Multi-Height Looper and Backing Shifter for Tufting
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Solution Overview
Problem
Current tufting machines face challenges in achieving precise yarn pile height differentiation and efficient yarn placement, leading to excessive yarn waste and limited pattern complexity due to mechanical complexity, speed limitations, and difficulties in creating precise transitions between low and high pile heights.
Innovation Solution
The integration of variable gauge tufting with reciprocating backing support and looper arrangements that allow for different fixed looper heights to seize yarns at varying distances from the backing fabric, enabling precise yarn placement and pile height control on a stitch-by-stitch basis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a servo scroll yarn feed attachment is used to control tufting heights of multiple yarns, then yarn placement precision is improved, but device complexity increases and production speed decreases
Solution Approach 1:
The invention divides the yarn feed system into multiple independent servo motors, each controlling a separate yarn tube. This segmentation allows precise individual control of each yarn's feed rate and tension, enabling accurate yarn placement without requiring a complex centralized control system. Each yarn can be independently managed, simplifying the overall device architecture while maintaining high precision.
Solution Approach 2:
The invention employs dynamic tension control through adjustable tensioning members for each yarn tube, allowing real-time adjustment of yarn tension during operation. This dynamic control enables precise yarn placement by compensating for variations in yarn properties and feed rates, while keeping the mechanical structure relatively simple through software-controlled tension adjustment rather than complex mechanical mechanisms.
2Adaptability or versatility
If multiple yarns are tufted at varied heights with servo control, then pattern complexity is improved, but production speed deteriorates
Solution Approach 1:
The invention changes the control parameter from mechanical height adjustment to yarn feed rate control. By varying the feed rate of each yarn through independent servo motors, the system achieves different effective yarn heights without mechanical height adjustments. This allows complex patterns to be created by modulating feed rates dynamically, maintaining high production speed while achieving versatile pattern complexity.
Solution Approach 2:
The invention uses periodic reciprocation of the needle bar combined with continuous yarn feed to create varied yarn heights. During the reciprocating cycle, different yarns are fed at different rates, and by controlling when each yarn is fed relative to the needle position, the system creates height variations without slowing overall production. This periodic action enables complex patterns to be woven into the fabric structure itself.
3Adaptability or versatility
If yarns are fed to multiple needles with alternating colors, then color variety is improved, but yarn waste increases
Solution Approach 1:
The invention implements self-service yarn management where each yarn tube is equipped with independent tension control and feed rate adjustment. This allows the system to automatically optimize yarn usage by feeding each yarn only when and where needed, eliminating waste from overfeeding or incorrect yarn selection. The independent control enables precise delivery of the correct yarn to the correct needle, reducing waste while maintaining color variety.
Solution Approach 2:
The invention replaces mechanical yarn selection mechanisms with electronically controlled yarn feed. Instead of using complex mechanical systems to select and route yarns to needles, the system uses servo-controlled feed rates and software logic to deliver the correct yarn to each needle. This substitution reduces mechanical complexity and improves yarn delivery precision, thereby reducing yarn waste while maintaining the ability to handle multiple colors.
Data Source
AI summary
A shiftable backing feed is utilized with a tufting machine having reciprocating needles and gauge parts for seizing yarns at a plurality of fixed heights, wherein fabric support apparatus reciprocates in synchronization with the cycles of the needle bar to support the backing during penetration of the backing fabric yet allow backing shifts between stitches.