tufts of yarn at a rate higher than the pattern stitch rate for the pattern of the tufted article being formed.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 212,770, filed June 21, 2021.

[0002] (Incorporated by reference) The disclosure of U.S. Provisional Patent Application No. 63 / 212,770, filed June 21, 2021, is incorporated by reference herein for all purposes as if set forth in its entirety.

[0003] (Technical field) TECHNICAL FIELD This disclosure relates generally to a tufting machine and method of forming a tufted fabric. In particular, this disclosure relates to a tufting machine including selectively controllable gauge components and a method of forming a patterned tufted fabric. [Background technology]

[0004] In the tufting field, there is an increasing demand for the production of carpets and rugs with new visual patterns, including the use of multiple different colors, to keep up with changing consumer tastes and increasing market competition, especially with respect to commercial and hospitality carpets. Accordingly, carpet designers and manufacturers are increasingly focused on creating newer, different, and more eye-catching patterns for carpets, rugs, and other tufted textiles, including patterns that selectively place and display particular colors or types of yarn within their pattern fields, so that the resulting tufted textile is formed with a substantially true pattern density of the visible tufts of the pattern. Furthermore, it is desirable to attempt to reproduce as closely as possible the look and feel of a patterned carpet, rug, or other textile formed on a loom, that can be created and formed on a broadloom tufting machine, to allow for increased efficiency in the production of such patterned tufted carpets, rugs, and / or other textiles. Additionally, it is generally desirable to increase control over the formation of tufts of selected colors or types of yarn to form patterned carpet without substantially affecting the operation of a tufting machine, including increasing the need for maintenance or positioning of parts such as gauge components of the tufting machine, or increasing the output of such tufting machine.

[0005] It can therefore be seen that a need exists for systems and methods for forming tufted textiles, such as carpets and rugs, that address these and other related and unrelated problems in the art. Summary of the Invention [Means for solving the problem]

[0006] Briefly, the present disclosure relates generally to tufting machines and methods for forming patterned tufted articles in which the placement and pile height of yarn or stitch tufts formed in a backing can be selectively controlled to enable the formation of patterned tufted articles, such as carpets, having a variety of pattern effects that not only include the formation of tufted articles having free-flowing, multi-color and / or multiple pile height patterns, but also have a substantially woven or loom-formed appearance.

[0007] In one aspect, the tufting machine typically includes a control system for controlling the operating elements of the tufting machine to form or create a tufted article according to a desired or designed pattern. The resulting tufted article can include a variety of pattern effects, including having a plurality of various or different pile heights, different types of tufts in the same and / or various rows of tufts, and other texture effects, and an arrangement of various colors and / or types of yarns visible at selected locations and pile heights across the backing. In at least some embodiments, the resulting tufted article is provided with a retained and / or visible color yarn / stitch density per inch that substantially matches the desired or defined pattern density or stitches per inch of the pattern being formed / tufted.

[0008] In an embodiment, the tufting machine includes one or more needle bars having a series of needles mounted along them. The needles can be arranged in-line, staggered, or in other arrangements. As the backing is fed through the tufting zone of the tufting machine, the yarn is introduced therein as the needles are shuttled in and out of the backing. A shifting mechanism can further be provided for laterally shifting the needle bar across the tufting zone, and multiple shifting mechanisms can be utilized as needed. The shifting mechanism is generally operable in response to commands or communications from a control system to step or shift the needle bar laterally across the backing according to a programmed and / or designed pattern shift step for the pattern being tufted, thereby providing the conveyed yarn along / across the backing to a tuft or stitch position.

[0009] Tufting machines further typically include at least one yarn delivery mechanism or attachment for controlling the delivery of yarn to their respective needles. Such yarn delivery mechanisms or pattern attachments may include, but are not limited to, various roll, scroll, servo scroll, single-end, double-end or multi-end yarn delivery attachments, such as the Yarntronics™ or Infinity™ / Infinity IIE™ yarn delivery attachments manufactured by Card-Monroe Corp. Other types of yarn delivery control mechanisms may also be used. The control system generally includes programming for the control of at least one yarn delivery mechanism or pattern attachment, which may be operated to selectively control the delivery of yarn to their needles to form tufts of yarn, which may include forming tufts having a selected pile height and / or not forming tufts, to create a desired pattern appearance.

[0010] In some embodiments, the control system may further comprise or operate with a stitch distribution control system, and the control of the backing feed and the control of the operation of the shift mechanism to shift at least a portion of the needles may be coordinated with the control of at least one yarn feed mechanism, whereby different yarns may be provided to different stitch locations or pixels, and the yarns shown on the face or surface of the tufted article may generally be fed in sufficient amounts to form tufts of the desired height, while the invisible yarns not shown in the tufted field when the gauge component is lowered to the no-stitch position are generally not picked. Thus, for each pixel or stitch location of the pattern, a series of yarns may be provided, and picking up of non-selected yarns may be avoided, which may be visibly unselected or appear at such stitch locations when the gauge component is in the no-stitch position. Furthermore, in some embodiments, the yarn feed may also be controlled to include pulling or pulling some yarns down, forming a sculpted or varying pile height effect, and / or lengthening the loops of yarns picked up by the movement of the gauge component in conjunction with the yarn feed control. Additionally, some yarns can be pulled back or lowered to a level or range to leave a sufficient portion of the yarns not revealed within the backing to allow the unselected or non-revealing yarns to be held or tucked into the backing without interfering with the face or with the retained visible tufts of yarns of the pattern by such non-revealing yarns being substantially minimized. Thus, in embodiments, only the desired or selected yarns / colors to be placed at a particular stitch location can be retained at such stitch location to form tufts or different pile heights and colors. The remaining yarns / colors can be removed or pulled back to the extent that they can be tucked or retained into the backing, but not revealed or shown in the pattern field being sewn at the time.The control system may further control and coordinate the operation of one or more selected gauge component assemblies with the yarn delivery mechanism of the tufting machine according to instructions for the selective formation of loops and / or tufts of yarn and the pattern being formed to control their length or pile height.

[0011] Additionally, a gauge component assembly is disposed beneath the backing. The gauge component assembly generally comprises a series of gauge components, including, for example, but not limited to, loopers, hooks, level cut loop loopers, cut / loop clips, and the like. The gauge components are disposed along the tufting zone and are movable in a first direction to reciprocate to engage the needles as they penetrate the backing and pick up loops of yarn from the backing. In some embodiments, each of the gauge components can further be selectively movable in a second or additional direction substantially perpendicular to their reciprocating direction. For example, the gauge components can be moved in a substantially vertical, e.g., up and down, motion relative to the stroke or reciprocating motion of the needles up and out of the backing to selectively pick up and form loops of yarn within the backing, and can also be moved in a reciprocating motion toward and away from the needles. Additionally, movement of the gauge components in a second direction (e.g., vertically or otherwise) can be controlled to form loops of various lengths of yarn at various pile heights in the backing, including forming loops of different pile heights, or even no yarn loops in the backing. In still further embodiments, other configurations and / or combinations of loop pile loopers, cut pile hooks, cut / loop hooks, level cut loopers or hooks, and / or other gauge components can also be used.

[0012] In some embodiments, the gauge components can include loopers or hooks each having a body having a first portion and a second portion that can include an elongated throat terminating in a pointed proximal end or bill, the first portion of the body of each gauge component can extend through the gauge block or module and can be coupled at a distal end to a drive system including a plurality of actuators, each of which can be selectively actuated to control movement of the gauge component in the second direction, and coupled to an associated or corresponding one of the gauge components by a connector assembly.

[0013] In some embodiments, each of the gauge modules can include a module or block body having a first rear portion adapted to couple or mount along the gauge bar and a second or forward portion having at least one channel or passage formed therein in which the gauge part is received. The modules can further include interchangeable inserts that can be received within the passages or channels formed in the module body, the interchangeable inserts further including slots or recesses adapted to receive and guide the gauge part during movement of the gauge part through / along the passages of the module block. Alternatively, the inserts can be integral with the modules, such as by being glued or otherwise substantially permanently affixed or secured to the body of their modules or gauge blocks, and in some embodiments can be substantially affixed while allowing at least serviceable removal as needed.

[0014] In an embodiment, the replaceable insert is formed from a hardened material that may include, but is not limited to, various metal carbides, metals, ceramics, and / or synthetic materials, and the body of the module may be manufactured from lightweight materials, such as aluminum and / or other metals, and various composite or synthetic materials. The insert may further include an opening or slot configured to receive a guide pin or other positioning device and one or more fasteners to secure the insert to the gauge module. The opening is further generally configured to allow the insert to be adjusted in at least one direction, e.g., longitudinally, and / or transversely, e.g., to adjust the position of the insert, and thus allow for placement or positioning of the gauge components across and / or along the gauge module. The insert may further be replaceable to allow easy removal of the insert, and thus one or more of the gauge components received therein may be replaced, e.g., to replace worn or broken gauge components or to change the spacing between the gauge components.

[0015] As a further alternative, in some embodiments, the module or gauge block itself can be removable and replaceable with other gauge blocks or modules, such as to accommodate changes in gauge spacing between gauge parts, changes in the type of size gauge parts being used, or to provide replacement of substantially all or at least most of worn or damaged gauge parts as a unit. Additionally, guide slots or recesses formed within the insert are configured to receive the bodies of the gauge parts sufficient to allow the gauge parts to slide substantially freely, but without allowing excessive shifting or twisting of the gauge parts, resulting in misalignment of the bills or throats of the gauge parts with their respective needles. The slots or recesses of the insert can further terminate at a rear end or portion that can be configured or adapted to allow an edge of the body of the gauge parts to lie against and / or include a base or engagement region against which the gauge parts can slide to help maintain a desired alignment of the gauge parts as they reciprocate or move through the module.

[0016] The gauge parts can be further arranged to engage the needle, including being substantially in-line, offset or staggered, and / or arranged in other configurations as needed to engage in-line, staggered and / or dual needle bar configurations. In embodiments, each gauge part can be further arranged at an angle relative to the needle as the needle penetrates the backing. For example, in some embodiments, the gauge parts can be arranged and / or extendable / retractable along a path of travel directed at an angle that can range from about 1° to about 10° from vertical to the needle and / or its stroke or vertical movement, while in other arrangements, no offset, i.e., an angle of 0°, can be provided. The offset of the gauge parts relative to the needle can be further varied such that the gauge parts can be extended and retracted along an angled or offset path of travel relative to the needle as needed to minimize potential engagement with the needle as the gauge parts move, depending on the spacing and / or arrangement of the needle.

[0017] In various embodiments, the drive system includes a series of selectively controllable actuators that drive movement of the gauge components, which may include electric cylinders, hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors or other motors, linear actuators, moving coil or voice coil actuators, and other like actuators, and / or combinations thereof. The actuators associated with or corresponding to each of the gauge components may further be selectively controlled according to pattern instructions to cause the gauge components to be moved to desired vertical positions relative to the associated needles for picking up loops of yarn from the needles, including picking up loops of yarn at different points in the stroke of the needles to form loops / tufts of different pile heights, as well as being retracted to a "no stitch" position where loops of yarn of selected types or colors are not generally picked up by such gauge components.

[0018] For example, the actuators can be connected to associated or corresponding ones of the gauge parts by connector assemblies for selectively driving movement of such gauge parts in a second direction relative to the needles as the gauge parts reciprocate in their first directions toward and away from engagement with the needles. The control system can further include programming for selectively engaging each actuator to control movement of the gauge parts, including moving the gauge parts to form tufts of yarn according to a pattern being executed by the tufting machine and / or to form tufts of various pile heights.

[0019] In further embodiments, the actuators can be controlled / triggered to move their gauge components along with the captured yarn loops to extend or tension such captured loops to provide other pile heights and / or other effects, such as tip shear or other pattern or texture effects. For example, the gauge components can engage and pick up a loop of yarn from a selected needle, and then can be retracted, for example, and moved to a lowered position, while the yarn feed for such loop is also controlled, thereby drawing the loop to a lowered or extended length position to create various pile height effects. The movement of the gauge components to the raised or extended positions with the captured loop of yarn can also be controlled by the control system, and the yarn feed for such loop of yarn is further controlled to draw back such yarn to maintain tension therein and / or form various pattern pile height effects.

[0020] In another aspect of the tufting machine and method of forming a patterned tufted article, the gauge components can be configured to move or pivot between a fully raised first operating position and an elevated operating position including a lowered stitchless position, with the distal end or tip of the gauge component generally directed and / or positioned below the needle penetration depth or stroke, typically below the needle pick-up point or take-up area, and potentially below the needle tip. The gauge components can comprise loopers, hooks, level cut loop loopers, or other gauge components, with a body pivotally mounted to a support or holder and a throat projecting forward from the body and terminating in a generally pointed tip or distal end. An actuator corresponding to such gauge components can be selectively engaged or operated such that the body of the corresponding or associated gauge component is pivoted to move the throat and distal end of the gauge component to a desired lowered height relative to the needle.

[0021] In various aspects, the gauge components are coupled to their respective or corresponding actuators of the drive system by a connector assembly including a connector or gate configured to extend between the actuator shaft or rod and a distal end of the associated or corresponding gauge component. In some embodiments, the connector or gate can include an arm or linkage having a first end configured to engage or connect with the drive rod of that actuator, an intermediate portion protruding from the first end, and a second end generally configured to engage with the distal end of the associated gauge component. In embodiments, each linkage or arm of the connector or gate can be further received within a housing or support structure. In one exemplary embodiment, such a housing or support structure can include a body formed from a durable, lightweight material, such as a carbon-filled nylon material or other similar composite or plastic material selected to provide durability and support for the linkage or arm while allowing for reduced weight. Other materials, including various metallic, synthetic, and / or composite materials, can also be used. The configuration of the gate and its housing can be further modified as needed.

[0022] When each actuator is actuated or deactuated, it causes the connector or gate coupled to it to move its associated or corresponding gauge component in a desired direction relative to the needle by extending or retracting the actuator shaft. For example, in some embodiments, the actuator can drive the gauge component in a direction substantially vertical to the movement of the gauge component to and from the backing of the needle, such as to adjust the height of the gauge component relative to the needle as the gauge component reciprocates toward and away from the needle. In other embodiments, actuation of the actuator and movement of the connector can help control movement of the gauge component or a portion thereof, controlling movement of a clip of a level cut loop looper toward and away from the needle in a direction substantially along the direction of reciprocating movement of the gauge component toward and away from the needle.

[0023] In yet another aspect, the gauge components are coupled to associated or corresponding actuators of the drive system by connector assemblies including gates or connectors each including a body having a first end and a second end in which a first portion of the body of the corresponding gauge component is received. In some configurations, a series of biasing members can be disposed between the second end of each gate and the spring plate. One or more linkages, which can include arms, rods, cables, or other similar members, can extend between the actuators and the connectors or gates and, in some embodiments, can be coupled to the gauge components.

[0024] Each linkage may generally have a first end adapted to extend through the spring plate and connect to a second end of its corresponding gate or gauge part, and a second end coupled to a corresponding or associated actuator. In embodiments, the linkages extend along a path from the actuator to their corresponding or associated gauge part / gate. In some embodiments, the linkages may further extend through a guide. In such embodiments, the guide may be configured to adjust the pulling force applied by the actuator.

