Quilting Machine Thread Adjuster for Unthreading Prevention
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Solution Overview
Problem
High-speed quilting machines face issues with thread management, leading to unthreading of needles and loopers when threads are cut between patterns, resulting in machine shutdowns or defective quilts due to insufficient or excessive thread length, causing missed stitches.
Innovation Solution
A quilting machine with a looper and adjuster system that captures and pulls a predetermined amount of thread between the looper and the last formed stitch, ensuring sufficient thread length to prevent unthreading while minimizing excess thread, and includes a thread tension monitor and lift arm to manage thread movement and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thread is cut after the previous pattern has been stitched, then loose threads between patterns are avoided, but the needle and/or looper may become unthreaded
Solution Approach 1:
The adjuster is moved to the first position before thread cutting occurs, thereby pre-capturing the thread at a point between the looper and the last formed stitch. This preliminary capture ensures sufficient thread length remains after cutting to prevent unthreading of the needle and/or looper.
2Productivity
If the thread is cut between patterns, then manual trimming is avoided, but the resulting quilt may require manual trimming if thread is too long
Solution Approach 1:
The system uses a thread tension monitor with a drop wire that detects thread tension changes. When tension exceeds a threshold, the lift arm restricts drop wire movement, providing feedback that triggers automatic thread length adjustment by the adjuster mechanism, ensuring optimal thread length without manual intervention.
3Reliability
If the looper thread has insufficient length, then the needle thread has difficulties picking up the looper thread, but if the thread is too long, then manual trimming is required
Solution Approach 1:
The system automatically monitors thread tension and adjusts thread length using the adjuster mechanism. The thread tension monitor detects when thread length becomes insufficient for proper stitch formation and automatically triggers the adjuster to pull the appropriate amount of thread, eliminating the need for manual trimming while ensuring reliable stitch formation.
4Productivity
If high-speed quilting is used, then productivity increases, but thread management issues cause machine shutdowns
Solution Approach 1:
The thread tension monitor continuously monitors thread tension during high-speed quilting operations. When tension changes indicate potential thread management issues, the system automatically activates the adjuster to correct thread length, preventing machine shutdowns and maintaining continuous high-speed operation.
Solution Approach 2:
The adjuster mechanism is positioned to capture thread at the first position before threading issues can occur. This preliminary positioning prevents unthreading events during high-speed quilting, ensuring machine continuity and maintaining productivity.
Data Source
AI summary
Apparatuses, methods, and computer program products for quilting webs. A quilting machine includes a cutting edge, a looper from which thread is provided to form stitches, and an adjuster assembly. The adjuster assembly extends an adjuster toward the thread between the looper and the retainer. When the adjuster is moved, a predetermined amount of thread is pulled away from the looper by the adjuster to provide a controlled length of thread between the looper and the cutting edge. The looper assembly may also include an air nozzle that urges the thread away from the adjuster after the thread has been cut. The thread passes through a thread tension monitor that monitors tension in the thread. The tension monitor includes a lift arm that selectively disables the tension monitor so that a loss of tension in the sewing head does not shut down the quilting machine.