Tufting machine needle drive system

Abstract

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

Description

Technical Field

[0001] (Related Application) This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 321,944, filed Mar. 21, 2022, which is currently pending. (Incorporation by Reference)

[0002] The disclosure and figures made in U.S. Provisional Patent Application No. 63 / 321,944, filed Mar. 21, 2022, are specifically incorporated herein by reference in their entirety as if fully set forth herein. (Technical Field)

[0003] The present disclosure relates to a tufting machine, and more specifically, to a tufting machine needle drive system for driving one or more needle bars of a tufting machine to enable increased operating speeds, improved maintenance efficiency, and other improvements.

Background Art

[0004] The use of tufting machines to produce tufted articles, such as tufted carpets, is well known in the art. Conventional tufting machines may have a drive system for driving the reciprocating motion of a needle bar carrying multiple needles in and out of the backing material passing laterally beneath the needle bar. When a needle penetrates the backing material, the needle carries the twisted yarn into the backing material, so that the twisted yarn is captured by a looper to produce a loop pile tuft, or captured by a hook or level cut loop looper and cut by a knife to produce a cut pile tuft. Typically, as the main drive shaft of the tufting machine rotates, the needle bar is moved back and forth toward and away from the backing material. However, such drive systems may have disadvantages from a maintainability standpoint. For example, some drive systems utilize a series of individual drive assemblies, which are mounted along the tufting machine and connected to the machine's main drive shaft. Some drive systems may also include belt-driven gear arrangements, which drive push rods coupled to the needle bar to reciprocate the needle bar. However, when the belt of such a drive assembly wears out and / or breaks and requires replacement, the entire drive system often has to be substantially disassembled to allow access to the belt. In addition, the operating speed of many conventional tufting machine drive systems is often limited, particularly with respect to cut pile tufting machines.

[0005] What is needed, therefore, is an improved drive system for tufting machines to address the aforementioned problems and other related and unrelated problems in the art. These include, but are not limited to, needle drive systems for driving the reciprocating motion of needles in a cut pile tufting machine at operating speeds similar to those of loop pile machines, and needle drive systems that provide a device that is efficient and easy to maintain, durable and robust. [Overview of the project] [Problems that the invention aims to solve]

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

[0007] In some embodiments, a tufting machine may include one or more needle bars having a series of needles mounted along it. The needles may be arranged in a straight line, alternately, or in other arrangements along one or more needle bars. Lining material may be fed through the tufting zone of the tufting machine, and the needles may penetrate the lining material in and out as the needle bars reciprocate by a drive system. Twisted yarn may be introduced into the lining material as the needles reciprocate in and out of the lining material. In some embodiments, a shift mechanism may be provided to shift one or more needle bars laterally across the tufting zone. In other embodiments, multiple shift mechanisms may be utilized as needed.

[0008] A tufting machine may generally further include at least one yarn feeding mechanism or pattern attachment to control the feeding of the twisted yarn to each of its needles. In embodiments, such a yarn feeding mechanism or pattern attachment may include, but is not limited to, various rolls, scrolls, servo scrolls, single-ended, double-ended, or multi-ended yarn feeding attachments. For example, in embodiments, Yarntronics TM Infinity TM , or Infinity IIE TM The yarn feeding mechanism or pattern attachment is manufactured by Card-Monroe Corp. Other types of yarn feeding mechanisms may also be used.

[0009] In embodiments, the shift mechanism and at least one yarn feeding mechanism or pattern attachment can generally communicate with the control system of the tufting machine. For example, the shift mechanism can receive commands or communications from the control system for the tufting machine to advance (or shift) at least one needle bar transversely across the lining material according to a pattern shift step programmed and / or designed for the pattern being tufted, so as to provide the yarn to be delivered to the tuft or stitch location along / cross the lining. In embodiments, at least one yarn feeding mechanism can also be operated to selectively control the feeding of the yarn to its associated needles to form a tuft of yarn, which may include forming a tuft with a selected pile height and / or not forming a tuft to produce a desired pattern appearance.

[0010] In addition, the tufting machine may include a gauge component assembly mounted below the lining, which may comprise a series of gauge components that, in embodiments, may include, for example, loop pile loopers, cut pile hooks, level cut loop loopers, cut / loop clips, knives, etc. The gauge component may be reciprocated to engage with the needle as the needle penetrates the lining material and picks up the loops of twisted yarn from there. In embodiments, the height or location of the gauge component below the lining material, and in some embodiments, the stroke or penetration depth of the needle through the lining, may be varied in addition to adjusting the stroke or penetration depth of the needle through the lining material to form varying loops of twisted yarn with varying pile heights in the lining material (including the formation of loops of different pile heights). Twisted yarn feeding control may also be used to control the pile height, for example, by leaving substantially no loops of twisted yarn in the lining or pulling them out completely. In embodiments, various configurations and / or combinations of loop pile loopers, cut pile hooks, cut / loop hooks, level cut loopers or hooks, and / or other gauge components may also be used.

[0011] In embodiments, the drive system for driving the reciprocating motion of the needles of a tufting machine may include spaced first and second drive shafts located within the head of the tufting machine, the drive shafts extending substantially parallel to each other along the head of the tufting machine and laterally across the lining material being fed through the tufting machine. The first and second drive shafts may include exposed ends projecting through side plates on the opposite side of the tufting machine frame, the exposed ends located outside the frame and projecting away from the outer surface of the side plates. In embodiments, the exposed ends of the first and second drive shafts may include shaft drive gears mounted thereon, which are coupled to motor drive gears, pulleys, or chain gears of one or more main motors to drive the first and second drive shafts.