[0025] Upon actuation, each selected actuator moves a linkage connected thereto, for example, by pulling or retracting the linkage to move the gate and / or corresponding gauge component in its second direction toward a retracted position and against the biasing force of the one or more biasing members to generally compress the biasing member as the gauge component moves toward its retracted position. Upon deactivation of the actuator, the linkage can be released to allow the one or more biasing members to reduce the compressive force and / or bias or direct the corresponding gauge component toward its fully extended position. In an embodiment, the biasing members can help control the second direction movement of the gauge component relative to the needle to allow substantially incremental movement and position of the gauge component in positions of varying height. Such positional variations can be used to create or change the length of the loop of yarn picked up by the gauge component, thus allowing for variations in pile height of the tuft of yarn formed on the backing, and movement to a no-stitch position where the gauge component is moved to a position not engaging the yarn carried by the needle.

[0026] In other embodiments, the connector assembly can include a linkage coupled to the body of one of the gauge parts and a corresponding or associated actuator. For example, the actuator can include a motor and the linkage includes an arm of a cable, rod, or combination thereof. In embodiments, the motor can also include a drive member, which in embodiments can include an eccentric, cam, or pulley or similar drive member configured to convert rotary motion to linear motion. When the drive member is rotated by its actuator, the linkage is extended or retracted, which in turn drives the movement of the corresponding or associated gauge part between its extended and retracted positions in a second direction, including moving the gauge part to a sutureless position.

[0027] In some embodiments, the connector assembly can include a linkage including a first arm or rod having a first end coupled to a drive member, such as a driving eccentric or pulley coupled to an associated one of the actuators, and a second end coupled at its first end to a second arm or rod. The second arm can have a second end pivotally connected to a first portion of the body of its corresponding gauge component. When each drive member is rotated by its motor, the first arm is extended and retracted along a first axis of movement, pivoting the second arm and moving the corresponding gauge component between its extended and retracted positions along the second axis of movement.

[0028] In yet another embodiment, each connector assembly can include an extension piece connected or integral with the body of the corresponding gauge component, or can include a linkage that can be connected to the extension piece. The opposite end of the linkage can be coupled to an actuator that is coupled to a drive member (e.g., an eccentric or pulley) driven by a motor, for example. When the motor rotates its drive member, the linkage can be extended or retracted to move the corresponding or associated gauge component between its extended and retracted positions.

[0029] In some aspects of the disclosure, a tufting machine is provided that includes at least one needle bar having needles mounted therealong; a backing feed roll that feeds a backing; at least one yarn feed mechanism that feeds yarn to the needles; a gauge element assembly disposed below the backing and having a plurality of gauge elements movable in a first direction toward and away from the needles as the needles reciprocate in and out of the backing and in a second direction; and a control system including programming for controlling the at least one yarn feed mechanism to control the feeding of yarn to the needles in cooperation with control or actuation of one or more actuators coupled to the gauge elements, the control or actuation of the one or more actuators causing retraction or extension of a selected one of the gauge elements, whereby a throat of a selected one of the gauge elements is moved between a fully retracted no stitching position and a fully extended position relative to a stroke of the needle into the backing to engage the needle and form a tuft of yarn in the backing according to a pattern being formed.

[0030] In some embodiments, the gauge component assembly can include at least one module carrying a series of gauge components in a reciprocating motion in a direction toward and away from engagement with the needle as the needle reciprocates within the backing, the at least one module can be machined, cast, molded, or otherwise formed from a metal, polymer, composite, or synthetic material, or combination thereof, and includes a module body having a first hardness. The module body is adapted to mount along the gauge bar and configured with a passageway defined therethrough. Inserts are attached to the module body on either side of the passageway, each insert having a series of spaced apart slots formed therein, each of the slots configured to slidably receive at least a portion of one of the gauge components. In embodiments, the inserts can be machined, cast, molded, or otherwise formed from a metal or metal carbide or powder metal material having a second or additional hardness greater than the first hardness of the module body, and the slots are formed or defined therein.

[0031] In some embodiments, a module can include a module body and one or more inserts.

[0032] In an embodiment, each of the gauge parts may include a body at least partially received in slots on either side of the insert and movable through a passage in the modular body in an additional direction relative to the stroke of said needle, the body of each gauge part having a first portion extending through the passage in at least one module and a second portion having a throat configured to pick up a loop of thread from the needle.

[0033] In an embodiment, a series of actuators are coupled to the gauge parts to control movement of the gauge parts through the module body, and a control system includes programming for controlling at least one yarn delivery mechanism to control the delivery of yarn to the needles in cooperation with controlling the operation of one or more of the actuators to extend or retract selected ones of the gauge parts such that the throats of selected ones of the gauge parts are moved between a no-stitch position and an engaged position relative to the stroke of the needle into the backing to selectively form tufts of yarn in the backing according to a pattern being formed.

[0034] In various embodiments of the tufting machine, the gauge components include level cut loop loopers, loop pile loopers, cut pile hooks, or cut / loop clips, and / or combinations thereof. In still further embodiments of the tufting machine, the actuators can include hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors or other motors, linear actuators, moving coil or voice coil actuators, and other similar actuators, and / or combinations thereof.

[0035] In yet other embodiments of the tufting machine, the gauge component assembly may further comprise a series of connectors extending between each gauge component and an associated actuator, each connector including a linkage received within and movable through the housing. In some embodiments, the housing of each connector may be formed from a polymer, composite or synthetic material or combinations thereof and includes a body having a channel extending therethrough, and each linkage comprises a metal or composite material or combinations thereof.

[0036] In other embodiments, the body of each housing can comprise a composite material including a polymer or plastic with a fibrous fill material and have a channel defined therein along which the linkage is movable, and the linkage of each connector can comprise a hardened metal body or arm, or a series of arms, extending through the body of the housing along a passage defined therein and having a proximal end configured to engage a first portion of one of the gauge parts and a distal end configured to be engaged by an actuator associated with the gauge part to translate movement by the actuator to the gauge part.

[0037] Further, in an embodiment, the inserts of the module are generally configured to overlie the upper surface of the module body, each including a slotted opening adapted to receive a fastener for adjustably mounting each of the first and second inserts to the module body, the inserts being positioned at selected intervals from one another and at selected positions relative to the passage defined through the module body. Furthermore, the inserts can be molded or housed, encapsulated, or substantially integrated within the module body. The inserts can also include tab or flange portions that can engage opposing sides of the module body, and a plate or intermediate portion can be provided therebetween. The intermediate portion can connect the tab or flange of the insert, with the slot of the insert at least partially formed therein and extending along it. Alternatively, the bearing plate of the support can be received along the first and second sides of the passage, between the tab or flange of the insert.

[0038] Thus, in some aspects of the disclosure, a gauge part assembly for a tufting machine includes at least one module having a module body with a passageway defined therethrough, and a series of gauge parts received within the passageway of the module body, each gauge part including a body having a first portion and a second portion having a throat, the gauge parts being carried with the module in a first direction toward and away from engagement with an associated needle of the tufting machine to pick up a loop of yarn from the needle along the throat of the gauge part, the gauge parts being selectively movable in a second direction along the passageway of the module body, and first and second inserts disposed along opposite sides of the passageway of the module body, each insert having a hardness greater than a hardness of the metal or composite material of the module body. the series of gauge parts being formed from a material having a hardness that can be easily adjusted to fit the gauge parts and having a series of spaced apart slots configured to receive at least a portion of one of the gauge parts, the slots of the first and second inserts being substantially aligned across the passageway; and a plurality of actuators, each actuator coupled to a first portion of an associated gauge part of the series of gauge parts and adapted to move its associated gauge part in a second direction through the at least one module passageway, whereby the gauge parts are extended or retracted through the module body to move a throat of the gauge part between an extended position for engaging and picking a loop of thread from the needle and a retracted position for substantially avoiding picking the loop of thread from the needle.

[0039] In yet another embodiment, the gage component assembly can include first and second inserts each including a body machined, molded, or cast from a metal, carbide, or powdered metal material, the body including a tab or flange portion in which the slot is formed. Additionally, the body of each of the first and second inserts further includes upper and lower tab or flange portions that engage the upper and lower surfaces of the module body, the slot extending through the upper and lower tab or flange portions.

[0040] In some aspects of the disclosure, a method of operating a tufting machine is disclosed, and according to one exemplary embodiment of the disclosure, when the needles of the tufting machine are reciprocated in and out of the backing, the gauge parts are reciprocated in a first direction toward engagement with the needles. Further, the actuators of at least selected ones of the gauge parts can be selectively engaged or disengaged to move their corresponding gauge parts between a fully retracted or non-stitching position, which changes the extended or elevated position, including a fully extended position, in which the gauge parts do not engage the associated or corresponding needles, and thus no loops of thread are formed thereby. In their elevated or extended positions, the gauge parts engage the needles at the pick-up portion of the needles as the needles enter and exit the backing and pick up the loops of thread from the needles.

[0041] Further, in embodiments, when the needles are shuttled from the backing, the yarn feed therefor can also be controlled to cause non-selected yarns, e.g., yarns that are not engaged or picked up by the associated gauge parts when the associated gauge parts are in a lowered, non-stitching position, to be generally held by those needles and retracted, drawn out, or otherwise pulled back or withdrawn from the backing by those needles. In other examples, the gauge parts can be moved to a raised or elevated position before or during engagement with the loops of yarn, and the yarn feed can be controlled to retract, withdraw, or pull back some loops of yarn to an extent sufficient to prevent such yarns from appearing in that stitch position in the completed patterned article. The loops of yarn picked from the needles can also have different pile heights or lengths depending on the position and / or movement of the gauge parts relative to their associated or corresponding needles. For example, in the fully raised position, smaller or shorter length loops of yarn can be formed to control the pile height, e.g., to form a lower pile height, or by controlling substantially hidden yarn loops, including loops of yarn that are substantially hidden within the backing and such loops are substantially removed by controlling the yarn feed (e.g., by being maintained / held by needles and not picked up by gauge components in the lowered, no-sewing position, etc.).

[0042] In an embodiment, as the loopers move to the lowered position, longer yarn loops can be picked up and formed by the loopers, pulling the yarn loops along with them as needed, thereby forming taller or higher yarn pile height tufts in the backing. Additionally, the actuators can be controlled to selectively lower or retract their corresponding gauge components with the yarn loops captured to form even longer yarn loops to enable additional patterning effects such as for tip shear.

[0043] The needles can more generally be shifted laterally relative to the longitudinal movement of the backing through the tufting zone to provide different colors or types of yarn at each stitch location of the pattern being formed on the backing. For example, the needles of one needle bar or multiple needle bars can be sewn with a series of desired colors in various thread-up sequences. Furthermore, the backing can typically be run at an actual or effective stitch rate that is substantially greater than the prescribed or desired pattern stitch rate of the pattern being formed. As a result, as the needles move, a desired number of different colors or types of yarn can be provided at each stitch location. By controlling the positioning and / or movement of the gauge components, loops of yarn can be selectively formed in the backing, and in some embodiments, the formation of such loops of yarn can be further controlled to form various pile heights of the resulting tufts. For example, in various aspects, as the needle bars are shifted, a series of different colors or types of yarn can be provided at each stitch location, and if a particular color or type of tuft of yarn is not selected to be sewn at that stitch location, the corresponding gauge component can be held in a retracted or lowered position such that loops of such non-selected yarn are generally not formed.

[0044] Further, in embodiments, the backing feed is controlled. For example, in embodiments, the backing feed can be controlled in conjunction with the needle movement, the control of the yarn feed, and the control of the positioning of the gauge components, such that the backing feed can be fed at a higher operable, effective, or actual stitch rate to allow for a substantially increased number of yarn applications to be formed on the backing, providing substantially complete gauge coverage of the selected color type of yarn tufts remaining on the surface of the tufted article, and substantially avoiding missing color or type of yarn or gaps being generated, indicated, or otherwise manifested in the pattern field of the patterned tufted article. Thus, the finished patterned tufted article can have a density of tufts per inch that substantially matches the desired or prescribed pattern stitch rate, i.e., for a pattern designed with a pattern stitch rate of 8, 10, or 12, or other number of stitches per inch, the resulting finished patterned tufted article can be formed with a density of visible and / or retained face yarn or tufts per inch that can approximately match the pattern stitch rate.

