Servo Shaker for Tufting Machine Vibration Control

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Solution Overview

Problem

High-speed tufting machines experience vibrations due to imbalance, which can damage the equipment, and existing adjustable mechanisms for stroke length and speed are cumbersome, requiring machine shutdown and lacking structural stability or precision in counterbalancing.

Innovation Solution

A servo motor-driven shaker assembly with counterbalancing weights is used to rotate and adjust the position of counterweights in opposition to vibrations, allowing for real-time adjustment and minimization of vibrations across varying throw lengths and speeds without stopping the machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high speed operation is used to increase productivity, then output per time is improved, but vibrations are generated that can damage the machine

Engineering Contradiction:

Improvestitches per minuteVSAvoidvibrations

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A counterweight is mounted on the drive shaft opposite to the eccentric to balance the radial forces generated during high-speed operation. The counterweight's mass and position are calculated to counteract the centrifugal force produced by the eccentric, thereby reducing vibrations while maintaining high productivity.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The system allows dynamic adjustment of the counterweight's position and the eccentric's throw to optimize the balance between productivity and vibration control. By changing parameters such as counterweight angle and eccentricity, the machine can maintain stable operation across different speed and stroke requirements.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If adjustable eccentrics are used to change stroke length, then adaptability is improved, but structural stability deteriorates due to insufficient radial force resistance

Engineering Contradiction:

Improvestroke length adjustmentVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The eccentric mechanism incorporates a dynamic adjustment system where the eccentric's position on the drive shaft can be modified while the machine is running or during brief stoppages. This allows stroke length changes without requiring complete disassembly, maintaining both adaptability and structural integrity through a robust mounting system that secures the eccentric in its adjusted position.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If interchangeable eccentrics are mounted on the rotating shaft to adjust throw, then adaptability is improved, but device complexity increases due to multiple eccentrics

Engineering Contradiction:

Improvethrow adjustmentVSAvoidnumber of eccentrics

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single drive shaft is designed to accommodate multiple eccentrics with different throws, each serving a specific stroke length requirement. The drive shaft includes standardized mounting positions and a universal securing mechanism that works with all eccentric types, allowing the system to handle multiple functions (different pile heights) without requiring separate drive shafts or complex switching mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If adjustable eccentrics are used to change needle stroke, then adaptability is improved, but loss of time increases due to machine shutdown requirement

Engineering Contradiction:

Improveneedle stroke adjustmentVSAvoidmachine shutdown time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The eccentric adjustment mechanism is designed to allow stroke length changes during machine operation or with minimal interruption. The securing system enables quick locking and unlocking of the eccentric position, and the counterweight can be repositioned dynamically, allowing the machine to maintain continuous production flow while adapting to different tufting requirements without complete shutdown.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively reduces vibrations in tufting machines by dynamically adjusting counterbalancing weights, ensuring optimal performance and minimizing yarn drop during different tufting operations, even at high speeds and varying yarn types.

Implementation Method 1

A counterbalancing weight is mounted on the drive shaft in opposition to an eccentric that drives a reciprocating needle bar

Methodology Applied

Scientific EffectCounterbalancing: Balance

Implementation Method 2

A controller rotates the counterbalancing weight an amount sufficient to minimize vibrations generated by the tufting machine

Methodology Applied

Scientific EffectServo motor control:

Data Source

PatentUS7578249B2Tufting machine head shaker

Publication Date: 2009.08.25 TUFTCO CORP

AI summary

An antivibratory system is provided by means of a servo motor driven shaker affixed to the head or bed frame of a tufting machine and programmed for rotation of a balancing weight to minimize vibration caused by operation of tufting machine at a particular speeds and needle stroke lengths.