[0012] The drive system may further include a series of needle strokes or drive assemblies positioned along the head of the tufting machine, through which a drive shaft extends. In embodiments, each needle stroke assembly may include a series of needle stroke drive gears connected to a drive member coupled to the drive shaft and thereby driven. In embodiments, the drive member may include a chain driven by alternating needle stroke drive gears of alternating needle stroke assemblies, for example, odd-numbered needle stroke assemblies may be rotated in one direction of rotation, while even-numbered needle stroke assemblies may be rotated in the opposite direction. By rotating the drive shaft in opposite directions, a series of connecting rods may be connected to a series of push rods coupled to at least one needle bar, driven substantially vertically or along a moving path to transmit the rotational motion of the first and second drive shafts to the push rods in linear reciprocating motion, wherein the opposite direction of rotation may allow the weight of the connecting rods to substantially offset such motion, thus enabling the opposite rotation of the first and second drive shafts in embodiments. In embodiments, counterweights are also mounted on the first and second drive shafts and can help balance the drive system and reduce / control its vibrations as the needle is reciprocated in and out of the lining material.

[0013] In embodiments, each drive member of the needle stroke assembly may be configured as a double-strand roller chain, which may include two paired rows or strands extending in a loop-shaped path around a first needle stroke drive gear mounted on one of the drive shafts and around a second needle stroke drive gear mounted on a secondary drive shaft. Other drive members may also be used.

[0014] In some embodiments, a secondary shaft may be further coupled to the connecting rod to drive the connecting rod in an up-and-down motion as the crankshaft rotates. For example, in some embodiments, the secondary drive shaft may have a series of cam members mounted thereon in an offset arrangement, the cam members being coupled to the connecting rod to drive the reciprocating motion of the connecting rod, and thus the push rod and needle bar. In some embodiments, the secondary drive shaft may comprise a crankshaft coupled to the connecting rod to drive its reciprocating motion. In addition, in some embodiments, a drive chain may be configured to increase shaft horsepower and for easier repair and / or replacement, without requiring the removal of the first and second drive shafts from the needle stroke assembly.

[0015] In embodiments, the drive system may further include a drive belt configured to surround motor drive gears mounted on the motor shafts of one or more drive motors and shaft drive gears mounted on the ends of the drive shafts of the drive system, extending in a meandering path around them. In embodiments, the drive belt and motor drive gears and drive shaft gears may have a high-torque drive arrangement configured to allow the motors to drive the first and second drive shafts with increased horsepower and torque. The drive gears and drive belt are mounted outside the tufting machine, for example, outside the end box and along the outer surface of the tufting machine, further providing ease of maintenance. As the motor drive gears are driven by the motors, the drive belt drives the shaft drive gears, causing the first drive shaft to rotate in one direction and the second drive shaft to rotate in the opposite or opposite direction to the first drive shaft.

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

[0017] In an embodiment, the drive belt may extend around a tension adjustment gear located on an adjustable support. The adjustable support may be movable along a side plate of the frame to which it is mounted, so as to move the tension adjustment gear relative to the drive belt, adjust the tension therein, and absorb, for example, slack in the drive belt.

[0018] In some aspects of the present disclosure, a tufting machine is provided, comprising a frame having a base, spaced side portions, an end box, and a head extending between the side portions, and at least one needle bar having a plurality of spaced needles mounted along thereon, wherein the needles carry a plurality of twists and are moved in a reciprocating motion toward and away from the lining material as the lining material moves through the tufting machine, such that the needles penetrate the lining material and form a tuft of twists in the lining material. In an embodiment, the drive system comprises at least one motor having a motor drive shaft mounted along at least one of the sides of the frame and coupled thereto to a motor gear; first and second drive shafts extending along the head of the tufting machine, each having an exposed end extending through the side of the frame so as to project away from the outer surface of the frame; and a plurality of needle stroke assemblies located within the head of the frame and spaced apart along the first and second drive shafts, each needle stroke assembly comprising a plurality of needle stroke drive gears. The plurality of needle stroke drive gears may include a series of first needle stroke drive gears coupled to and driven by one of the first or second drive shafts, and a series of second needle stroke drive gears coupled to and driven by the first needle stroke gears by a drive member. Rotation of the first and second drive shafts may cause alternating rotation of the needle stroke drive gears of the needle stroke assemblies in opposite directions. Multiple push rods can be coupled to at least one needle bar and needle stroke drive gear to convert the rotation of the first and second drive shafts into linear reciprocating motion of at least one needle bar.The drive system may further comprise first and second shaft drive gears mounted on the exposed ends of first and second drive shafts, the first and second drive gears being located along the outer surface of the side portion of the frame and outside the end box of the frame, a tension adjustment gear located along the outer surface of the side portion of the frame, a motor drive gear, a drive belt extending around the first and second shaft drive gears and the tension adjustment gear, and an adjustable support on which the tension adjustment gear is mounted, the support being configured to move along the outer surface of the side portion of the frame, to adjust the position of the tension adjustment gear relative to the first and second drive gears, and to maintain a selected tension in the drive belt.

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

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

[0021] In some embodiments of the tufting machine, the drive belt is a double-sided modified curved toothed timing belt. In embodiments, the drive belt has a width of at least about 2 inches to about 4 inches.

[0022] In an embodiment of the tufting machine, the drive member comprises a double-strand roller chain, each having a master connection coupling, the master connection coupling being configured to be removable from the double-strand roller chain to allow removal of the drive member from the needle stroke drive gear.

[0023] In some embodiments, the tufting machine further comprises a plurality of gauge parts positioned below the backing material, engaging the needles, and configured to pull the twist loop therefrom. In an embodiment, the gauge parts can comprise a cut pile hook and a knife for forming a cut pile tuft in the backing material. In some embodiments, the gauge parts can comprise a hook, a looper, a level cut loop looper, or a combination thereof.

[0024] In some embodiments, the operating speed of the tufting machine for forming a cut pile tuft can be at least about 1,800 RPM.

[0025] In addition, in an embodiment, the drive belt comprises a double-sided modified curve tooth timing belt having a width of at least about 2 inches, and in an embodiment, can comprise a multi-chain drive belt.

[0026] The present disclosure thus provides a tufting machine and a drive system therefor that enable an operating speed at an increased rate, including the operation of a tufting machine for forming a cut pile tuft at a similar operating speed to a loop pile tufting machine. In an embodiment, the drive system can be further configured such that worn parts of the drive system can be easily and simply replaced and the drive and timing mechanisms can be easily adjusted.