[0045] The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and will be more readily understood from the following detailed description and claims, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and are intended to provide further explanation without limiting the scope of the disclosure. The present invention provides, for example, the following: (Item 1) A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; and a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls the delivery of the yarn to the needles in coordination with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuator to move a selected gauge part along the second direction, whereby the throat of the selected gauge part is moved between a no-stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a pattern being formed and form a tuft of yarn in the backing. (Item 2) a shift mechanism for shifting the at least one needle bar laterally across the backing, the control system further comprising a program for providing a series of threads to selected stitch locations along the backing and drawing off non-selected threads by coordinating the shifting of the at least one needle bar by the shift mechanism, the feeding of the backing by the backing feed roll, control of the actuator coupled to the gauge component, and control of the at least one thread feeding mechanism that feeds the threads to the needles as the needles are shuttled in and out of the backing; 2. The tufting machine of claim 1, wherein such loops of non-selected yarn are not picked up by one of the gauge components and the backing is moved through a tufting zone at an actual stitch rate that is greater than the pattern stitch rate of the pattern being formed, providing a number of retained tufts per inch approximately equal to the pattern stitch rate of face yarns in the backing. (Item 3) Item 2. The tufting machine of item 1, wherein the gauge components comprise a level cut loop looper, a loop pile looper, or a cut pile hook. (Item 4) Item 2. The tufting machine of item 1, wherein the actuator comprises a hydraulic cylinder, a pneumatic cylinder, a stepper motor, a servo motor, an electric cylinder, a linear actuator, a moving coil or voice coil actuator, a solenoid, or a combination thereof. (Item 5) and at least one module carrying a series of gauge parts in a reciprocating motion in a direction toward and away from engagement with the needle as the needle is reciprocated through the backing, the at least one module comprising: a modular body adapted to be mounted along a gauge bar, the modular body having a passageway defined therethrough, the modular body being formed from a metal, a polymer, a composite or synthetic material, or a combination thereof, and having a first hardness; an insert disposed along the passage; Equipped with each of the inserts having a slot configured to slidably receive at least a portion of one of the gauge parts; Item 2. The tufting machine of item 1, wherein the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body. (Item 6) 2. The tufting machine of claim 1, wherein the drive system further comprises a plurality of connectors configured to connect each gauge part to at least one linkage for an associated actuator, each of the connectors comprising a body having a first end in which the first portion of the body of a corresponding gauge part is received and a second end connected to the at least one linkage, and a series of biasing members disposed between the second end of each connector and a spring plate. (Item 7) each linkage comprises a cable, wire, rod, or belt extending through the spring plate and including a first end connected to the second end of one of the connectors and a second end coupled to the associated actuator; to retract the selected gauge part, the associated actuator retracts the linkage coupled to the selected gauge part, thereby causing the selected gauge part to move along the second direction toward a retracted position compressing at least one biasing member; 7. The tufting machine of claim 6, wherein to extend the selected gauge part, the at least one biasing member is enabled to reduce compressive force and urge the corresponding gauge part toward its extended position. (Item 8) 2. The tufting machine of item 1, wherein the drive system further comprises a series of connector assemblies connecting each gauge part to an associated actuator, each of the connector assemblies including a series of connectors each coupled to at least one of the linkages and configured to receive the first portion of the body of a corresponding gauge part, the actuators comprising motors, and each linkage comprising a cable, wire, rod, or belt having a first end adapted to connect to one of the connectors and a second end coupled to one of the motors. (Item 9) 9. The tufting machine of claim 8, further comprising a series of biasing members disposed between each of the connectors and a spring plate, wherein actuation of a selected one of the motors retracts the connector coupled thereto on an associated linkage, moving the corresponding gauge part toward a retracted position and compressing one or more of the biasing members, and when the one or more biasing members reduce compression, the corresponding gauge part is moved toward its extended position. (Item 10) Item 2. The tufting machine of item 1, wherein the actuator comprises a motor and the linkage comprises a cable, wire, rod, belt, arm, or combination thereof. (Item 11) 2. The tufting machine of claim 1, wherein the actuator comprises motors, each motor including a drive member coupled to the motor, the drive member being driven in a rotational motion by the motor, and the linkage is coupled to the drive member of one of the motors, whereby when the drive member is rotated by the motor, the linkage is extended or retracted. (Item 12) Item 12. The tufting machine of item 11, wherein each of the linkages comprises a first arm or rod having a first end coupled to the drive member of the motor and a second end coupled to a second arm or rod at the first end of the second arm or rod, the second arm having a second end pivotally coupled to the first portion of the body of one of the gauge parts, and when the drive member is rotated by the motor, the first arm is extended or retracted along a first axis of movement, causing the second arm to pivot and move the one of the gauge parts between its extended and retracted positions. (Item 13) 2. The tufting machine of claim 1, wherein each linkage includes an extension piece connected to or integral with the first portion of the body of the corresponding gauge component. (Item 14) Item 2. The tufting machine of item 1, wherein the at least one needle bar comprises a pair of needle bars, each of the pair of needle bars having a series of needles mounted in series and spaced apart therealong. (Item 15) A tufting machine, comprising: at least one needle bar having a plurality of needles mounted therealong, the at least one needle bar moving in a reciprocating motion to move the plurality of needles in and out of a backing passing beneath the at least one needle bar; at least one yarn delivery mechanism for delivering yarn to the needles; a gauge component assembly disposed beneath the backing, the gauge component assembly comprising: a plurality of modules, each module including a module body having a passageway defined therethrough, and one or more inserts attached to the module body along the passageway defined through the module body; a series of gauge parts slidably received within the passages of the modules, each of the series having a throat, the gauge parts being carried with the modules in a first direction toward and away from engagement with the needles of the tufting machine to selectively pick up loops of yarn from the needles along the throats of the gauge parts, the series of gauge parts being selectively movable through the passages of the modules in a second direction; Drive system and Equipped with the drive system comprising a plurality of actuators coupled to the gauge components and a series of connector assemblies connecting each gauge component to an associated actuator; a gauge component assembly, each of the connector assemblies including a connector for engaging a portion of a corresponding gauge component and at least one linkage coupled to each connector and an actuator associated with the respective connector; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls the delivery of the yarn to the needles in coordination with controlling actuation of one or more actuators, the actuation of the one or more actuators causing a retraction or extension of the linkage coupled to the one or more actuators to engage the needles and move selected ones of the gauge components between at least one extended position for picking loops of yarn from the needles and a retracted position for substantially avoiding picking loops of yarn from the needles to selectively form tufts of yarn in the backing according to a pattern being formed. (Item 16) Item 16. The tufting machine of item 15, wherein the connector assembly further comprises at least one biasing member disposed between each connector and the spring plate, each linkage extending through the spring plate and having a first end connected to the connector and a second end coupled to a drive member of the associated actuator, wherein upon actuation, retraction of the at least one linkage by the associated actuator causes the connector and corresponding gauge part to be moved relative to the biasing member toward a retracted position, and upon release or extension of the at least one linkage, the biasing member urges the corresponding gauge part toward its at least one extended position. (Item 17) Item 16. The tufting machine of item 15, wherein the actuator comprises a motor, and each linkage comprises a cable, wire, rod or belt and includes a first end adapted to connect to one of the connectors and a second end coupled to one of the motors. (Item 18) Item 18. The tufting machine of item 17, further comprising a series of biasing members disposed between each of the connectors and a spring plate, wherein actuation of a selected one of the motors retracts each of the connectors coupled thereto and moves the corresponding gauge part toward a retracted position and compresses one or more of the biasing members, and when the one or more biasing members reduce compression, the corresponding gauge part is moved toward at least one of its extended positions. (Item 19) Item 16. The tufting machine of item 15, wherein the actuator comprises motors, each of the motors having a drive member to which the linkage for the associated gauge part is coupled, each linkage adapted to convert rotational motion of the drive member by that motor into linear motion for moving the corresponding gauge part in the second direction, the linkage comprising a cable, rod, arm, wire, belt, or combination thereof. (Item 20) Item 16. The tufting machine of item 15, wherein each linkage includes an extension piece connected to or integral with the first portion of the body of the corresponding gauge component. (Item 21) Item 16. The tufting machine of item 15, wherein the modules further comprise inserts disposed on either side of the passage of each module, each insert having a hardness greater than the hardness of the module body and including a series of slots into which the gauge parts are received. (Item 22) 22. The tufting machine of claim 21, wherein the module body of each module is machined, molded or cast from metal or composite material, and each of the inserts comprises a body machined, molded or cast from metal, carbide or powder metal material and has a tab or flange portion with the slot formed therein. (Item 23) 1. A tufting machine for forming tufts of yarn in a backing, the tufting machine comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; at least one yarn delivery mechanism for delivering the yarn to the needle; a plurality of gauge elements disposed beneath the backing, at least some of the gauge elements being movable in a first direction toward the needle and a second direction substantially parallel to a stroke of the needle; a drive system coupled to the gauge part in a second orientation of the gauge part, the drive system comprising: A plurality of actuators; a connector assembly connecting each gauge component to an associated actuator, each of the connector assemblies including a connector extending between each gauge component and its associated actuator and one or more biasing members disposed adjacent each connector, each biasing member configured to apply a biasing force to the connector; a drive system comprising: a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls delivery of the yarn to the needles in coordination with actuation of one or more selected actuators, the actuation of the one or more selected actuators engaging the needles according to a forming pattern and moving the gauge components associated with the yarn along the second direction between a no stitch position and at least one extended position relative to a stroke of the needle into the backing to form a tuft of yarn in the backing; 1. A tufting machine comprising: a tufting machine having a tufting member and a connector coupled to the one or more selected actuators, the one or more biasing members biasing the associated gauge parts toward a retracted position and against the biasing force applied to the gauge parts by the one or more biasing members; and upon deactivation of the one or more selected actuators, the one or more biasing members bias the associated gauge parts toward at least one of their extended positions. (Item 24) and at least one module to which at least some of the gauge components are attached, the at least one module comprising: a modular body adapted to be mounted along a gauge bar, the modular body having a passageway defined therethrough, the modular body being formed from a metal, a polymer, a composite or synthetic material, or a combination thereof, and having a first hardness; an insert disposed along the passage; Equipped with each of the inserts having a slot configured to slidably receive at least a portion of one of the gauge parts; Item 24. The tufting machine of item 23, wherein the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body. (Item 25) 24. The tufting machine of claim 23, wherein the drive system further comprises at least one linkage extending between each of the connectors and its associated actuator, each of the connectors comprising a body having a first end in which a first end of a corresponding gauge part is received and a second end connected to the at least one linkage, and wherein the one or more biasing members of each connector assembly are disposed between the second end of each connector and a spring plate. (Item 26) 26. The tufting machine of claim 25, wherein the actuator comprises a motor, and each linkage comprises a cable, wire, rod or belt and includes a first end adapted to connect to one of the connectors and a second end coupled to one of the motors. (Item 27) 24. The tufting machine of claim 23, wherein the actuator comprises a hydraulic cylinder, a pneumatic cylinder, a stepper motor, a servo motor, an electric cylinder, a linear actuator, a moving coil or voice coil actuator, a solenoid, or a combination thereof, and further comprises at least one linkage coupled between each connector and its associated actuator. (Item 28) the at least one linkage comprises a cable, wire, rod, or belt, extends through a plate disposed adjacent the actuator, and includes a first end coupled to one of the connectors and a second end coupled to the associated actuator; to retract the selected gauge parts, the associated actuator retracts the at least one linkage coupled to each of the selected gauge parts, thereby causing the selected gauge parts to move toward a retracted position and compressing at least one of the one or more biasing members; 28. The tufting machine of claim 27, wherein to extend each of the selected gauge parts, the at least one biasing member is enabled to extend the at least one linkage to reduce compressive force and move each of the selected gauge parts toward their extended positions. (Item 29) 24. The tufting machine of claim 23, wherein the actuator comprises motors, each of the motors having a drive member with at least one linkage coupled to an associated gauge part, each linkage adapted to convert rotational motion of the drive member by that motor into linear motion for moving the associated gauge part in the second direction, the linkage comprising a cable, rod, arm, wire, belt, or combination thereof. (Item 30) 24. The tufting machine of claim 23, further comprising a shift mechanism for shifting the at least one needle bar laterally across the backing, wherein the control system further comprises a program for providing a series of yarns to selected stitch locations along the backing and drawing out non-selected yarns by coordinating the shifting of the at least one needle bar by the shift mechanism, the feeding of the backing, control of the actuator coupled to the gauge components, and control of the at least one yarn delivery mechanism that delivers the yarn to the needles as the needles are shuttled in and out of the backing, wherein such loops of non-selected yarns are not picked up by one of the gauge components, and the backing moves through a tufting zone at an actual stitch rate that is greater than a pattern stitch rate of the pattern being formed, providing the backing with a number of retained tufts per inch approximately equal to the pattern stitch rate of a face yarn. (Item 31) 24. The tufting machine of claim 23, wherein actuation of the one or more selected actuators causes the connector coupled to the one or more selected actuators to move against the biasing force applied thereto by the one or more biasing members to incrementally move the associated gauge part toward a retracted position. (Item 32) 1. A method for forming a tuft of yarn in a backing, the method comprising: moving the backing along a path of travel through a tufting machine; feeding different colors or types of yarn to the needles as they are shuttled within the backing to provide yarn for pick-up by a plurality of loopers or hooks; reciprocating said plurality of loopers or hooks toward said needles as said needles are reciprocated within said backing; placing at least some of the plurality of loopers or hooks in a retracted or extended position to avoid picking up loops of yarn from the needles or to pick up loops of yarn having one or more selected lengths to form tufts of one or more pile heights; at each stitch location where a loop of the provided yarn should not be picked up from one or more selected needles by one or more loopers or hooks, moving the one or more loopers or hooks to a position sufficiently retracted to avoid picking up a loop of yarn from the selected needles and controlling the feed of such yarn to pull back such yarn with those selected needles; at each stitch location where the provided loop of yarn is to be picked up by a looper or hook of a plurality of loopers or hooks, controlling the feeding of the picked up loop of yarn so that the loop is retained at each stitch location; Including, The method, wherein positioning at least some of the plurality of loopers or hooks includes controlling one or more selected actuators to incrementally retract or extend the corresponding loopers or hooks, moving the corresponding loopers or hooks between a fully extended position and a fully retracted, sutureless position through one or more intermediate incremental positions. (Item 33) Positioning at least some of the plurality of loopers or hooks may include retracting connectors disposed between each of the selected one or more actuators and their corresponding loopers or hooks in a first direction sufficiently to overcome a biasing force exerted against the connectors by a biasing member, and moving the loopers or hooks from their fully extended positions, through one or more of their intermediate incremental positions, as required, to the fully retracted sutureless position; said biasing force moving the connector in a second direction opposite to said first direction to allow said loopers or hooks to be extended as needed from their fully retracted sutureless position, through one or more of their intermediate incremental positions, to their fully extended position; 33. The method of claim 32, further comprising: (Item 34) 33. The method of claim 32, wherein incrementally extending or retracting at least some of the loopers or hooks comprises raising or lowering selected loopers or hooks relative to the needle stroke or penetration depth. (Item 35) 33. The method of claim 32, further comprising shifting at least a portion of the needles laterally across the backing. (Item 36) Item 33. The method of item 32, wherein moving the backing along the backing movement path includes feeding the backing at an actual stitch rate determined by multiplying the desired stitch rate by approximately the number of different colors or types of threads in a selected thread lift sequence. (Item 37) 1. A method of forming a tufted patterned article, the method comprising: delivering a backing along a path of travel; reciprocating a series of needles in and out of said backing; reciprocating a series of gauge elements disposed beneath the backing in a first direction toward and away from engagement with the needles to control a plurality of threads to be fed to the needles as the needles are reciprocated in and out of the backing and to pick loops of thread from the needles by at least some of the gauge elements; moving selected ones of the gauge components in a second direction substantially perpendicular to the direction of their reciprocating motion between a no stitch position in which no loop of thread is picked up and a plurality of extended positions relative to the stroke or penetration depth of the needle to position the gauge components at desired heights relative to the needle for picking up one or more varying lengths of thread loops; controlling yarn feed of each of the one or more variable length loops of yarn picked from the selected needle by a gauge element to selectively form tufts of variable pile heights according to a pattern, forming the tufts of yarn of the variable pile heights in the backing; Including, The method, wherein moving selected ones of the gauge parts in their second direction includes controlling one or more selected actuators to incrementally retract or extend the selected ones of the gauge parts between a fully extended position and a fully retracted, sutureless position through one or more intermediate incremental positions. (Item 38) Item 38. The method of item 37, further comprising shifting at least a portion of the needle laterally relative to the path of travel of the backing. (Item 39) Moving selected ones of the gauge parts in their second direction includes: retracting connectors disposed between each of the one or more selected actuators and the selected ones of the gauge parts downwardly relative to the biasing member sufficiently to overcome a biasing force exerted by the biasing member on the connectors, and moving the selected ones of the selected gauge parts from their fully extended positions, through their one or more intermediate incremental positions, and optionally to the fully retracted sutureless position; controlling said actuator to allow said biasing force to bias said connector upwardly, and extending said selected ones of said gauge parts from a fully retracted, sutureless position, through one or more of their intermediate incremental positions, and optionally to their fully extended position; 38. The method of claim 37, further comprising: (Item 40) 38. The method of claim 37, further comprising suturing at least some of the needles in a selected thread up sequence with a series of different colors or types of thread. (Item 41) Item 41. The method of item 40, further comprising shifting at least some of the needles laterally relative to the path of movement of the backing to provide a different color or type of yarn to each of a plurality of stitch locations, and wherein feeding the backing comprises moving the backing at an actual stitch rate determined by increasing a desired stitch rate of the patterned article by a number of different colors or types of yarn in the selected thread up sequence. (Item 42) 13. The method of claim 12, further comprising controlling the feeding of the thread to the selected needle so that if a loop of thread is not picked up by the selected one of the gauge parts that has been moved to a no-sewing position of the gauge parts, such thread exits the backing or is low enough to hold such thread against the backing. [Brief description of the drawings]

[0046] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate the 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 the structural details of the present disclosure in more detail than may be necessary for a basic understanding of the exemplary embodiments described herein and the various ways in which they may be implemented. Those skilled in the art will further appreciate and understand that, according to common practice, the various features of the drawings described below are not necessarily drawn to scale, and the dimensions of the various features and elements of the drawings may be enlarged or reduced to more clearly show the embodiments of the present disclosure described herein.

[0047] [Figure 1] FIG. 1 is a side view of one exemplary embodiment of a tufting machine having a selectively controllable looper assembly in accordance with the principles of the present disclosure.

[0048] [Diagram 2] FIG. 2 is a side view of the tufting zone of the tufting machine of FIG.

[0049] [Diagram 3] FIG. 3 is a perspective view of the tufting machine of FIGS.

[0050] [Figure 4] FIG. 4 is an exploded perspective view of an exemplary embodiment of a gauge module or gauge block and gauge components movable therethrough, and a gate or connector of a connector assembly connecting the gauge components to an actuator, according to the principles of the present disclosure.

[0051] [Diagram 5] 5A-5B are perspective views of a portion of a series of needles and their respective gauge components in one exemplary embodiment according to the principles of the present disclosure.

[0052] [Figure 6A]6A-6C are side views illustrating an embodiment of the operation of selectively actuatable gauge components according to the principles of the present disclosure. [Figure 6B] 6A-6C are side views illustrating an embodiment of the operation of selectively actuatable gauge components according to the principles of the present disclosure. [Figure 6C] 6A-6C are side views illustrating an embodiment of the operation of selectively actuatable gauge components according to the principles of the present disclosure.

[0053] [Figure 7A] 7A-7D illustrate an embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure. [Figure 7B] 7A-7D illustrate an embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure. [Figure 7C] 7A-7D illustrate an embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure. [Figure 7D] 7A-7D illustrate an embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure.

[0054] [Figure 8] 8A-8B are side views illustrating a variation of the embodiment of the drive system and connector assembly for controlling the movement of the gauge components of FIGS. 7A-7D.

[0055] [Figure 9A] 9A-9C illustrate a further embodiment of a drive system and connector assembly for controlling movement of gauge components in accordance with the principles of the present disclosure. [Figure 9B] 9A-9C illustrate a further embodiment of a drive system and connector assembly for controlling movement of gauge components in accordance with the principles of the present disclosure. [Figure 9C]9A-9C illustrate a further embodiment of a drive system and connector assembly for controlling movement of gauge components in accordance with the principles of the present disclosure.

[0056] [Figure 10] 10A-10B illustrate another embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure.

[0057] [Figure 11] 11A-11B illustrate another embodiment of a drive system and connector assembly for controlling movement of gauge components according to the principles of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0058] Referring now to the drawings, in which like numerals indicate like parts throughout the several views, FIGS. 1-9B generally illustrate an embodiment of a tufting machine 10 and method for forming a patterned tufted article in accordance with the principles of the present disclosure, in which the placement of stitches or tufts 5 of yarn Y can be controlled to desired locations within a backing B. Such tufts or stitches can be formed in a sculpted, multiple pile height tufted appearance and can be positioned with increased selectivity and / or control to form additional varying or free-flowing pattern effects. For example, tufted articles can be formed with tufts of yarn formed at various pile heights to provide a sculpted appearance and with various colors or types of yarn to form multi-colored patterns of various geometric and / or free-flowing designs. It will further be understood 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 tufted articles in multiple pile height patterns in accordance with the principles of the present disclosure.

[0059] As shown diagrammatically in FIG. 1, in one embodiment, a tufting machine 10 includes a frame 11, which may include a head or top 12 that houses a needle bar drive mechanism 13 and defines a tufting zone T. The needle bar drive mechanism 13 (FIGS. 1 and 2) includes a series of push rods 14, which may typically be connected by connector rods 17 to a needle bar drive mechanism 16 (such as a gear box / assembly) shown in FIG. 1 or a similar mechanism, which in turn may be connected to and driven by a main drive shaft 18 of the tufting machine, for example by one or more drive belts or drive chains 19, which main drive shaft 18 is itself driven by a motor, such as a servo motor. Alternatively, the push rods 14 of the needle bar drive mechanism 13 may be connected to the main drive shaft 18 via connector rods 17, so as to be driven directly from the main drive shaft or by a separate drive system (not shown).

[0060] An encoder or similar sensor may further be provided to monitor rotation of the main drive shaft and report the position of the main drive shaft to a control system 25 (FIG. 1) which controls the operation of the tufting machine 10. The control system 25 may generally comprise a tufting machine controller including a computer / processor or system controller 26 having an operator interface 26A, such as a touch screen, keyboard, mouse, etc., through which an operator may input patterns, make adjustments, etc. In some embodiments, the control system 25 may comprise or include a stitch distribution control system such as that disclosed in U.S. Pat. No. 8,359,989, the disclosure of which is incorporated by reference as if fully set forth herein, and the controller 26 further includes programming of control methods for forming tuft patterns, including a carved pattern having tufts formed at multiple pile heights, and various color / stitch placement control patterns as disclosed in U.S. Pat. No. 8,359,989.

[0061] The control system 25 generally includes programming that allows for monitoring and control of the operating elements of the tufting machine 10, such as the needle bar drive mechanism 13, the yarn feed attachment 27, the backing feed roll 28, the main drive shaft 18, the needle bar shift mechanism 40 (FIG. 3), and the gauge component assembly 30 mounted below the tufting zone T of the tufting machine, in accordance with calculated / determined pattern instructions, as will be described more fully below. The control system 25 (FIG. 1) can further receive and execute or store pattern information in a memory device of the system controller 26. In response to the developed / programmed pattern instructions, the control system 25 controls the operating elements of the tufting machine 10 to form a desired tufting pattern on the backing B as the backing passes through the tufting zone T by the backing feed roll 28 in the direction of arrow 33, as shown in FIGS. 1-3.

[0062] In some embodiments, the system controller 26 of the control system 25 can be generally programmed with instructions to form one or more desired patterns for one or more tufted articles, including a series of pattern steps, which steps can be created or calculated manually or by use of a design center or design software as will be appreciated by those skilled in the art, or can receive such patterns via input from a disk, USB or other external drive, or via a network connection. Alternatively, the controller 26 can include image recognition software to allow scanning and / or design pattern images, such as designed patterns, including pile heights and other characteristics, such as placement of loop pile and cut pile tufts in a pattern indicated by different colors or similar markers or indicators, and the designed pattern images, including photographs, drawings and other images, can be input, programmed, recognized and processed by the control system, including receiving input from a design center or through various design software systems, or through a scanner or other imaging device 31 (FIG. 1). The control system can recognize and identify various pattern characteristics, including color and / or texture differences in the designed pattern image, indicative of texture effects, such as placement or location of loop and / or cut pile tufts, and assign selected yarns thereto.

[0063] Additionally, in embodiments, the control system 25 may operate in conjunction with or may comprise or include a stitch distribution control system, as disclosed in U.S. Pat. No. 8,359,989 (incorporated as if fully set forth herein by reference). For example, but not by way of limitation, the control system may incorporate programming to provide the functionality of such a stitch distribution control system, or a separate stitch distribution control may be linked to it. The control system may also be provided with software / programming that allows for color reading and recognition of the input scanned pattern, and may assign feed locations of yarns fed from the feed creel to various of the needles based on the thread up sequence of the needles of the needle bar, optimizing the feed of the various colored yarns in the creel for their best use, forming a recognized pattern field from the pattern image. The control system may further include programming that allows for the creation of a pattern field or pattern mapping (including a mapping of a series of pattern pixels or tuft / stitch placement locations that identify the spaces or locations where various colored yarns and / or cut / loop pile tufts are selectively placed to form the imaged pattern). The desired pattern density, i.e., the desired number of stitches per inch that will appear on the surface of the finished patterned tufted article, can be selected, as well as the actual effective or working process stitch rate of the pattern calculated to achieve the desired fabric stitch rate appearance of the pattern.

[0064] The control system 25 of the present disclosure may further include programming for receiving, determining and / or executing various shift or cam profiles, or may calculate suggested shift profiles based on scanned, input, or other designed pattern images or pattern files. For example, in one non-limiting embodiment, a designed pattern file image, photograph, drawing, etc. may be loaded, scanned, or otherwise input at the tufting machine or a network connection, and the control system may read, recognize, and calculate pattern steps / parameters including control of yarn feed, control of backing movement and / or needle shuttle to form tufts in the backing at an effective stitch rate to achieve a desired pattern density, cam / shift profiles, and placement of yarns to match the scanned and / or designed pattern image, and then control the operation of the tufting machine to form this selected pattern. The operator may further select or modify the stitch rate, yarn feed, selected cam profile or calculated shift profile, such as by indicating whether the pattern should have 2, 3, 4, 5, 6 or more colors, or a desired number of pattern repeats, and / or may manually calculate, input and / or adjust or change the creel assignments, shift profiles and / or color mappings created by the control system as needed via manual override control / programming.

[0065] As shown in Figures 1-3, the tufting machine 10 further includes one or more needle bars 35 mounted to and driven by the push rod 14. The needle bar 35 moves a series of needles 36 in and out of the backing B in a reciprocating motion (indicated by arrows 37 / 37') to carry or insert the yarn Y into the backing. In some embodiments, the needles can be arranged in a single in-line row along one or two needle bars. In other embodiments, the needles 36 can be mounted in a staggered arrangement along a single needle bar or along a pair of needle bars, with offset rows of needles spaced laterally along the length of each needle bar and staggered across the tufting zone of the tufting machine. The needle bar 35 can be further laterally shiftable across the width of the backing to shift or step the needles 36 in a direction transverse to or generally perpendicular to the longitudinal path of travel through the tufting machine. Thus, although one exemplary embodiment may be shown in the figures including a single needle bar 35 with an in-line row of needles 36 disposed therealong, the present disclosure is not limited to the use of a single needle bar or any particular configuration of needles. Instead, those skilled in the art will appreciate that additional configurations of dual needle bars and single needle bars having spaced rows of needles 36 that may be disposed in-line or in a staggered or offset configuration, both of which may be further shifted, may also be utilized in a tufting machine 10 incorporating a system according to the present disclosure.

[0066] Each of the needles generally includes a shank or body 38 terminating in a pointed end 38A and includes a take-off point or area 39 where the gauge part 32 can engage the needle and pick up the yarn Y from the needle, as shown in Figures 5A-6C. As the needle reciprocates in a motion substantially perpendicular to the direction of arrows 37 and 37' (Figure 2), the needle is selectively engaged by the gauge part 32 of the gauge part assembly 30 to penetrate the backing B along the stroke to a desired or predetermined penetration depth, carrying therewith the yarn Y, and picking up a loop of yarn L from the needle, as shown in Figures 6A-6C. Additionally, as shown in Figure 3, a shifting mechanism 40 can also be linked to the needle bar 35 (or needle bars) that is used to shift the needle bar laterally across the tufting zone in the direction of arrows 41 and 41' according to calculated or computed pattern instructions. The shifting mechanism 40 may include a Smart Step™ type shifter such as that manufactured by Card-Monroe Corp., or may include a variety of 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 or jute shifters operable separately from or in conjunction with the needle bar shifter to shift the backing laterally relative to the needles.

[0067] As further shown in FIG. 1, one or more yarn delivery mechanisms or attachments 27 can be mounted to the frame 11 of the tufting machine 10 to control the delivery of yarn Y to each needle 36 during operation of the tufting machine. For example, as shown in FIG. 3, a series of different types or colors of yarn (Y1-Y4) can be delivered to each of the needles in a selected threading sequence or series (e.g., ABCD), with the threading sequence generally being determined or selected based on the pattern being run. Additionally, while one yarn delivery unit 27 is shown along one side of the tufting machine 10 (for illustrative purposes), in other embodiments, multiple yarn delivery units can be mounted to one or both sides of the tufting machine for delivering yarn to the needles 36 of one or more needle bars 35.

[0068] There are a variety of yarn feed attachments that can be utilized with the stitch distribution control system of the present disclosure to control the feeding of different yarns Y to various ones of the needles 36. The pattern yarn feed attachment or mechanism 27 (FIG. 1) has a series of rolls that extend at least partially along the tufting machine and can include conventional yarn feed / drive mechanisms such as a roll or scroll pattern attachment driven by a motor under the direction of a control system 25 to control the feeding of the yarns across the tufting machine to form pattern repeats and / or multiple pile heights and / or other texture effects across the width of the backing. Such yarn feed mechanisms or attachments can include Quick Thread™, Enhanced Graphics™, and / or multi-pile height scroll yarn feed controls / attachments manufactured by Card-Monroe Corp.

[0069] In some embodiments, a pattern yarn feed attachment can be used, each having multiple yarn feed drive mechanisms 45 including a motor 46 and feed roll 47 to control the feeding of a particular set of repeated yarns to selected needles, as shown in FIG. 1, and including the use of individual yarn feed rolls or drive mechanisms 45 to control the feeding of a single yarn (or end) or multiple yarn ends (i.e., 2-4 or more yarns) to needles 36, such as the single-end and multi-end / servo scroll attachments including the Infinity™ and Infinity IIE™ systems manufactured by Card-Monroe Corp. Thus, while a yarn feed such as a single or multiple end type yarn feed mechanism 27 is shown in Figure 1, those skilled in the art will appreciate that the pattern yarn feed mechanism utilized to control the yarn feed can include single or double end yarn feed controls, scrolls, rolls, and / or similar attachments, and / or various combinations thereof, and can be mounted along one or both sides of the tufting machine. Still further, in an embodiment, the control system 25 can include programming to perform yarn feed compensation and / or yarn feed modeling to help control and reduce or minimize the amount of unretained / non-emerging yarn that is fed to avoid overfeeding of the yarn and thus minimize waste during the tufting operation.

[0070] The yarn delivery attachments, in cooperation with other operating systems of the tufting machine, including backing feed, needle bar shifting, and operation of the gauge component assembly 30, can be controlled to selectively feed yarns to their respective needles, allowing for the provision of several different colors or types of yarns to the backing, and the control of selective pick-up and retention of selected or desired yarn loops of the provided yarns (e.g., yarns selected to appear on the surface of the finished patterned article) to form tufts of such yarns having a selected or desired pile height. Furthermore, surface or face yarns or tufts that appear on the surface of the tufted article can be controlled to be delivered in sufficient quantities to form such tufts of selected colors or types of yarns at a desired or prescribed pile height, while non-appearing yarns that are to be hidden in certain color and / or texture fields of the pattern are not picked up by the gauge components to avoid such yarns interfering with the surface yarns or retained tufts that are to be visible in the pattern fields, and to avoid undesirable spaces or gaps between the retained tufts or face yarns.

[0071] In an embodiment, each color or type of yarn that can be placed / tufted at each pixel or stitch location can generally be provided at such pixel or stitch location for tufting, and only the yarn selected to be displayed or that appears at the pixel or stitch location is held to form the desired pile height. Thus, for a four-color pattern, for example, each of the four color yarns A, B, C, and D that can be tufted at a particular pixel or location can be provided at such pixel with only the selected yarn or yarns of the pattern, e.g., the "A" yarn, and the remaining non-selected yarns, B, BC, BD, and / or other combinations, can be provided to generally avoid forming loops of such yarns at such pixel or stitch location, and cannot be picked up by the gauge components in a low, non-stitching position, with controlled yarn feed to pull such yarns out by their needles. In some cases, if loops of yarns are picked up, they can be pulled back to a sufficient degree to further tack or hold the yarns with the backing, but without disturbing the placement of the held yarns at such pixel or stitch location, etc. Thus, when a yarn is provided at a pixel or stitch location, if the yarn is held or appears at the pixel or stitch location, the yarn feed 27 can be controlled to feed an amount of yarn to form a tuft of yarn at the pixel or stitch location. If a yarn is not selected for insertion at a particular pixel or stitch location, the gauge component can be controlled to be moved to a no-stitch position that does not pick up the loop of yarn provided at the particular pixel.

[0072] As further shown in FIGS. 1-3, the gauge component assembly 30 is generally mounted below the bed 34 and tufting zone T of the tufting machine 10. As the needles penetrate the backing, they are engaged by a series of gauge components 32 of the gauge component assembly 30 to form loops L (FIGS. 2-3) of yarn Y to form a tuft 5 of yarn of a selected length or pile height of a selected color or type. The gauge components 32 of the gauge component assembly 30, in various embodiments, can include a series of loopers or hooks 50, each of which can be mounted along a gauge module, gauge block, or other holder that can be mounted along a gauge bar 52 or similar mount or attachment for coupling the gauge components to a drive mechanism such as a pivot arm 53 that can be driven from the main drive shaft of the tufting machine, or can be driven by a separate motor / drive mechanism for reciprocating the gauge components in a first direction toward and away from engagement with the needles 36, as shown by arrows 54 and 54' in FIGS. 1-3. Additionally, one skilled in the art will appreciate that various types of gauge components may be used including cut pile hooks, loop pile loopers, level out loop loopers, cut / loop clips, or other gauge components.