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

[0028] The accompanying drawings, included and incorporated herein and constituting part thereof, to provide a further understanding of the embodiments of the Disclosure, illustrate the embodiments of the Disclosure and, together with the detailed descriptions, illustrate the principles of the embodiments discussed herein. No attempt is made to show the structural details of the Disclosure in more detail than may be required for a basic understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced. Those skilled in the art will further recognize and understand, in accordance with general practice, that various features of the drawings discussed below are not necessarily drawn to exact scale, and that the dimensions of various features and elements of the drawings may be enlarged or reduced to more clearly illustrate the embodiments of the Disclosure described herein.

[0029] [Figure 1A] Figures 1A-1B are perspective views of the upper portion of a tufting machine with its components disassembled, illustrating a schematic embodiment of a tufting machine with a drive system for driving the reciprocating motion of the needle of the tufting machine according to the principle of this disclosure. [Figure 1B] Figures 1A-1B are perspective views of the upper portion of a tufting machine with its components disassembled, illustrating a schematic embodiment of a tufting machine with a drive system for driving the reciprocating motion of the needle of the tufting machine according to the principle of this disclosure.

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

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

[0032] [Figure 4] Figure 4 is a schematic side elevation view of the tufting machine drive system as shown in Figure 1A-2. [Modes for carrying out the invention]

[0033] Now, referring in detail to embodiments selected for the purpose of illustrating the present disclosure, Figures 1A-4 generally illustrate an embodiment of a tufting machine 10 having a drive system 5 for forming a patterned tufted article according to the principles of the present disclosure, wherein a stitch or tuft (Figure 1A) of twisted yarn Y may be inserted or placed at a desired location within a lining material B, and the lining material B moves along a path 6 through the tufting machine below the needle of the tufting machine by the operation of a lining feed roll 7.

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

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

[0036] As shown in Figures 1A-2 and 1A-4, the tufting machine 10 further includes one or more needle bars 30, which are coupled by a push rod 81 to a series of needle strokes of the drive system 5 or to the drive assembly 28, and the push rod 81 reciprocates at least one needle bar 30 toward and away from the lining material B in the direction of arrows 32 / 32'. Multiple needles 31 are mounted along one or more needle bars and are typically spaced at selected gauge increments such as 1 / 8 inch, 1 / 10 inch, 5 / 16 inch, etc. The needles 31 are moved linearly by the push rod 81 and carried together with at least one needle bar 30 to reciprocate and move up and down (as shown by arrows 32 / 32'), thereby the needles penetrate in and out of the lining material B, carrying or inserting the twisted yarn Y into the lining and forming a tuft in the lining material B. Loop pile tufts, cut pile tufts, or combinations of loop and cut pile tufts can be formed in the lining material.

[0037] At least one needle bar 30 is further shiftable laterally across the width of the lining material, thereby allowing the needle 31 to be shifted or advanced laterally or approximately perpendicular to the longitudinal path 6 through the tufting machine. For example, the shift mechanism may be connected to one or more needle bars to shift at least one needle bar laterally across the lining material. The shift mechanism is a Smart Step, such as those manufactured by Card-Monroe Corp. TM The shift mechanism may include, or alternatively, a type shifter, a servo motor or hydraulically controlled shifter, and / or various other types of shifting mechanisms, including pattern cam shifters as conventionally used. Additional shifting mechanisms may also be used, including a lining material or jute shifter that can operate separately or in conjunction with the needle bar shifter for shifting the lining material laterally relative to the needle.

[0038] In some embodiments, the needles 31 may be arranged in a single linear row along one or more needle bars 30. In other embodiments, the needles 31 may 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. Thus, an exemplary embodiment including a single needle bar 30 (with a linear row of needles 31 arranged along the single needle bar 30) may be shown in general terms in Figures 1A-1B, but the disclosure is not limited to the use of a single needle bar or a particular configuration of needles. Alternatively, it will be understood by those skilled in the art that additional arrangements of one or more needle bars having spaced rows of needles (both of which may be further shifted) which may be arranged in a linear, staggered, or offset configuration may also be utilized within a tufting machine 10 incorporating the system according to the disclosure.

[0039] Each needle generally terminates at a tip and includes a shank or body containing a pick-up point or area, where a gauge component 35 of the gauge component assembly (Figures 1B and 4) will engage with the twisted yarn Y and pick them up from the needle. As the needle is reciprocated in a substantially vertical motion in the direction of arrows 32 and 32' (Figure 2), the needle will penetrate in and out of the lining material B along the stroke to a desired or predetermined penetration depth, carrying the twisted yarn Y with the needle and selectively engaging with the gauge component 35 of the gauge component assembly to pick up the loops of twisted yarn from the needle.

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

[0041] The gauge component is generally positioned below the bed plate and, as the needle penetrates the lining material, is reciprocated toward and away from the needle to engage with the twisted yarn inserted through the lining material (not shown) and pick it up. When the needle is near its bottom dead center, the gauge component may be further positioned at a fixed height to protrude through the loop sewn by the needle, capture the loop of twisted yarn, and temporarily hold it.

[0042] For example, the gauge component 35 is mounted below the bed of the tufting machine 10, spaced at a desired or selected distance, and can engage with the needle 31 at a selected needle stroke or penetration depth. When the needle 31 penetrates the lining material, the needle 31 is engaged by the gauge component 35 of the gauge component assembly to pick up and form loops of the twisted yarn Y in the lining material to form a tuft of the twisted yarn of a selected color or type with a selected length or pile height.

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

[0044] One or more yarn feeding mechanisms or pattern attachments 40 (Figures 1A, 2, and 4) may be further mounted on the frame 11 of the tufting machine 10 to control the feeding of the yarn Y to each of the needles during the operation of the tufting machine. In various embodiments, various yarn feeding mechanisms or pattern attachments may be used, and they include, but are not limited to, a roll or scroll pattern attachment having one or more yarn feeding rolls that extend at least partially along the tufting machine and are driven by a motor under the direction of the tufting machine control system, as schematically shown in Figures 1A and 2.