[0073] As shown in FIG. 4, in one embodiment, the gauge components 32 can include loopers or hooks 50 each having an elongated body 55 that can be slidably mounted within and moveable through the gauge module 51. The body 55 of each looper or hook 50 includes a first portion 60 and a second portion 61 that includes an elongated throat 62 that, in one embodiment as shown in FIG. 4, can generally extend at an angle relative to an intermediate portion 56 of the body 55 and can terminate in a generally pointed proximal end or bill 63. For example, the throat 62 and proximal end 63 can be configured similarly to a loop pile looper. Other configurations of the gauge components can also be used. 4, a first portion 60 of the body of each looper or hook 50 generally projects through the gauge module or block 51 and may have a slot or recess 64 formed therein by which the loopers or hooks may be individually (or in pairs or groups) engaged and / or coupled to a drive system 65 for controlling selective movement of one or more of the gauge parts. In an embodiment, the drive system 65 / 150 may include actuators 66 (FIG. 2), each of which is connected or coupled to a corresponding or associated one of the gauge parts by a gate or connector 67 (FIG. 4) of a connector assembly 70.

[0074] FIG. 4 shows one exemplary embodiment of a gauge module or gauge block 51 including a body 75 that can have a substantially rectangular or square configuration as shown, although other configurations can be used to receive a series or set of gauge components 32, such as loopers or hooks 50. In some embodiments, the module body 75 of each gauge module 51 is formed from a metal or metal alloy material, although various composite, synthetic and / or other materials can also be used. For example, but not limited to, the body of the gauge module can be made from mild or tool steel, or light steel such as aluminum, or other similar light but substantially stiff and durable materials. In embodiments, the module body can be machined, molded, or cast or otherwise formed. The material from which the body of the gauge module is formed can further be selected to provide a reduced weight of the gauge module while still providing sufficient durability and rigidity to hold and / or substantially maintain their alignment or gauge components in position to engage the needle pick-up portion during reciprocating movement of the engaging and disengaging gauge components during operation of the tufting machine.

[0075] As shown diagrammatically in FIG. 4, the module body 75 of each gauge module 51 includes a first forward or front portion 76 and a second rearward or back portion 77. The back portion 77 of the body 75 of each gauge module 51 is more generally configured to engage and attach to a gauge bar such as that shown in FIG. 3. For example, the back portion of the body can include tabs or other positioning devices 77A for aligning the gauge module along the gauge bar, and further includes at least one fastener opening 78. To releasably attach the gauge module 51 to the gauge bar, a removable fastener, such as a socket, hex screw, or other similar removable fastener or attachment device, is inserted through the fastener opening 78 and into a corresponding opening in the gauge bar. As a result, in some embodiments, the gauge module, with their gauge components included, can be removed and replaced as a unit without necessarily having to replace individual gauge components, for example, to facilitate replacement of broken or damaged gauge components or to change gauge spacing or alignment of the gauge components of a tufting machine.

[0076] 4, a fastener 79A, such as a bolt, or other similar removable fastener, can extend through the needle bar or a block or other portion attached to the needle bar and can be received within a sleeve or guide member 79B, which can further include an upper portion that protrudes through the body 75 of the gauge module 51. The fastener can include a threaded body that engages with the body of the module to secure the module body to the needle bar while allowing for removal and replacement of the gauge module as needed.

[0077] As further shown in FIG. 4 , a passageway 80 is generally formed through the body 75 of each gauge module 51, with the passageway 80 generally disposed along an intermediate portion 81 of the body between its first and second portions 76 / 77. The passageway 80 is sized and / or configured to receive a plurality of gauge components, such as loopers or hooks 50, therein. In an embodiment, the body 55 of each of the loopers or hooks 50 is generally received within and extends therethrough, with a first portion 60 of each of the loopers or hooks generally projecting downwardly beyond a lower or bottom surface 82 of the module body 75 and a second portion 61 of each looper or hook generally extending / projecting upwardly from a top or upper surface 83 of the module body 75.

[0078] Additionally, one or more inserts 85 may be mounted on both sides, e.g., top and bottom, of each module body at positions or locations aligned along a passageway 80 defined throughout the body of each gauge module, as generally shown in FIG. 4. The inserts are configured to engage and guide the gauge components as they are moved along and through the passageway of the gauge module body. For example, in an embodiment as shown in FIG. 4, a pair or set of inserts 85A and 85B may be provided, with one of the inserts (e.g., a first insert 85A) mounted along a first left or front side 80A of the passageway 80 and one of the inserts (e.g., a second insert 85B) mounted along a second right or rear side 80B of the passageway 80, each of the inserts 85A and 85B generally disposed in a substantially facing, opposed, parallel relationship in which the gauge components 32 may engage and move between them. In some embodiments, a pair of first inserts can be mounted along the top and bottom surfaces of the module body along a first or left side of the passageway, and a pair of second inserts 85B can be mounted along the top and bottom surfaces of the module body along a second or right side of the passageway.

[0079] Each of the inserts 85 is generally formed from a hardened metal or metal alloy material, a metal carbide, a ceramic, and / or a powdered metal material including metal powders including tungsten, titanium, or other material that may have a hardness greater than the hardness of the material of the gauge module body. For example, in some embodiments, the inserts may be formed from a metal carbide material having a hardness of about 74+RC or greater and the module body may be formed from mild steel. In other embodiments, the inserts may be formed from ceramics, powdered metal materials including tungsten, titanium, or similar hard metal components, metal carbides, or other materials having a hardness of about 74+RC to about 85+RC or greater.

[0080] Each of the inserts 85 may further include an insert body 86 having a tab or flange portion 87 extending either forwardly or rearwardly from the passageway of the gauge module body and generally located and engaging the top and bottom surfaces 83 / 82 of the module body. Each of the inserts 85 may also include at least one opening or slot 89 formed along the tab or its flange portion through which a fastener, such as a set screw 90, or other similar removable fastener, may be received. The slot or opening 89 formed in the tab or flange insert may generally align with a corresponding slot or locator opening 91 formed along the top and / or bottom surfaces 83 / 82 of the module body to aid in positioning and attaching each insert to its module body and along its gauge module passageway. The inserts may be shifted laterally across the module body substantially parallel to the passageway 80 and may further be adjusted toward and away from one another across the passageway of the gauge module body after which fasteners may be inserted therein and tightened to secure the inserts 85 to their module bodies. Additional locator guide pins 92 may further be received in slot or locator openings formed along the flange or tab portion 87 of each insert to further aid in positioning the insert along and across the passages of the module body as desired.

[0081] In additional embodiments, the inserts 85 can be substantially integrated with their modules. The inserts can be bonded, molded, encapsulated, and / or otherwise secured to the body of their modules, with the inserts being substantially integrated with the module body to form a substantially unitary structure of the module body, with the inserts forming or defining a portion of the passageway. For example, in some cases, the inserts can be placed or received within the passageway of the module body and substantially permanently attached thereto, while in other embodiments, the inserts can be machined, molded or cast as part of the module body itself, define the looper or hook passageway and slot, and can be coated or treated with a hard metal coating, such as a carbide or other substantially wear-resistant coating. In such cases, the gauge components can be provided in pairs with their gauge modules, and can be replaced as a pair by removing and replacing or substituting the gauge modules and gauge components as a unit. In other embodiments, the inserts can be substantially engaged or locked to their modules, with limited ability to remove or remove one or more of the inserts as needed for utility.

[0082] As further shown in FIG. 4, the inserts further generally include a series of spaced apart serially disposed slots or slits 95 along the body 86 of each insert along its rear portion 88. Each of the slots 95 is generally sized or configured to receive a gauge component 32, such as a hook or looper 50, as shown in FIG. 4. The slots 95 of the inserts are also generally disposed at selected intervals, such as the gauge intervals of the gauge components, such that each slot 95 of the first insert 85A is generally aligned with a corresponding or associated one of the slots 95 of the second insert 85B. The aligned, corresponding or associated slot of each insert receives at least a portion of the body of each gauge component received therein, e.g., a portion of the leading edge 55A and the trailing edge 55B of the body 55 of each looper or hook 50, such that the inserts define a reduced or minimized area or contoured contact area 98 between the gauge module and the looper or hook.

[0083] In some embodiments, the ends 96 of the slots 95 can be substantially formed to define a seat or support surface against which the first and second edges of each of the loopers or hooks received in each slot can be placed, and supported for mounting the loopers or hooks within the insert and then securing the insert to its respective gauge module with the loopers or hooks received therein. The slots of the inserts help guide the loopers or hooks as they are extended, retracted, or otherwise moved through the passages of their gauge modules, and maintain alignment of the loopers or hooks (and thus the throats and bills of the loopers or hooks) with the needles (the needles as they reciprocate in and out of the backing and are engaged by the loopers or hooks).

[0084] In an embodiment, each of the inserts may include an insert body 86 having a first top or upper portion and a second lower or bottom portion with a middle portion extending therebetween and connecting the first and second portions of the body of each insert. At least one of the upper and / or lower portions of the body of each insert may be further formed as a tab or flange extending forward or rearward from the middle portion and passage of the gauge module body, generally covering and engaging the upper and lower surfaces 83 / 82 of the module body and helping to position and secure each insert within the passage of the gauge module. Thus, the first and second inserts 85A / 85B may have a substantially unitary structure including upper and lower portions with their slots extending through their upper and lower portions and along the middle body portion to allow further engagement and guiding of at least a portion of the first and second edges of the looper or hook. In embodiments, the inserts can be machined, molded or cast to have a substantially unitary body, which allows for a reduction in parts and can increase the contact points / area between the inserts and the loopers or hooks for improved consistency and / or control of movement while reducing the need for separate inserts along the top and bottom surfaces of the module body and both sides of its passageways.

[0085] Alternatively, the first, second and intermediate body portions of each insert can be formed as separate components and attached together along the passageway of the module body. For example, in some embodiments, intermediate guide or bearing plates can also be used to help guide the movement of the loopers or hooks, with the guide or bearing plates extending along the passageway between the inserts disposed along the top and bottom surfaces of the module body. Such guide or bearing plates can provide a body or surface on which the first and second edges or leading and trailing edges of the loopers or hooks can ride / slide as they move along the passageway of the module body. The guide or bearing plates can also function as connecting members or parts between the inserts or each pair or set of inserts. Such guide or bearing plates may be formed from a similar hardness material (e.g., metal or carbide, powdered metal or other hardness material, or a material that may be hardened or coated or bonded with a material that has increased or reduced wear resistance) and may provide a hardened surface against which one or both of the looper or hook edges can slide, or in some cases may be easily replaceable and function as a sacrificial plate to protect the module body along the sides of the passageway.

[0086] During operation of a tufting machine as disclosed in the embodiments of the present disclosure, loopers, hooks, or other gauge components are moved in multiple directions, including reciprocating or moving in a first direction to engage and disengage with needles, while also moving in a second direction through their gauge modules or gauge blocks, for example, between a raised or extended position to engage with needles and a lowered position (including a no stitching position). In some operations, the gauge components can be moved after a loop of yarn has been picked from the needle, for example, to form an extended or longer loop. Thus, the tufting machine allows for the formation of highly detailed tufting patterns that can include various pile heights and other carved and multi-color pattern effects. However, such repeated cyclical movement of the gauge components can cause significant and rapid wear of the gauge components, particularly the gauge modules, as the loopers, hooks, or other gauge components slide and frictionally engage their edges with the body of the modules. As these components wear, their ability to engage the needles, form loops of yarn, and form tufted patterns with substantial precision can be reduced. For example, the gauge components may become misaligned and / or may not engage the needle properly or with a desired level of precision, requiring more frequent replacement of the gauge components / gauge modules.

[0087] The use of metals (such as high hardness heat treated steels), metal carbides, ceramics, and / or other high hardness metallic materials, including powdered metals including tungsten, titanium or other similar high hardness materials, providing an insert with a hardness of at least 75+RC or greater, and the configuration of the insert to define a contact area 98 between the looper or hook and the gauge module with a minimized area or profile, substantially increases the wear life of the gauge module and the looper or hook. The high hardness of the insert protects the gauge module from direct contact and rapid wear with the gauge module as the looper or hook cycles through the gauge module, while the reduced size of the contact area 98 defined by the insert is configured to reduce frictional engagement of the insert with the looper or hook while substantially consistently guiding and maintaining alignment of the looper or hook during such movement. The looper or hook may also generally be pre-cured or heat treated to harden the looper or hook body, and in some embodiments, the surface of the looper or hook body may be coated, treated or bonded with a reduced friction material to help reduce friction between their edges 55A / 55B that engage and slide along the slots of the insert, and thus help extend their wear life. Other coatings that may be applied may include materials with enhanced wear resistance to help protect the looper or hook from wear during use. For example, in some applications, the wear life of the looper or hook has been found to exceed 50 to 100 million machine cycles, and in some embodiments, at least about 100 to 500 million cycles or more.

[0088] The increased hardness of the insert protects the gauge module and allows it to be formed from a substantially lighter, lower hardness material, such as mild steel, aluminum, or alloys thereof. For example, instead of requiring the gauge module to be formed from a substantially higher hardness material, such as tungsten, and / or to be substantially heat treated to significantly increase its hardness, the gauge module can be machined, molded, or cast, or otherwise formed from a lightweight metal, composite, or other similar material having a hardness that can be substantially lower than that of the insert (e.g., the body of the gauge module can be formed from mild steel or aluminum alloys having a hardness of less than about 60RC), which helps to reduce the weight and cost of the overall gauge component assembly without reducing operational cycle performance. Such reduction in weight of the gauge module or block can further provide enhanced control of the movement of the loopers through the passages of those gauge modules, and the reciprocating movement of the loopers or hooks toward and away from the needle, for example, by reducing inertia that may need to be overcome during the reciprocating movement of the loopers or hooks toward and away from the needle.

[0089] In one embodiment, as generally shown in FIG. 2 and FIG. 6A-6C, the actuators may comprise hydraulic, electric, or pneumatic cylinders 68, and in some embodiments may also comprise motors such as servo motors, stepper motors, linear actuators, voice coil or moving coil actuators, solenoids, or other types of actuators, and / or combinations thereof. Each of the actuators may include a cylinder rod or drive shaft 69, which is generally connected to an associated or corresponding one of the loopers or hooks by a connector or gate 67. In some embodiments, actuators may further be used to control the operation of multiple loopers or hooks 50. Additionally, as will be appreciated by those skilled in the art, other types of actuators may also be used, including solenoids, motors, or other similar actuation mechanisms.

[0090] Each of the actuators is generally coupled to a control system 25 that selectively controls the actuation of the actuators to control the firing and / or movement of each looper relative to the needle. The actuators are controlled to selectively extend and retract the loopers or hooks so that the position of their throats / bills can be changed in a second direction with respect to the reciprocating movement of the needle in and out of the backing and with respect to the movement of the loop looper or hook 50 in the direction of arrows 54 / 54'. For example, in an embodiment, the looper or hook will be moved in a substantially vertical (i.e., generally up and down) motion relative to the needle as shown by arrows 54 and 54' in Figures 2, 5A-5B, and 6A-6C as the looper or hook reciprocates in the direction of arrows 71 and 71' toward and away from engagement with the needle 36. Not only can the actuators be controlled to extend and retract the loopers or hooks between an extended position and a sutureless position, but they can also be selectively controlled to extend and / or retract the loopers to a series of varying positions or heights with respect to the stroke or penetration depth of the needle. Thus, the position or location of the looper or hook throat relative to the needles can be controlled and varied to pick up and / or form loops of yarn from selected ones of the needles at various pile heights or lengths, or no yarn pick-up, as shown in Figures 6A-6C.

[0091] For example, in the fully extended position, selected ones of the loopers or hooks 50 can pick up loops of yarn from needles engaged thereby, which loops can generally be formed at a first selected or desired pile height, while others of the loopers or hooks can be extended or retracted to positions or locations between the fully extended and retracted positions to pick up and form loops of yarn at a second or other different length or pile height. Some of the loopers or hooks can also be moved by their actuators to a fully lowered or retracted position to place them in a no-sewing position, whereby the throat / bill of such loopers or hooks is positioned below the end of the needle's full penetration depth or stroke and therefore will not pick up loops of yarn from their corresponding or respective needles. In other operations, after loops of yarn are captured, by selectively controlling or triggering the actuators to retract (or lower) their respective loopers or hooks, the captured loops of yarn can be pulled lower to elongate or create a higher pile or longer length of yarn for additional patterning effects such as tip shear and / or other texturing effects.

[0092] As shown in Figures 5A-5B, each of the gauge components 32, such as loopers or hooks 50, can be arranged in a set or group, each included in a module 51, with the modules mounted in series along the gauge bar to provide a plurality of gauge components spaced at predetermined intervals (e.g., 1 / 10, 1 / 8, 5 / 16, etc. gauge intervals) across the tufting zone. The gauge components 32 are positioned to engage the needles (including being positioned substantially in-line, offset, staggered, and / or in other configurations as needed depending on the configuration of the needle bar or needles on the needle bar (e.g., if the needles are arranged in line, staggered, and / or in other configurations along a single or double needle bar)). Each of the loopers or hooks 50 can further be positioned at an angle or offset relative to the needles penetrating the backing such that they move along an angled path of travel 71 / 71' or are extendable / retractable relative to the needles and / or their removal points. Such offset movement of the looper or hook can be further varied as needed depending on the needle spacing and / or placement to minimize potential engagement of the looper or hook by the needle as the looper is being retracted.

[0093] For example, in some embodiments, the looper or hook may be positioned and / or moved along the path of travel at an angle / offset, indicated by θ in FIG. 5B, which may range from about 1° to about 10° or more from vertical and / or relative to the stroke of the needle when the looper or hook is retracted, and one exemplary embodiment is at an angle of about 4° to 6° relative to the path or direction of reciprocation of the needle as it completes its stroke or reciprocation in and out of the backing, while in other embodiments, substantially no offset may be provided between the looper or hook and the needle, i.e., an angle of about 0° may be substantially provided relative to the needle. Thus, when a looper or hook is extended to a sufficient position / height to engage the needle pick-up area 39 (FIGS. 5A-6A), its throat / bill is generally properly aligned or positioned to engage and pick up a loop of yarn from a corresponding needle. As the loopers or hooks are retracted, they may be moved further along an offset path of travel so that, in general, their throats / bills can be installed or positioned at a location outside the needle path of travel to minimize potential inadvertent thread pick-up when the loopers or hooks are retracted and / or in the retracted no-suture position.

[0094] 4 further illustrates a non-limiting embodiment of a gate or connector 67 that can be used with gauge components such as loopers or hooks 50 (FIG. 4) to couple the gauge components to their associated actuators 68 / 151 (FIGS. 2-4 and 7A-11B). However, it will be understood by those skilled in the art that the connectors or gates illustrated in any of the embodiments described herein are not limited to use with a particular tufting type machine or a particular type of gauge component, but can be used with a variety of different types of gauge components, including loopers or hooks 50 as illustrated in FIGS. 2-6C and 7A-11B, and can be used with a variety of other types of gauge components, such as level cut loop loopers or hooks and / or other gauge component arrangements.

[0095] As generally shown in FIG. 4 , each of the connectors or gates 67 generally includes a housing or support structure 101 in which a connector arm 102 can be substantially contained, enclosed, or housed. The housing 101 of each connector or gate generally includes a first or proximal portion 103, an intermediate portion 104, and a second or distal portion 106. Additionally, each connector body further includes a passageway or channel 107 defined therethrough along which the connector arm 102 can be received and moved. The housing 101 of each connector 67 generally can be formed from a lightweight, durable material such as a composite, plastic, or synthetic material, or combinations thereof. For example, a composite or polymeric material such as nylon, polyamide nylon, or other similar polymeric material can be used, and can be mixed with or provided with or include a fiber-filled material such as carbon fiber, glass fiber, or other supporting fibers that can provide additional reinforcement to the housing body material. The housing material can further be adapted or selected to reduce weight to help reduce inertia during start / stop and movement, e.g., extension and / or retraction of the gauge parts by their associated actuators, as well as provide resilience and shock reduction or damping or cushioning effect during such movement and start / stop operations.

[0096] In some embodiments, the housing 101 of each connector can be overmolded onto its connector arm 102 or can be formed in part and applied around the connector arm such that the connector arm is substantially enclosed or contained therein. The connector arms 102 can further be made from a metal, such as steel or other similar high strength material, selected to provide sufficient high strength and rigidity to enable each connector arm to withstand repeated impacts and increased movement cycles during operation of the tufting machine. For example, but not limited to, the connector arms 102 can include hardened steel material and, in some cases, can be further heat treated or annealed, such as at their ends, areas of contact and / or engagement with loopers or hooks, and between each connector arm and the drive shaft or rod 69 of the associated actuator or actuators 68 as shown in FIG. 4. In embodiments, a bushing or sleeve can also be provided in the areas of contact or engagement and connection between the drive shaft or rod of each actuator and its associated gate or connector arm.

[0097] In some embodiments, the connector arm 102 can further include a skeletonized metal body configured to allow for a reduction in its weight. In such embodiments, the housing 101 of each connector or gate can provide additional support and rigidity to the connector arm 102, helping to guide and maintain its consistent reciprocation or motion during operation. As a result, the connector or gate 67 can provide a more economical connector or gate design, allowing for a skeletonized or reduced profile and lighter weight linkages or connector arms to be used with the additional support and impact resilience and damping effects provided by the housing 101 of each connector or gate applied over and / or enclosing or encapsulating the linkages or connector arms.

[0098] In various embodiments, each of the connectors or gates 67 can be formed with a variety of sizes and configurations. For example, the middle portion of each connector housing can have a shorter or longer span depending on the gauge, distance, length of travel, or length of the connector arm, and thus can be modified for different tufting machines and / or tufting applications. By way of example only, in embodiments, the connectors or gates can include various configurations for use with different gauge tufting machines, such as 1 / 8 gauge or 1 / 10 gauge machines, although it will be understood that other gauges (5 / 16, 1 / 16, 1 / 12, 1 / 14, etc.) and / or types of machines can also be used. The middle portion of each connector housing can further be oriented at an angle, in some cases oriented at an angle extending downward, and in other cases oriented at an angle extending upward, with adjacent connectors being of opposite angle orientations or configurations to minimize the space or footprint occupied thereby.

[0099] Additionally, the connector arms 102 of each connector or gate 67 can be formed in various lengths as needed or desired. Each linkage generally has a first or proximal end 110 that can be adapted or configured to engage or connect to one or more actuator shafts or drive rods of an associated one or more actuators, and has a generally angled body portion or portion 111 that extends through the connector housing along a housing passage or channel 107 and terminates at a distal, flanged or hooked end 112. The body portion 111 of each linkage is further disposed and / or aligned within and enclosed within its housing passage, which helps provide stability and / or helps guide movement of the linkage along its connector housing channel.

[0100] For example, in some instances, pins or other inserts can be used around or on the linkages during formation of the housings to align and support the linkages in place, and the pins can be removed thereafter. Alternatively, several guide pins (including or acting as bearings) can be provided to help maintain and guide movement along one or more portions of the connector arm. Additionally, in some other embodiments, slots can be provided along the body of each housing through which guide pins can be received to help guide movement of the linkages, and can further help provide additional impact resiliency.

[0101] In additional embodiments, guide pins or catches can be inserted through the housing along with similar means to help guide and control or maintain movement of the linkage along the slots or guideways or along the passages or channels of the connector housing without twisting, turning or becoming misaligned. In yet other embodiments, a pivot pin can be provided about which the connector arm can move or pivot rather than being moved substantially linearly.

[0102] As further shown in FIG. 4, the distal hook end 112 of each of the connector arms 102 can be supported along at least one side of the distal hook end 112 by a second or distal portion 106 of its connector housing 101, which can help guide and support the hook end during sliding movement of the linkage. The hook-shaped end of the connector arm engages with a corresponding hook-shaped portion, recess or slot of a corresponding gauge component. For example, in an embodiment, it engages with a slot or recess 64 formed in the first portion 60, or a distal end of a corresponding or associated one of the loopers or hooks 50. In other embodiments, the hook-shaped end of the linkage can engage with a clip for a level cut looper, level cut loop looper, or other movable gauge component. When each actuator is selectively fired or activated / deactivated, the movement of its actuator shaft or drive rod is transferred to an associated one of the gauge components via the connector arm of its corresponding connector or gate. Thus, the connectors or gates can provide an economical, rigid, high strength connection between each actuator and their associated gauge components, which can be removed or changed as needed without having to replace the actuators associated with them.

[0103] 7A-11B show further non-limiting embodiments of a drive system 150 for controlling the movement of a gauge component 32, such as a looper or hook 50 or other type of gauge component, in a second direction relative to the path or stroke of the needle as it reciprocates in and out of the backing. In the exemplary embodiments of FIGS. 1-6C, actuators such as electric, pneumatic, or hydraulic cylinders are generally shown, but one skilled in the art will appreciate that other types of actuators can also be used. For example, the drive system 150, actuator 151 shown in FIGS. 7A-11B is shown as including a motor 152, such as a stepper motor, torque motor, or other type of motor, but other types of actuators, such as a moving coil or voice coil actuator, an electric cylinder, a linear actuator, a solenoid, and / or combinations thereof, can also be used.

[0104] Additionally, as discussed above, the tufting machine control system 25 (FIGS. 7A and 9A) further includes programming for controlling the actuator 151 to control the movement of the gauge component 32 (e.g., looper or hook 50) in a second direction, for example, to control the movement of the gauge component between extended and retracted positions, including moving the gauge component in a generally vertical direction as indicated by arrows 71 and 71' to retract the gauge component to a fully lowered, no-sewing position, and for controlling variable positions or heights of the throat / bill of the gauge component. The use of actuators such as motors, electric cylinders, linear actuators, etc. that are not driven by compressed gas or fluid can substantially minimize or avoid the need for compressors typically required to drive other types of driven actuators, and can also allow for greater precision programming and control of the movement of the gauge component between different positions or heights. Thus, the gauge component can be moved in smaller increments between several positions or heights relative to the needle by control of such actuators. For example, and without limitation, the gauge member can be moved in increments ranging from about 1 / 32-1 / 16 inch to about 1 / 4-3 / 4 inch relative to the needle to position the gauge member in various positions to create yarn tufts of various pile heights, e.g., the gauge member can be moved vertically or in addition to the direction in which the gauge member reciprocates toward and away from the needle, about 1 / 16 inch, about 1 / 8 inch, about 1 / 4 inch, 1 / 2 inch, 5 / 8 inch, and / or to a fully lowered position where no yarn loops are picked up.

[0105] The control system 25 further includes programming that allows it to control one or more thread delivery attachments 27 in conjunction with or in correlation to the position of the looper or hook. In embodiments, such as where a single-ended or double / multi-ended thread delivery mechanism (e.g., Infinity™ thread delivery manufactured by Card-Monroe Corp.) is used, the motor 46 of each of the thread delivery drive mechanisms 45 can be controlled in cooperation with the control of the actuator 151 controlling the positioning of the looper or hook to minimize or prevent the thread tension of the thread captured by the looper or hook from varying substantially across the width of the pattern. In some embodiments, the control system can control the motor to control the second directional movement of the looper or hook relative to the needle 36, which movement can be based on a multiple or percentage of the amount of thread delivered by the thread delivery mechanism. For example, if a selected thread delivery motor is controlled by the control system to deliver approximately ½ inch of thread to a selected needle, the actuator corresponding to the looper or hook that engages such selected needle can move approximately ¼ in an inch. In other embodiments or examples, if the yarn feed motor feeds ¼ inch yarn, the corresponding looper or hook can be moved approximately ⅛ inch. Other multiples or variations of looper or hook movement in coordination or association with the feeding of yarn to selected needles can also be used, as desired, to substantially maintain yarn tension and substantially minimize or prevent its variation across the pattern width of the tufted pattern being formed.

[0106] 7A and 7C-7D, actuators 151 of drive system 150 are shown as including a series of motors 152 disposed under drive arms or mechanisms 53 (FIG. 7A) that carry gauge components 32 (or other gauge components), such as loopers or hooks 50, in a reciprocating motion in a first direction indicated by arrows 54 and 54', toward and away from engagement with the needle as the needle 36 is reciprocated in and out of the backing. Motors 152 may include servo or stepper motors or other programmable motors (as well as programmable drive mechanisms or actuators including electric cylinders, linear actuators or moving coil or voice coil actuators that can eliminate or reduce the need to pump fluid to a compressor to drive the movement of the gauge components) and are coupled to corresponding or associated ones of loopers or hooks 50 by connector assemblies 153.

[0107] As shown in FIGS. 7B-7C , each of the connector assemblies 153 includes a gate or connector 154 that can be connected to or receives the lower or distal end 64 of a gauge component. Each gate or connector 154 is further connected to one or more of the motors 152 via a linkage 156, such as a cable, rod, wire, belt, or other similar connector. In some embodiments, a pair of linkages 156 can be connected to each gate or connector 154. However, it will be understood by those skilled in the art that a single linkage or multiple linkages can be used to connect each of the gauge components to an associated or corresponding one of the motors 152.

[0108] As further shown in FIGS. 7B-7D, in an embodiment, the linkage 156 can extend through one or more guides 157 and through a spring plate or support 158. A biasing member 159 can be attached between the distal end of the connector and the spring plate 158. The biasing member can include a spring, such as a compression spring, wave spring, or other similar biasing member including a cylinder, arranged such that when the linkages of selected gauge components are retracted, their corresponding gauge components are pulled or lowered toward the retracted position and the biasing member is compressed. When tension in the linkage is released, such as by reversing the operation of a motor connected thereto or otherwise releasing the linkages from driving engagement with their motors, the biasing member exerts a biasing force against the gate or gauge component, thereby biasing the gauge components along their second direction, such as moving the gauge components toward their extended position or elevated height, when the biasing member reduces the compression force.

[0109] The motor 152 can further be controlled by the system controller to counter the biasing force applied by the biasing member and maintain a desired tension in the linkage as may be required to control the movement and / or positioning of the gauge component relative to the needle. Additionally, the motor can be controlled by the control system in conjunction with control of the yarn feed to further cause movement of the gauge component between a raised position where a loop of yarn is captured and a lowered position, thereby further allowing for variation in pile height of the formed tuft of yarn. Additionally, the biasing force applied by the biasing member can be used to help control movement of the gauge component in a second direction, for example, to help control movement of the gauge component between a lowered position and a raised position by the motor 152.