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

[0046] A tufting machine will generally further include a control system configured to control the operation of the tufting machine 10, including control of backing feeding, control of yarn feeding by a yarn feeding attachment or mechanism, and control of the drive / operating speed of the main drive shaft, for example, one or more motor drive shafts 45 of one or more motors 46 of the drive system 5 (Figure 1A-4). For example, the control system may include programming, which, in cooperation with other operating systems of the tufting machine, is configured to control the yarn feeding mechanism or pattern attachment (including the operation of backing feeding, needle bar shifting, and gauge component assembly) to selectively feed the yarn to their respective needles. In embodiments, the control system may control the supply of several different colors or types of yarn into the backing material to form a tuft of such yarn with a selected width across the backing material or with a desired pile height and / or other texture effect, and the selective picking and holding of loops of the selected yarn (e.g., yarn selected to appear in the face of a finished patterned article).

[0047] In some embodiments, the control system may generally include a computer / processor or system controller and a tufting machine controller that includes an operator interface such as a touchscreen, keyboard, or mouse, which allows the operator to input and adjust patterns. In some embodiments, the control system may include or include a stitch distribution control system, and the controller of the control system may further include programming for a control methodology for forming tufted patterns, including engraved patterns, multi-color patterns, etc., having tufts formed with multiple pile heights. In addition, one or more encoders, motor controls, and / or other similar sensors adapted to monitor the rotation of the motor drive shaft and report the position of the motor drive shaft to the control system may also be provided for controlling the operation of the tufting machine 10.

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

[0049] In embodiments, the motor may be mounted on the opposite side of the tufting machine frame and, as shown in Figures 1A, 3, and 4, on each of its sides 16, on a support plate or platform 19 attached to the upper portion 18 of the tufting machine frame. Each motor will further include a motor drive shaft 47 and a motor drive gear 48 mounted distal to it. In embodiments, the motor drive gear 48 may include a gear, pulley, or chain gear. The motor 46 will be operated under the control of the control system during the tufting operation to drive the needle stroke assembly 28 of the drive system 5, causing the reciprocating motion of the needle bar 30. As will be understood, the term “gear” may include gears, chain gears, pulleys, cogs, wheels, or other similar transmission elements.

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

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

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

[0053] A secondary drive shaft 56 or stud shaft is rotatably received into each shaft support section 53 by a bearing or bushing 57 and can protrude through the bearing or bushing 57, the bearing or bushing 57 being mounted in a shaft support section adjacent to the upper end 53A of the shaft support section. In an embodiment, the secondary drive shaft includes a proximal end 58 that protrudes in a first direction through the shaft support section and is attached to a rotary cam member 59, and a distal end 61, the distal end 61 which protrudes in the opposite direction through the support section and is engaged to be rotatably supported by a bearing 62 of a stub shaft support 63, the stub shaft support 63 which may be formed together with or attached to a support framework 51.

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

[0055] In embodiments, as shown in Figures 1A-1B, the drive member 75 may include a belt and / or chain, and in some embodiments, for example, comprises a double-strand roller chain 76. For example, but not limited to, the drive member may include a double-strand size #60 drive chain. Each of the double-strand drive chains 76 may include two rows or strands of chain links in a substantially endless loop-like path, and a master connection link 77 connects strands that can be disengaged, thereby allowing each drive chain to be released and removed from engagement with the first and second needle-stroke drive gears 71 and 72.

[0056] In addition to providing or enabling a substantial increase in horsepower to drive the reciprocating motion of at least one needle bar, the drive chain can be further configured to facilitate efficiency in the maintenance and repair of the drive system 5 by allowing the drive chain to be removed and easily taken out for repair and / or replacement of the drive chain, needle stroke drive gear, secondary drive shaft, and / or other components of the needle stroke assembly 28, but without requiring the removal of the first and / or second drive shafts 25A / 25B.

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

[0058] Enabling the use of drive members configured to adapt to such increases in horsepower allows the drive system to drive at least one needle bar 30 at an increased speed. For example, in an embodiment featuring a cut pile tufting machine, the drive system 5 can be operated to drive the reciprocating motion of at least one needle bar at a speed approximately equivalent to that obtainable using a loop pile tufting machine, for example, a maximum speed of about 1,500 rpm to about 2,000 rpm. In embodiments, speeds of 1,500 rpm to 1,900 rpm, 1,500 rpm to 1,800 rpm, 1,500 rpm to 1,700 rpm, 1,500 rpm to 1,600 rpm, 1,600 rpm to 2,000 rpm, 1,600 rpm to 1,900 rpm, 1,600 rpm to 1,800 rpm, 1,600 rpm to 1,700 rpm, 1,700 rpm to 2,000 rpm, 1,700 rpm to 1,900 rpm, 1,700 rpm to 1,800 rpm, 1,800 rpm to 2,000 rpm, 1,800 rpm to 1,900 rpm, and 1,900 rpm to 2,000 rpm can be achieved, but faster speeds can also be expected.

[0059] As further shown in Figure 1A-2, in the embodiment, the alternating needle stroke assemblies 28 of the drive system 5 can be coupled to opposite sides of the first and second drive shafts 25A / 25B. For example, the first needle stroke drive gear 71 of each odd needle stroke assembly can be coupled or mounted along the first drive shaft 25A, and the drive members of such needle support assemblies can couple their first needle stroke drive gears 71 to their second needle stroke drive gear 72 in order to drive the rotation of the secondary drive shaft 56 of the odd needle stroke assembly in a first direction by the rotation of the first drive shaft 25A. The first needle stroke drive gear 71 of the even needle stroke assembly 28 can similarly be coupled or mounted along the second drive shaft 25B, and the drive chain 76 of the even needle stroke assembly couples the second drive shaft 25B to its second needle stroke drive gear 72 in order to drive the rotation of each secondary drive shaft 56 of the even needle stroke assembly in the opposite, reverse direction when the second drive shaft 25B rotates.

[0060] In the embodiment, each needle stroke assembly 28 may further include a cam arm 80 having a first or upper end attached to a rotary cam member 59 and a second distal end connected by a connecting rod 81 to one of the push rods 33, the push rod 33 being connected to at least one needle bar 30. When the first and second drive shafts 25A / 25B are rotated, their rotation is transmitted to a secondary drive shaft 56 of each needle stroke assembly via the respective needle stroke drive gears and drive members of the needle stroke assembly, the secondary drive shaft 56 then rotates the rotary cam member 59 attached thereto. When the rotary cam member 59 is driven in conjunction with the rotation of the first and second drive shafts 25A / 25B, the cam arm 80 is driven in a reciprocating vertical linear motion. This up-and-down motion is transmitted to a push rod 33 via a connecting rod 81, which can be coupled to at least one needle bar 30 by a support bracket or foot 82, thereby causing at least one needle bar to reciprocate up and down in the directions of arrows 32 and 32' to cause a needle 31 carried by the at least one needle bar 30 to reciprocate in and out of the lining material B passing beneath it.

[0061] As shown in Figures 1A, 1B, and 3, in an embodiment, the drive belt 85 encircles (or extends) in a substantially meandering path around the motor drive gear 48 and the shaft drive gear 49 attached to the exposed ends 26A / 26B of the first and second drive shafts 25A / 25B. In an embodiment, the drive belt and the motor drive gear and drive shaft gear may have a high-torque drive arrangement configured to allow the motor to drive the first and second drive shafts with increased horsepower and torque.

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

[0063] In addition, in some embodiments, the drive belt may comprise a toothed timing belt having a series of spaced teeth, which in some embodiments will include a series of curved teeth. In some embodiments, the drive belt may comprise a double-sided curved toothed timing belt. In other embodiments, the drive belt may comprise a double-sided high-torque belt, which has a series of spaced teeth along it, and which in some embodiments may include a plurality of curved teeth.

[0064] As shown in Figure 3, the motor drive gear 48 and shaft drive gear 49 will be along an externally exposed surface, or outer surface, along the side 16 of the tufting machine frame 11. In this configuration, the drive belt 85 is not exposed to any lubricating material (e.g., oil or other material) that could degrade the drive belt, which could occur in previous drive systems where the drive belt and drive connection to the drive shaft were contained within the end box 21 of the tufting machine frame. As shown, the drive belt extends around the motor drive gear 48 and the shaft drive gear 49 mounted on the exposed ends 26A / 26B of the first and second drive shafts 25A / 25B in a meandering arrangement configured such that the rotation of the drive motor causes the rotation of the first drive shaft and the second drive shaft in opposite reverse directions.

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

[0066] In embodiments, the support 91 is adjustable or movable vertically along the side plate 17 of the tufting machine frame, allowing adjustment in the tension applied to the drive belt, for example, to eliminate or absorb slack in the drive belt that may develop over time during the operation of the drive belt. In embodiments, the support 91 is mounted on a slide, a rail 92 along a track, and / or other guide member, as shown in Figure 1A, and can be guided along a substantially linear movement path relative to the drive belt along the side plate 17. In embodiments, the movement of the support 91, and therefore the tension adjustment gear 90, can be controlled by actuators such as servo motors, cylinders, which are operated under the control of the tufting machine control system (and / or manually controlled by an operator). For example, in embodiments, a sensor or detector is provided to be positioned along one or more of the shaft gears and / or tension adjustment gears, which can detect slippage, slack, or a decrease in tension of the drive belt and provide an indication thereof to a controller of the control system, and / or signal such conditions by an indicator such as light, a gauge, etc.

[0067] The drive belt 85 transmits or transmits the rotation of the motor drive shaft 48 to the shaft drive gear 49 so that the first and second drive shafts each rotate in synchronous, opposite directions. When the first and second drive shafts 25A / 25B are rotated, each drive member 75 of the needle stroke assembly 28 transmits such rotation to the secondary drive shaft 56, which then drives the eccentric movement of the cam arm 80 attached to the rotary cam member 59 so that the cam arm moves in a reciprocating vertical movement. In an embodiment, the timing of each movement of the cam arm can be arranged so that the movement of each cam arm of the needle stroke assembly can stop at the top dead center position and at the bottom dead center almost simultaneously.

[0068] In addition, in some embodiments, a connecting rod 81 or push rod 33 that connects the cam arm 80 to at least one needle bar 30 can be replaced to position the needle bar at a predetermined location relative to the lining material, thereby allowing for variations in the penetration or stroke depth of the needle 31 into the lining material without necessarily varying the height of the bed plate. Alternatively, in embodiments, the bed plate and / or gauge components are movable, allowing for adjustment in the pile height of the tufted yarn formed in the lining material.

[0069] Generally, the timing of the strokes of the alternately arranged cam arms 80 and connecting rods 81 of the needle stroke assembly 28 can be selected to be approximately 180° out of phase with each other, thereby the needle 31 is fully raised when the cam arm is at top dead center and fully lowered when the cam arm is at bottom dead center. The reverse rotation drive shafts 25A / 25B thus rotate the secondary drive shafts 56 of the alternate needle stroke assembly in the reverse rotation direction, thereby driving the cam arms, and therefore the connecting rods and push rods coupled thereto, in synchronized and dynamically canceled-out motion during the movement of the needle bar 30 in the upward / downward direction.

[0070] To further provide dynamic countermeasures, in some embodiments, the first and second drive shafts 25A / 25B may be equipped with counterweights 95 (Figure 1A-2), which may rotate in conjunction with the first and second drive shafts. Such counterweights may be selected and / or configured to balance the first and second drive shafts that drive their rotation and to help substantially dampen or cancel out the vertical force generated by the reciprocating motion of at least one needle bar 30.

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

[0072] Such an arrangement allows the tufting machine 10 of the present disclosure to remain substantially balanced during operation, and the tufting machines (including cut pile tufting machines) to be configured to operate at speeds generally equivalent to those of loop pile tufting machines. In embodiments, the cut pile tufting machine may be provided to operate at speeds of 1,500 RPM to 2,000 RPM or higher.