[0110] In some embodiments, the linkage can include a substantially rigid rod, wire, arm, or other similar connecting member, and the motor can be controlled to move the linkage in opposite directions to control movement of the gauge parts along a path in a second direction as the gauge parts reciprocate in a first direction toward and away from the needle. In such embodiments, a biasing member may or may not be used.

[0111] 8A and 8B show a variation of the drive system 150 shown in FIGS. 7A-7D. In FIGS. 8A-8B, the gauge component 32 is shown as including a level cut loop looper 161 including a looper or hook body 162 having an elastic clip 163. In this embodiment, each of the level cut loop loopers 161 can be mounted within a module or gauge block 164 that is mounted along an arm or drive mechanism 53 that reciprocates the level cut loop looper in a first direction of movement toward and away from the needle. Each of the clips 163 of each of the level cut loop loopers 161 generally includes an elongated body 166 having a first or proximal end 163A and a second or distal end 163B. The distal end of each clip is further generally received within a gate or connector 154 of the connector assembly 153. A biasing member 159 may generally be disposed between a distal or rear end of each gate or connector 154 and a spring plate 158, as described with respect to the embodiment of Figures 7A-7D. Each connector assembly 153 further includes one or more linkages 156, such as cables, rods, wires, belts, arms, etc., that may extend through the spring plate, extend through the biasing member, and may be coupled at one end 156A to a distal end of each gate and at an opposite end 156B to one or more motors 152.

[0112] 8A-8B, the actuator 151 can be oriented to the side of the level cut loop looper. In such an embodiment, the linkage extends laterally and is coupled to the motor and gate for the clip of the level cut loop looper.

[0113] During operation of the drive system 150, as shown in Figures 8A and 8B, as the level cut loop loopers 161 reciprocate in a first direction toward and away from the needles of the tufting machine, the clips of the level cut loop loopers can be further selectively controlled to extend or retract the clips as needed to form cut pile tufts or loop pile tufts. For example, as the level cut loop loopers reciprocate toward the needles, such as the path shown by arrows 54 / 54 in Figure 7A, the clips of selected ones of the level cut loop loopers can be retracted by controlling a motor or motors coupled to the linkage 156 to move the linkage along a path of movement in a second direction to retract or extend the clips (Figure 8A). With the clips in the retracted position, the level cut loop loopers can pick up and hold a loop of yarn thereon to form cut pile tufts.

[0114] The motor can then be reversed or disengaged from the linkage to allow the biasing force exerted by the biasing member against the gate to return the clip connected to the gate to an extended position and move along the body of the level cut loop looper to a position that prevents capture of the loop of yarn by the level cut loop looper, thereby releasing the captured loop of yarn to form a loop pile tuft. The biasing force exerted by the biasing member can further be used in conjunction with operation of the motor or other actuator to help control movement of the gauge parts in a second direction, for example, to help control movement of each of the gauge parts between various lowered and raised positions in smaller and / or more defined increments or distances.

[0115] Additionally, the control system of the tufting machine includes programming for controlling the yarn feed to each of the needles in conjunction with the operation of the level cut loop loopers and their clips to control the length of the loop of yarn picked up or captured by the gauge components to create various pattern effects as further described below.

[0116] 9A-9C illustrate further variations or embodiments of a drive system 150 for selectively controlling the positioning of gauge components 32 of a tufting machine. As shown in FIGS. 9B and 9C, the gauge components 32 may include a looper, hook, or other gauge component having an elongated body 175 having a first or proximal end 176 defining a throat 176A and terminating at a point or bill 177, and a second distal end 178 pivotally mounted to a holder or module 179. The second or distal end 178 of each gauge component may further include a slot or recess 181 configured to engage (or receive) a mating pin or other connector 182 disposed at a first or proximal end 183A of a gate or connector 183 of the connector assembly 153. The connector assembly 153 may further include a biasing member 186, such as a spring, disposed between a second or distal end 184 of each gate or connector 183 and a spring plate or support 187, with a linkage 188 connecting the gate or connector holding the gauge component to a corresponding or associated actuator 151.

[0117] The linkages 188 may include cables, rods, wires, belts or other similar connectors, and in an embodiment, may extend through the spring plates, each connecting at a first end 188A to a distal end 183B of one of the gates or connectors 183 and at a second end 188B to a corresponding actuator 151, such as one or more motors 152 (e.g., servo motors, stepper motors, torque motors, moving coil actuators, linear actuators, electric cylinders, etc.). The linkages may be further extended through one or more guides 189 as needed to help control the movement and / or tension within the linkage. As shown in FIGS. 9A-9B, when the gauge parts are reciprocated in a first direction toward or away from the needle 36, the actuators connected to the corresponding or associated ones of the gauge parts may be selectively controlled by the control system such that the linkage of the selected gauge part may be retracted or extended. As the linkage is retracted, the gate connected to the link is pulled rearward against the one or more biasing members 186, toward the spring plate 187 in the direction of arrow 191, generally causing compression of the biasing members. In response, the gauge parts are generally caused to pivot or move in a second direction toward a retracted or lowered position, as indicated by arrow 71' in FIG. 9C.

[0118] Upon disengagement of the linkage or reversal of the actuator (e.g., reversing the motor and thereby releasing the linkage), the biasing force applied by the biasing member as the biasing member is decompressed causes these gates to be biased forward in the direction of arrow 191', which can cause the gauge component to be pivoted in the reverse direction as indicated by arrow 71, causing the first or proximal end of the gauge component to be raised towards an extended or raised position to engage and retrieve the loops of yarn or loops of yarn from the needle. The control system can control the actuator to provide an opposition to the biasing force from the biasing member to control the movement and / or positioning of the gauge component to the extended position. The actuator can be further controlled by the control system in conjunction with the control of the yarn feed to further move the first or proximal end of the gauge component between the raised and lowered positions where the loops of yarn are captured, thereby further enabling a change in pile height of the formed tuft of yarn.

[0119] 10A and 10B show another variation of a drive system 150 for controlling the movement of the gauge parts 32 in a second direction in addition to the movement of the gauge parts in a first direction toward and away from the needles of the tufting machine. As shown in FIGS. 10A and 10B, each of the gauge parts 32 (shown here as including a looper or hook 50) can have an elongated body 196 having an upper end 197 that projects toward the needle and includes an elongated throat that terminates in a bill or tip 198, and a lower or distal end 199 that projects through a module or holder 201 and can be coupled to a drive member 202 connected to an actuator 151. In this embodiment, the actuator can include a motor 152, such as a servo motor, stepper motor, torque motor, and other types of motors, although a cylinder or drive mechanism can also be used. Additionally, in some embodiments, the lower distal end of each gauge part can be coupled or connected to a linkage or extension piece 204 that can be coupled to the drive member of an associated or corresponding actuator.

[0120] In an embodiment, the drive member 202 may include an eccentric, pulley, or disk, or other rotatable drive member. The drive member may be driven by an actuator in a rotational motion, and as the drive member is rotated, a linkage coupled thereto is extended or retracted such that the gauge parts are moved in a substantially linear motion in their second direction. Thus, the throat of the gauge part is moved between an extended or raised position and a retracted, lowered position, including being moved to a fully lowered, no-suture position where the throat of the gauge part generally does not engage the thread pick-up loop from the needle. When the drive member is further rotated by the actuator in the reverse direction or toward a nearly full rotation, the gauge part can be returned to a desired height or position relative to the needle.

[0121] 11A-11B show further variations or embodiments of a drive system 150 for controlling the movement of the gauge part 32 of a tufting machine to control or adjust the position or height of the gauge part relative to the needle of the tufting machine by movement of the gauge part in a second direction relative to the stroke of the needle (e.g., in a vertical or up-down movement) as the needle reciprocates in a first direction toward and away from the needle, as shown in FIGS. 2, 7A and 9A and described above. In the embodiment shown in FIGS. 11A-11B, the drive system 150 includes an actuator 151, such as a motor 152, typically a servo motor, stepper motor, torque motor, or other type of motor, although a cylinder or other drive mechanism can also be used. Each motor can further include a rotatable drive member 210 coupled thereto. The drive member 210 can include an eccentric, pulley, cam, or other similar drive member coupled to the motor so as to be rotated in an eccentric motion.

[0122] A connector assembly 215 connects the gauge parts to a corresponding or associated one of the actuators, the connector assembly including a linkage 216. In this embodiment, the linkage is shown to include a rod, arm, bar, or section. Other types of linkages can also be used. As shown in FIG. 11A and FIG. 11B, the linkage can include a first arm 218 connected at one end 218A to a drive member of a related or corresponding one of the actuators and connected at an opposite end 218B to an intermediate arm 219, the intermediate arm being pivotally connected at its first or proximal end 221A to a second arm 221, the second end or distal end 221B of the second arm being engaged or connected to a lower end or distal end 222 of the corresponding or associated one of the gauge parts. 11B, rotation of the drive member causes a first arm of an associated linkage to be extended or retracted in the direction of arrows 223 / 233', which in turn causes a pivotal movement of each of the second arms of such linkage. This in turn causes a corresponding or associated gauge component connected to the distal end of the second arm to be moved in that second direction, positioning the bill or throat of the gauge component at a selected position or height relative to the stroke of the needle as it penetrates the backing.

[0123] In operation, according to some embodiments, tufted articles can be formed in accordance with the systems and methods of the present disclosure, and the tufted articles can be formed in a variety of patterns and pattern effects, including the use of multiple different colors and / or types of yarn to form such patterns, and including sculpting or multiple pile height effects. For example, the systems and methods of the present disclosure can be operated in conjunction with a stitch distribution control system or thread color placement system, such as those disclosed and illustrated in U.S. Patent Nos. 8,141,505, 8,359,989, and 8,776,703, the disclosures of which are incorporated by reference as if fully set forth herein.

[0124] In such embodiments, the stitches or tufts of yarn formed in the backing may further be formed at an increased or higher actual operational or effective process stitch rate as compared to the fabric or pattern stitch rate desired or prescribed for the tufted pattern being formed. If the stitch rate or density of the pattern or fabric of the pattern being formed requires that the tufted article have the appearance of 8, 10, 12, etc., stitches per inch formed therein and / or exhibited on its surface, the actual operational or effective number of stitches per inch formed during operation of the tufting machine is substantially greater than the stitch rate of the desired or prescribed pattern or fabric. Thus, the actual formation of stitches or tufts of yarn in the backing is accomplished at an increased actual workable or effective process stitch rate, thereby effectively forming a larger number of stitches per inch in the backing than should be shown in the finished pattern, and stitches or face yarns that are not desired to be shown or remain on the face of the pattern field or area are not picked up by the gauge components and, as the case may be, pulled back or pulled from the backing to an extent that allows such yarns to be retained or pulled in the backing while substantially avoiding the formation of undesirable or unnecessary gaps or spaces between the retained or face yarns of the pattern (i.e., tufts of yarn that will remain visible or appear in the finished pattern of the tufted article).

[0125] For illustrative purposes, in one exemplary embodiment, the effective process stitch rate can be based on or determined by increasing the fabric or pattern stitch rate of the pattern that is approximately formed by the several colors selected or tufted in the pattern. For a pattern that has a desired fabric or pattern stitch rate of about 10-12 stitches per inch and uses 2-4 colors, the effective or operable process stitch rate (i.e., the rate at which stitches are actually formed in the backing) can be from about 18-20 stitches per inch to about 40 or more stitches per inch. However, it will be further understood by those skilled in the art that further variations or adjustments of such operable or effective process stitch rate runs for a particular pattern can be made depending on the type and / or size of the yarn and / or other factors. For example, if a thicker, larger size or heavier yarn is used, the effective process stitch rate can be subject to additional variations as needed to account for the use of such larger yarn (e.g., for a four color pattern, the effective process stitch rate can be further varied, such as running at about 25-38 stitches per inch, although further variations can be used as needed). Thus, while a selected or programmed pattern to be executed may be designed or desired to have a desired pattern density or stitch rate therefor of 10 to 12 stitches per inch, the system may actually operate to form upwards of 20 to 48 or more stitches per inch, depending on the number of colors and / or yarn type, and visually, only the desired / selected 10 to 12 stitches will generally appear from the surface of the finished tasseled article.

[0126] Additionally, when a series of different colors are being tufted, the needles 36 of the needle bar 35 are generally provided with the desired thread lift, e.g., for a four-color pattern, A, B, C, D thread lifts can be used on the needles. Alternatively, when two needle bars are used, the needles of each needle bar can be provided with an alternating thread lift sequence, i.e., A / C thread lift on the front needle bar and B / D color thread lift on the rear needle bar. Additionally, the needles of such front and rear needle bars can be positioned in staggered or offset alignment. The needle bar or needle bars are more generally shifted by control of the needle bar shifter 40 (FIG. 2) according to the shift profile of the pattern being formed, in conjunction with control of the backing and control of the yarn feed, to effectively provide the loopers or hooks with each one of the thread colors (i.e., 2, 3, 4, 5, etc.) or different types of thread that can be sewn at a selected pattern pixel or tuft / stitch location by shifting the needle bar laterally relative to the backing as the backing is fed through the tufting zone.

[0127] For example, for a four-color pattern, each of the one to four colors that can be stitched at the next pixel or stitch location, i.e., one, two, three, four, or none of the yarns that can be provided at the selected pixel or stitch location, is provided to the desired looper or hook as the backing is incrementally moved by about 1 / 8 to 1 / 40 of an inch with each shift motion or cam movement cycle. The looper or hook engages and forms a loop of yarn with the desired yarn or yarns retained to form the selected tuft, while the remaining yarns are generally allowed to remain with their needles without being picked up by the looper or hook. Some yarns can be picked up as needed, and the yarn delivery mechanism can be controlled to do so, including pulling those unretained yarns that are pulled out of the backing to float along the backing. Thus, each looper or hook is given the ability to tuft any one, or possibly more than one (i.e., 2, 3, 4, 5, 6, etc.) of the colors of the pattern, or, possibly, any of the colors provided to it, for each pattern pixel or tuft / stitch location associated with it during each shift sequence and corresponding incremental movement of the backing. As discussed above, if none of the different types or colors of yarn are tufted or placed at a particular tuft or stitch location or pixel, the yarn delivery can be controlled to limit or otherwise control the needle yarns that can be provided to such stitch location or pixel to pull back substantially all of the yarn or otherwise prevent such yarn from being placed or appearing at that stitch location, and / or the needle bar can be further controlled to jump or otherwise bypass or skip the provision of needles / yarns to that stitch location or pixel.

[0128] The feed of backing B can further be controlled in a variety of ways, i.e., by the stitch distribution control system. For example, the tufting machine backing roll 28 can be controlled to hold the backing in place for a given number of stitches or cycles of the needle bar, or the backing can be moved at a desired number of stitches per inch, i.e., about 1 / 40 inch for each penetration, or a variation thereof can be such that for a pattern having four colors and an effective stitch rate of 40 stitches per inch, it moves about 1 / 10 of an inch as four stitches are introduced into the backing. The movement of the backing can further be modified or manipulated on a stitch-by-stitch or pixel-by-pixel basis, such that the average movement of all stitches over a cycle substantially matches the calculated incremental movement of the operable or effective process stitch rate. For example, for a four-color cycle, the first stitch can be performed at 1 / 80 inch, the next two at 1 / 40 inch, and the fourth at 1 / 20 inch, so that the average movement of the backing over the four stitch cycles for each stitch provided is an average of 1 / 40 inch, as needed, to achieve the desired stitch / color placement.

[0129] Thus, each different yarn / color yarn that can be tufted at a particular stitch location or pixel can be provided to such stitch location or pixel when the pattern is formed on the backing. To achieve such provision of yarn at each pixel or stitch location, the needle bar can generally be shifted as needed / desired per the calculated or selected cam profile or shift profile of the pattern being performed / formed using a combination of single and / or double jumps or shifts based, for example, on the number of colors being performed in the pattern and the area of ​​the pattern field being formed by each particular color. Such combinations of single and double shift jumps or steps can be utilized to avoid overtufting or engagement of previously sewn tufts as the needle bar is shifted laterally and the backing advances at its effective or effective stitch rate. The backing can also be shifted by a backing or jute shifter or the like in conjunction with or separately from the needle bar shifting mechanism.

[0130] Once the needle penetrates the backing B, as shown in Figures 1 and 2, the loopers or hooks 50 of the gauge component assembly 30 reciprocate towards the needle in the direction of arrow 54, thereby engaging, picking up or pulling a loop of thread from an associated or corresponding needle. Additionally, actuators 66 for the loopers or hooks can be selectively controlled and engaged to extend or retract the selected looper or hook, thereby positioning the needle 63 and its throat portion 62 in a desired position relative to the needle as the needle 36 penetrates and completes its stroke in and out of the backing.

[0131] As shown in Figures 5A-6C, the position or positioning of the bill and / or throat portion of the looper or hook can be varied between a fully extended position or height and a lowered or retracted position to provide selective pick-up of yarn loops, including a "no stitch" position in which no yarn loops are picked up, which may generally be substantially prevented from being picked up and / or formed by such looper or hook, and control of the length of the yarn loops selectively picked up from the yarn provided at each of the stitch locations or pixels in accordance with the instructions of the pattern being formed. As a result, the location at which selected or desired face yarn loops shown in the "finished" pattern are picked up from the needle by the looper or hook can be controlled, and the formation of tufts resulting from such picked up yarn loops remaining in the backing can be further controlled so that a variety of different pile heights can be formed.

[0132] The yarn type / color of each set of yarn provided at each pixel or stitch location that is retained or shown on the surface of the backing at a particular stitch location is generally determined according to pattern instructions or programming for the formation of a tufted pattern. Controlling the actuation and / or positioning of the loopers or hooks 50 corresponding to or associated with the needles carrying such yarns can enable the tufting machine to selectively pick up and hold loops of such yarn at each stitch location where such yarn remains according to the pattern, thereby forming a resulting tuft of such yarn at a selected pile height. For example, if a provided yarn is not to be displayed or shown, the corresponding looper or hook can be retracted to a no-stitch position such that no loops of yarn are picked up, and the yarn feed therefor is controlled such that such yarn is not retained at the pixel or stitch location. With respect to the retained yarns / colors, i.e., the yarns that are shown on the surface of the patterned tufted article, the position or height of the loopers or hooks and the yarn feed mechanism that feeds these yarns can generally be cooperatively controlled to enable the pick-up and formation of sufficient loops of such yarn to form the desired type of tuft and pile height.

[0133] Further control of backing feed at increased effective or effective processing stitch rates (e.g., the actual rate at which stitches are formed on the backing) in accordance with the principles of the present disclosure further provides a tighter or compressed field of stitches or tufts per inch, so that unpicked up yarns can be removed to a sufficient degree to tuck or hold such yarns against the backing as needed, without creating undesirable spaces or gaps between retained face yarns (those that appear on the surface of the tufted article according to the pattern) and without interfering with or showing through such retained face yarns formed on the backing. Additionally, the control system can perform yarn feed compensation and / or modeling of yarn feed to control and reduce the amount of unretained or unseen yarns that may be "floating" on the back side of the backing to further help reduce / minimize excess yarn feed and / or waste.

[0134] Additionally, the yarn delivery mechanism controlling the delivery of each yarn to each needle can be selectively controlled to substantially pull the yarn carried by the needle out of the backing or by the reciprocating motion of the needle, and can cause some of the yarn loops to be retracted or pulled back / lowered to a position substantially low enough to generally avoid such non-selected ends of the yarn occupying selected stitch locations or to otherwise interfere with the placement of the selected face yarn or yarns as indicated by the particular color fields being formed according to the pattern.

[0135] For example, in some embodiments, when a selected or particular looper or hook is retracted to a fully retracted or "no stitch" position, generally no loop is picked up from the needle associated with such fully retracted looper or hook, while the yarn feed is correspondingly controlled such that the yarn is permitted to move back into and out of the backing with that needle. Furthermore, in some instances where a loop of yarn is formed, such as, for example, when a looper or hook is in a fully extended position and forms a low loop, the resulting loop of yarn may further be purled or pulled substantially low from the backing by controlling the yarn feed to such an extent that an amount of yarn remains engaged or "tucked" into the backing, while substantially removing such yarn to such an extent that the unselected ends of such yarn generally do not interfere with the placement of the surface-appearing or selected yarn at a particular stitch location within the color field being sewn.

[0136] The placement of the invisible yarn that is tacked or otherwise secured to the backing can also be controlled to prevent the formation of such extended length tails that may later become caught or cause other defects in the finished tufted article. For example, the control system can also be programmed / set to tuck or form such invisible yarn low stitches at desired intervals, e.g., every 1 inch to 1.5 inches, although larger or smaller intervals can also be used. Yarn compensation can also generally be used to help ensure that a sufficient amount of yarn is delivered when necessary to allow the invisible yarn to hook onto the backing while preventing the yarn from emerging or springing up through another color, i.e., with several yarns placed together, preventing the yarn from being pulled onto and protruding from one of the stitch yarns. Furthermore, if extended lengths or tails are formed for multiple invisible yarns, the spacing at which such different yarns are stacked within the backing can be varied to avoid such stacked yarns interfering with each other and / or color field yarns being formed (i.e., one at 1 inch, another at 1.5 inches, etc.).

[0137] Additionally, actuators such as actuator 66 in FIGS. 1-6C and actuator 151 in FIGS. 7A-11B can also be controlled to vary the position, location and / or height of the gauge components relative to the needles to allow for loop or yarn pick-up or not allow for yarn loop pick-up as well as pick-up of different length yarn loops by the gauge components. In an embodiment, the position and movement of the gauge components, in conjunction with control of the yarn delivery mechanism, can be incrementally controlled to cause the formation of extended or elongated yarn loops, for example, by engaging, retracting or lowering their respective loopers or hooks with a captured yarn loop. Thus, the captured yarn loop can be further pulled and / or stretched, while the corresponding yarn delivery of such yarn can also be controlled to deliver additional amounts of such yarn as needed. As a result, even longer or longer yarn loops can be formed in the backing to create higher pile tufts and / or to create other desired pattern effects, such as for tip shear and / or other patterning features.

[0138] Selective control of actuators to selectively retract and extend loopers or hooks can further be used to provide additional variations or transition steps or pile heights in the pattern. For example, the gauge components can be moved incrementally relative to the needles by controlling their actuators alone, or in conjunction with a biasing force applied by a biasing member to moderate and / or allow control of the movement of the gauge components in smaller increments as needed to provide more gradual or subtle differences or changes in pile height, or to provide more dramatic or defined separation between the pile heights of the yarn tufts being formed.

[0139] Thus, across the width of the tufting machine, the control system controls the shifting and feeding of the yarn of each color or desired pattern texture effect such that each color that can or may be sewn at a particular tuft location or pattern pixel is provided within that pattern pixel space or tuft location, but only the yarn tuft selected for a particular color or pattern texture effect remains at that tuft / stitch location or pattern pixel. As further noted, it is also possible to provide additional or more colors to each of the loopers or hooks during the tufting step to form mixed color tufts, or to provide a tweed effect if desired, where two or more stitches or yarns are placed at the desired pattern pixel or tuft location. Thus, the result of the operation of the stitch distribution control system provides a multi-color visual effect of pattern colors or texture effects that are selectively positioned to obtain the desired density and pattern appearance of the finished tufted article. This further allows for the creation of a greater variety of geometric, free-flowing and other pattern effects by controlling the placement of tufts or yarns at selected pattern pixels or tuft locations.

[0140] Thus, the systems and methods for tufting engraved multiple pile height pattern articles of the present disclosure can enable an operator to develop and execute a variety of tufting patterns having different looks, textures, etc. on a tufting machine without necessarily having to utilize a design center to derive and create the patterns. Instead, in the present disclosure, in addition to manually preparing patterns and / or as an alternative to using a design center, an operator can scan an image (i.e., photo, drawing, jpeg, etc.) or upload a designed pattern file on the tufting machine and the stitch distribution control system can read the image and develop program steps or parameters to thereafter control the tufting machine with substantially no further operator input or control required to form the desired tufted patterned article.

[0141] The above description generally illustrates and describes various embodiments of the present disclosure. However, it will be understood by those skilled in the art that various modifications and changes can be made to the above configuration of the present disclosure without departing from the spirit and scope of the present disclosure disclosed herein, and it is intended that all matters contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure should be interpreted to include various modifications, combinations, additions, substitutions, etc. to the above and above-mentioned embodiments, which should be considered to be within the scope of the present disclosure. Thus, the various features and characteristics of the present disclosure described herein can be selectively exchanged and applied to other illustrated and non-illustrated embodiments of the present disclosure, and numerous modifications, changes, and additions can be further made without departing from the spirit and scope of the present disclosure described in the appended claims.

Claims

1. A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; at least one module carrying a series of said gauge parts, said at least one module comprising: a modular body adapted to be mounted along a gauge bar, the modular body having a passageway defined therethrough, the modular body being formed from a metal, a polymeric material, or a combination thereof, and having a first hardness; an insert disposed along the passage; Equipped with at least one module, the insert comprising a metal or metal carbide material having a second hardness greater than the first hardness of the module body; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls the delivery of the yarn to the needles in coordination with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuator to move a selected gauge part along the second direction, whereby the throat of the selected gauge part is moved between a no-stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a pattern being formed and form a tuft of yarn in the backing.

2. a shift mechanism for shifting the at least one needle bar laterally across the backing, the control system further comprising a program for providing a series of threads to selected stitch locations along the backing and drawing off non-selected threads by coordinating the shifting of the at least one needle bar by the shift mechanism, the feeding of the backing by the backing feed roll, control of the actuator coupled to the gauge component, and control of the at least one thread feeding mechanism that feeds the threads to the needles as the needles are shuttled in and out of the backing; 2. The tufting machine of claim 1, wherein such loops of non-selected yarns are not picked up by one of said gauge components and said backing is moved through a tufting zone at an actual stitch rate that is greater than a pattern stitch rate of the pattern being formed, providing a number of retained tufts per inch approximately equal to the pattern stitch rate of face yarns in said backing.

3. The tufting machine of claim 1 , wherein the gauge components comprise a level cut loop looper, a loop pile looper, or a cut pile hook.

4. 10. The tufting machine of claim 1, wherein the actuator comprises a hydraulic cylinder, a pneumatic cylinder, a stepper motor, a servo motor, an electric cylinder, a linear actuator, a moving coil or voice coil actuator, a solenoid, or a combination thereof.

5. A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls delivery of the yarn to the needles in cooperation with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuators to move selected gauge elements along the second direction, whereby the throats of the selected gauge elements are moved between a no stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a forming pattern and form a tuft of yarn in the backing; The tufting machine, wherein the drive system further comprises a plurality of connectors configured to connect each gauge part to at least one linkage for an associated actuator, each of the connectors comprising a body having a first end in which the first portion of the body of a corresponding gauge part is received and a second end connected to the at least one linkage, and a series of biasing members disposed between the second end of each connector and a spring plate.

6. each linkage comprises a cable, wire, rod, or belt extending through the spring plate and including a first end connected to the second end of one of the connectors and a second end coupled to the associated actuator; to retract the selected gauge part, an actuator associated with the selected gauge part retracts the linkage coupled to the selected gauge part, thereby causing the selected gauge part to move along the second direction toward a retracted position compressing at least one biasing member; 6. The tufting machine of claim 5, wherein to extend the selected gauge part, the at least one biasing member is enabled to reduce compressive force and urge the corresponding gauge part toward its extended position.

7. A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls delivery of the yarn to the needles in cooperation with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuators to move selected gauge elements along the second direction, whereby the throats of the selected gauge elements are moved between a no stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a forming pattern and form a tuft of yarn in the backing; The drive system further comprises a series of connector assemblies connecting each gauge part to an associated actuator, each of the connector assemblies including a series of connectors each coupled to at least one of the linkages and configured to receive the first portion of the body of a corresponding gauge part, the actuators comprising a motor, and each linkage comprising a cable, wire, rod or belt having a first end adapted to connect to one of the connectors and a second end coupled to one of the motors.

8. 8. The tufting machine of claim 7, further comprising a series of biasing members disposed between the connector and the spring plate, wherein actuation of a selected one of the motors retracts the connector coupled to an associated linkage thereto, moving the corresponding gauge component toward a retracted position and compressing one or more of the biasing members, and when the one or more biasing members reduce compression, the corresponding gauge component is moved toward its extended position.

9. The tufting machine of claim 1 , wherein the actuator comprises a motor and the linkage comprises a cable, wire, rod, belt, arm, or combination thereof.

10. 2. The tufting machine of claim 1, wherein the actuators comprise motors, each motor including a drive member coupled to the motor, the drive member being driven in a rotational motion by the motor, and the linkage is coupled to the drive member of one of the motors, whereby when the drive member is rotated by the motor, the linkage is extended or retracted.

11. A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls delivery of the yarn to the needles in cooperation with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuators to move selected gauge elements along the second direction, whereby the throats of the selected gauge elements are moved between a no stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a forming pattern and form a tuft of yarn in the backing; the actuators comprise motors, each motor including a drive member coupled thereto, the drive member being driven in rotational motion by the motor, the linkage being coupled to the drive member of one of the motors, whereby when the drive member is rotated by the motor the linkage is extended or retracted; each of the linkages comprises a first arm or rod having a first end coupled to the drive member of the motor and a second end coupled to a second arm or rod at the first end of the second arm or rod, the second arm having a second end pivotally coupled to the first portion of the body of one of the gauge parts, and when the drive member is rotated by the motor, the first arm is extended or retracted along a first axis of movement, causing the second arm to pivot and move the one of the gauge parts between its extended and retracted positions.

12. A tufting machine, comprising: at least one needle bar, said at least one needle bar having a plurality of needles mounted therealong; A backing material feed roll for feeding the backing material; at least one yarn delivery mechanism for delivering yarn to the needles; a plurality of gauge parts disposed beneath the backing, each of the gauge parts including a body having a first portion and a second portion, the second portion having a throat configured to pick up a loop of thread from the needle, the gauge parts being movable in a first direction toward and away from engagement with the needle and in a second direction; a drive system for movement of the gauge parts in their second direction, the drive system comprising: A plurality of actuators; a linkage coupled to each gauge component and an associated one of said actuators; a drive system comprising: each linkage is retracted or extended by its associated actuator to cause movement of the gauge parts in the second direction; a control system including programming for controlling the at least one yarn delivery mechanism; Equipped with the at least one yarn delivery mechanism controls delivery of the yarn to the needles in cooperation with selective actuation of one or more of the actuators, the selective actuation extending or retracting the linkage coupled to the actuators to move selected gauge elements along the second direction, whereby the throats of the selected gauge elements are moved between a no stitch position and an extended position relative to a stroke of the needle into the backing to engage the needle according to a forming pattern and form a tuft of yarn in the backing; Each linkage includes an extension piece connected to or integral with the first portion of the body of a corresponding gauge component.

13. 2. The tufting machine of claim 1, wherein said at least one needle bar comprises a pair of needle bars, each of said pair of needle bars having a series of needles mounted in series and spaced apart therealong.

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