[0073] The tufting machine of this disclosure exhibits virtually no vibration transmitted to the floor on which the machine 10 is mounted and / or to any twisting and feeding mechanisms that may be associated with the machine. Furthermore, the noise of the machine is reduced, thereby the environmental impact is not as great as that of conventional machines when the machine 10 is in operation.

[0074] In addition to the embodiments described herein, embodiments of this disclosure further relate to one or more of the following embodiments of a drive system based on the principles of this disclosure, and embodiments may include various embodied features or elements and / or combinations of feature steps or elements as disclosed herein. The following disclosed embodiments should not be taken as limiting the scope of any of the embodiments of this disclosure. (Example 1)

[0075] It is a tufting machine, and a tufting machine is, A machine frame having sides and a head extending between the sides, It has a plurality of spaced needles mounted along them, and the needles are configured to move in a reciprocating motion toward and away from the lining material as it moves through the tufting machine to penetrate the lining material in order to form a tuft of twisted yarn in the lining material, A drive system, and the drive system is A motor having a motor drive shaft with motor gears coupled to it, mounted along at least one of the sides of the frame, First and second drive shafts extending along the head of a tufting machine, each having an exposed end extending through the side of the frame, A plurality of needle stroke assemblies are arranged at spaced positions along the first and second drive shafts, wherein each needle stroke assembly is, A pair of needle stroke drive gears, each including one needle stroke drive gear coupled to and driven by one of a first and a second drive shaft, and another needle stroke drive gear coupled to the first needle stroke drive gear with respect to a secondary drive shaft, A drive member extending between the needle stroke drive gears of each pair of needle stroke drive gears and connecting them, such that the secondary drive shaft rotates in conjunction with the rotation of the first and second drive shafts, A plurality of push rods coupled to at least one needle bar and a secondary drive shaft, wherein when the secondary drive shaft is rotated in conjunction with the rotation of the first and second drive shafts, the plurality of push rods are driven in a linear motion to reciprocate the needle toward and away from the lining material, A needle stroke assembly, The first and second shaft drive gears are mounted on the exposed ends of the first and second drive shafts outside the end box of the frame, A tension adjustment gear located adjacent to the first and second drive gears, A drive belt extending around a motor drive gear, first and second shaft drive gears, and tension adjustment gear, An adjustable support is positioned along the outer surface of the side of the frame, with a tension adjustment gear mounted on top of it. The drive system comprises a support that moves along the outer surface of the side of the frame, adjusting the position of the tension adjustment gear relative to the first and second drive gears, and maintaining the selected tension in the drive belt. A tufting machine equipped with [a specific feature / feature].

[0076] The tufting machine according to Embodiment 1 of paragraph (0072), wherein the drive belt is a double-sided curved toothed timing belt.

[0077] The tufting machine according to Embodiment 1 of paragraph (0072), wherein the drive member comprises a double-strand drive chain having at least one connecting link configured to disengage so as to allow the drive chain to be removed from around the needle stroke drive gear and the respective pushrod gear.

[0078] The tufting machine according to Embodiment 1 of paragraph (0072), further comprising a plurality of gauge components located below the lining material and configured to engage with a needle and pick up the loops of twisted yarn from there.

[0079] The tufting machine according to Example 1 of paragraph (0075), wherein the gauge component comprises a cut pile hook and a knife for forming a twisted cut pile tuft in a lining material.

[0080] The tufting machine for forming a cut pile tuft has an operating speed of at least about 1,800 RPM, as described in Example 1 of paragraph (0076).

[0081] The tufting machine according to Embodiment 1 of paragraph (0072) comprises a multi-chain double-sided curved toothed timing belt having a width of at least about 2 inches to about 6 inches.

[0082] Each needle stroke assembly further comprises a frame mounted to the head of the machine frame, a pair of lower bearings that receive first and second drive shafts, and at least one upper bearing that receives a secondary drive shaft, as described in Embodiment 1 of paragraph (0072). (Example 2)

[0083] It is a tufting machine, and a tufting machine is, Frame and, A needle bar having multiple spaced needles mounted along them, wherein the needles carry multiple twisted yarns, and the needle bar has at least one needle bar, Multiple gauge components configured to pick up loops of twisted yarn from a needle, A drive system coupled to at least one needle bar and The drive system is equipped with A motor mounted along a frame, including at least one motor and a motor drive shaft coupled thereto with motor gears, First and second drive shafts extending across the frame of a tufting machine, each having at least one exposed end extending through the side of the frame and projecting outward from the outer surface of the side of the frame, A plurality of needle stroke assemblies are arranged at spaced positions along the first and second drive shafts, wherein each needle stroke assembly is A plurality of needle stroke drive gears, including at least one drive needle stroke gear coupled to one of the first and second drive shafts, and at least one needle stroke drive gear coupled to a secondary drive shaft, A needle stroke drive gear and at least one drive member extending between the needle stroke drive gear and the secondary drive shaft, At least one pushrod is coupled to at least one needle bar, operably connected to a secondary drive shaft, and configured to convert the rotation of the first and second drive shafts into reciprocating motion of at least one needle bar. A needle stroke assembly, First and second shaft drive gears mounted on the exposed ends of the first and second drive shafts, wherein the first and second drive gears are located outside the end box of the frame along the outer surface of the side of the frame, A tension adjustment gear positioned adjacent to at least one of the first and second drive gears, A drive belt extending around a motor drive gear, first and second shaft drive gears, and tension adjustment gear drives the rotation of the first and second drive shafts. Equipped with, As the first and second drive shafts are rotated, at least one needle bar is moved in a reciprocating motion toward and away from the lining material as the lining material moves through the tufting machine, so that the needle penetrates the lining material and forms a tuft of twisted yarn in the lining material. A tufting machine, wherein the tension adjustment gear is mounted on an adjustable support configured to move along the outer surface of the side of the frame, adjusting the position of the tension adjustment gear relative to the first and second drive gears and maintaining the selected tension within the drive belt.

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

[0085] The tufting machine according to Embodiment 2 of paragraph (0080), wherein each of the drive members includes at least one connecting coupling configured to be disengaged so as to allow removal of the drive member from around the needle stroke drive gear and the respective pushrod gear.

[0086] The tufting machine according to Example 2 of paragraph (0080), wherein the gauge component comprises a cut pile hook and a knife for forming a twisted cut pile tuft in a lining material.

[0087] The tufting machine for forming a cut pile tuft in a lining material has an operating speed of at least about 1,800 RPM, as described in Example 2 of paragraph (0080).

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

[0089] It is a tufting machine, and a tufting machine is, Frame and, A needle bar having multiple spaced needles mounted along them, wherein the needles carry multiple twisted yarns, and the needle bar has at least one needle bar, Multiple gauge components configured to pick up loops of twisted yarn from a needle, A drive system coupled to at least one needle bar and The drive system is equipped with At least one motor mounted along the frame, First and second drive shafts extending across the frame of a tufting machine, each having at least one exposed end extending beyond the periphery of the frame, A plurality of needle stroke assemblies positioned along first and second drive shafts, each needle stroke assembly is A coupled drive member and A rotary cam member operably connected to at least one drive member and configured to convert the rotation of a first or second drive shaft into the reciprocating motion of at least one needle bar, A needle stroke assembly, A tension adjustment gear mounted on an adjustable support adjacent to at least one exposed end of the first and second drive shafts, A motor, the first and second drive shafts, and a drive belt coupled to a tension adjustment gear are used to drive the rotation of the first and second drive shafts. A tufting machine comprising, wherein when first and second drive shafts are rotated, at least one needle bar is moved in a reciprocating motion toward and away from the lining material as the lining material moves through the tufting zone of the tufting machine, such that a needle penetrates the lining material and forms a tuft of twisted yarn in the lining material.

[0090] The tufting machine according to Embodiment 3 of paragraph (0086), further comprising a secondary drive shaft coupled to at least one of a first needle stroke drive gear and a second needle stroke drive gear, such that the secondary drive shaft rotates in conjunction with the rotation of the first and second drive shafts.

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

[0092] The tufting machine according to Embodiment 3 of paragraph (0086), further comprising first and second drive gears mounted on the exposed ends of first and second drive shafts, wherein the drive belt extends around the first and second drive gears in a substantially meandering path such that the first and second drive shafts rotate in opposite directions.

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

[0094] One or more embodiments of the tufting machine described in Example 3 of paragraph (0090) further comprises one or more pairs of opposite rectangular clamping blocks positioned to grip the first and second drive shafts from opposite sides.

[0095] The drawings and specification disclose embodiments of a drive system for driving a needle bar or multiple needle bars of a tufting machine, employing specific terminology, but such terminology is for illustrative purposes only and not for limiting purposes. In addition, embodiments of the drive system and its operation are described in detail with specific reference to the illustrated embodiments, however, various changes and modifications can be made to the structures discussed above in this disclosure without departing from the spirit and scope of this disclosure as disclosed herein, and it will be understood by those skilled in the art that everything included in the above description or shown in the accompanying drawings is intended to be interpreted as illustrative and not to be taken as limiting.

[0096] Furthermore, the scope of this disclosure shall be interpreted to encompass various modifications, combinations, additions, alterations, etc., to the embodiments described herein, and such modifications shall be deemed to fall within the scope of this disclosure. Thus, various features and characteristics of this disclosure as discussed herein may be selectively replaced and applied to other illustrated and non-illustrated embodiments of this disclosure, and numerous modifications, alterations, and additions may be made thereto without departing from the spirit and scope of this disclosure as described in the appended claims.

Claims

1. A tufting machine, wherein the tufting machine is A machine frame having sides and a head extending between the sides, At least one needle bar, the at least one needle bar having a plurality of spaced needles mounted along them, the at least one needle bar configured to move in a reciprocating motion toward and away from the lining material moving through the tufting machine, thereby the needles penetrating the lining material to form a tuft of twisted yarn in the lining material, Drive system and Equipped with The drive system is At least one motor mounted along at least one of the sides of the machine frame, wherein the at least one motor has a motor drive shaft, and the motor drive shaft is coupled to a motor gear, First and second drive shafts extending along the head of the tufting machine, each of the first and second drive shafts having an exposed end extending through the side of the machine frame, A plurality of needle stroke assemblies are arranged at spaced positions along the first and second drive shafts, wherein each needle stroke assembly is A plurality of pairs of needle stroke drive gears, each pair comprising one needle stroke drive gear coupled to and driven by one of the first and second drive shafts, and another needle stroke drive gear coupled to the one needle stroke drive gear with respect to a secondary drive shaft, A drive member extends between each pair of needle stroke drive gears, connecting them, thereby causing the secondary drive shaft to rotate in conjunction with the rotation of the first and second drive shafts. The at least one needle bar and the plurality of push rods coupled to the secondary drive shaft A needle stroke assembly comprising, wherein when the secondary drive shaft is rotated in conjunction with the rotation of the first and second drive shafts, the plurality of push rods are driven in linear motion to reciprocate the needle toward and away from the lining material, The first and second shaft drive gears are mounted on the exposed ends of the first and second drive shafts outside the end box of the machine frame, A tension adjustment gear located adjacent to the first and second drive gears, The motor gear, the first and second shaft drive gears, and the drive belt extending around the tension adjustment gear, An adjustable support positioned along the outer surface of the side of the machine frame, wherein the tension adjustment gear is mounted on the adjustable support and Equipped with, A tufting machine, wherein the adjustable support is configured to move along the outer surface of the side of the machine frame, to adjust the position of the tension adjustment gear relative to the first and second drive gears, and to maintain a selected tension in the drive belt.

2. The tufting machine according to claim 1, wherein the drive belt is a double-sided curved toothed timing belt.

3. The tufting machine according to claim 1, wherein the drive member comprises a double-strand drive chain, and each of the double-strand drive chains has at least one connecting link configured to be disengaged so as to allow removal of the double-strand drive chain from around the needle stroke drive gear and the respective push rod.

4. The tufting machine according to claim 1, further comprising a plurality of gauge components located below the lining material and configured to engage with the needle and pick up the twisted yarn loop from the needle.

5. The tufting machine according to claim 4, wherein the gauge component comprises a cut pile hook and a knife for forming a twisted yarn cut pile tuft in the lining material.

6. The tufting machine according to claim 5, wherein the operating speed of the tufting machine for forming a cut pile tuft is at least about 1,800 RPM.

7. The tufting machine according to claim 1, wherein the drive belt comprises a multi-chain double-sided curved toothed timing belt having a width of at least about 2 inches to about 6 inches.

8. The tufting machine according to claim 1, wherein each needle stroke assembly further comprises a frame attached to the head of the machine frame, a pair of lower bearings that receive the first and second drive shafts, and at least one upper bearing that receives the secondary drive shaft.

9. A tufting machine, wherein the tufting machine is Frame and, At least one needle bar, the at least one needle bar having a plurality of spaced needles mounted along them, the needles carrying a plurality of twisted yarns, and at least one needle bar Multiple gauge components configured to pick up loops of twisted yarn from the aforementioned needle, A drive system coupled to the at least one needle bar and Equipped with, The drive system is At least one motor mounted along the frame, the at least one motor includes a motor drive shaft, the motor drive shaft is coupled to a motor gear, and the at least one motor includes The first and second drive shafts extend across the frame of the tufting machine, each of the first and second drive shafts extending through the side of the frame and having at least one exposed end projecting outward from the outer surface of the side of the frame, A plurality of needle stroke assemblies are arranged at spaced positions along the first and second drive shafts, wherein each needle stroke assembly is A plurality of needle stroke drive gears, wherein each plurality of needle stroke drive gears includes at least one drive needle stroke gear coupled to one of the first and second drive shafts, and at least one needle stroke drive gear coupled to a secondary drive shaft, A needle stroke drive gear and at least one drive member extending between the needle stroke drive gear and the secondary drive shaft, At least one push rod coupled to the at least one needle bar and operably connected to the secondary drive shaft, A needle stroke assembly comprising, wherein the at least one push rod is configured to convert the rotation of the first and second drive shafts into the reciprocating motion of the at least one needle bar, The first and second shaft drive gears are mounted on the exposed ends of the first and second drive shafts, wherein the first and second drive gears are located outside the end box of the frame along the outer surface of the side surface of the frame, A tension adjustment gear positioned adjacent to at least one of the first and second drive gears, To drive the rotation of the first and second drive shafts, a drive belt extends around the motor gear, the first and second shaft drive gears, and the tension adjustment gear. Equipped with, As the first and second drive shafts are rotated, the at least one needle bar is moved in a reciprocating motion toward and away from the lining material as the lining material moves through the tufting machine, thereby the needle pierces the lining material and forms the tuft of the twisted yarn in the lining material. A tufting machine, wherein the tension adjustment gear is mounted on an adjustable support, the adjustable support moves along the outer surface of the side of the frame, and is configured to adjust the position of the tension adjustment gear relative to the first and second drive gears and to maintain a selected tension in the drive belt.

10. The tufting machine according to claim 9, further comprising one or more counterweights attached to at least one of the first and second drive shafts, wherein the counterweights are configured to substantially dampen the vertical force resulting from the reciprocating motion of the at least one needle bar.

11. The tufting machine according to claim 9, wherein each of the drive members includes at least one connecting coupling configured to be disengaged so as to allow removal of the drive member from around the needle stroke drive gear and each push rod.

12. The tufting machine according to claim 9, wherein the gauge component comprises a cut pile hook and a knife for forming a twisted yarn cut pile tuft in the lining material.

13. The tufting machine according to claim 9, wherein the operating speed of the tufting machine for forming a cut pile tuft in the lining material is at least about 1,800 RPM.

14. The tufting machine according to claim 9, wherein the drive belt comprises a multi-chain double-sided corrected curved toothed timing belt having a width of at least about 2 inches to about 5 inches.

15. A tufting machine, wherein the tufting machine is Frame and, At least one needle bar, the at least one needle bar having a plurality of spaced needles mounted along them, the needles carrying a plurality of twisted yarns, and at least one needle bar Multiple gauge components configured to pick up loops of twisted yarn from the aforementioned needle, A drive system coupled to the at least one needle bar and Equipped with, The drive system is At least one motor mounted along the frame, The first and second drive shafts extend across the frame of the tufting machine, each of the first and second drive shafts having at least one exposed end extending beyond the periphery of the frame, A plurality of needle stroke assemblies positioned along the first and second drive shafts, each double needle stroke assembly is A coupled drive member and A rotary cam member is operably connected to the at least one drive member and configured to convert the rotation of the first or second drive shaft into the reciprocating motion of the at least one needle bar. A needle stroke assembly, A tension adjustment gear mounted on an adjustable support adjacent to at least one exposed end of the first and second drive shafts, To drive the rotation of the first and second drive shafts, the motor, the first and second drive shafts, and the drive belt coupled to the tension adjustment gear are used. Equipped with, A tufting machine wherein, when the first and second drive shafts are rotated, the at least one needle bar is moved in a reciprocating motion toward and away from the lining material as the lining material moves through the tufting zone of the tufting machine, so that the needle penetrates the lining material and forms a tuft of the twisted yarn in the lining material.

16. The tufting machine according to claim 15, wherein the drive system further comprises a secondary drive shaft, the secondary drive shaft being coupled to at least one of a first needle stroke drive gear and a second needle stroke drive gear, thereby causing the secondary drive shaft to rotate in conjunction with the rotation of the first and second drive shafts.

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

18. The tufting machine according to claim 15, further comprising first and second drive gears mounted on the exposed ends of the first and second drive shafts, wherein the drive belt extends around the first and second drive gears in a substantially meandering path, so that the first drive shaft and the second drive shaft rotate in opposite directions.

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

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

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