Tufting Machine Needle Holder Retention via Embedded Magnets

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Solution Overview

Problem

The existing tufting machines face issues with vibration and distortion due to irregular collisions between needle holders and stop bars, and require frequent maintenance due to spring sensitivity to pollution and dust, leading to friction and potential damage.

Innovation Solution

Embedding magnets in the stop bar and using a cushioning member to absorb impacts, along with a staggered arrangement of needle holders and magnets to ensure continuous magnetic alignment, reduces vibration and eliminates spring-related friction, allowing for thicker and more stable support shafts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If springs are used to hold needle holders in position, then the needle holders can be retained in their uppermost position, but the springs are sensitive to pollution and dust requiring regular maintenance and cause friction that can damage shafts

Engineering Contradiction:

Improveneedle holder retentionVSAvoidmaintenance requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical spring system with a magnetic field-based retention system. Magnets embedded in the stop bar create magnetic attraction forces that hold the needle holders in their uppermost positions without physical contact, eliminating friction and maintenance issues associated with springs while maintaining reliable retention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnets as an intermediary between the stop bar and needle holders. These magnets create an invisible magnetic field that acts as the retaining force, replacing the direct mechanical contact of springs and eliminating the harmful friction and pollution sensitivity while maintaining the retention function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If narrow stop bars are used with magnets attached, then the machine structure remains compact, but frequent irregular collisions cause vibration and distortion in the needle bars

Engineering Contradiction:

Improvestructure compactnessVSAvoidneedle bar stability

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The patent merges the magnet attachment with the stop bar structure by embedding magnets directly into the stop bar. This integration creates a more robust and stable structure that can withstand collision forces without causing vibration or distortion, while maintaining compactness through the unified design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces cushioning members that make contact with the needle holders before they can collide with the stop bar. This pre-cushioning absorbs impact forces and prevents direct collisions, thereby eliminating vibration and distortion while maintaining the compact structure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If rectangular magnet strips are used with gaps between them, then the magnet arrangement is simple, but gaps can align with needle holders reducing magnetic retention force

Engineering Contradiction:

Improvemagnet arrangement simplicityVSAvoidmagnetic retention consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent changes the magnet strip configuration from rectangular with perpendicular gaps to parallelogram-shaped strips with angled gaps. This asymmetric arrangement ensures that gaps between strips never fully align with needle holders during operation, maintaining consistent magnetic retention force while keeping the overall structure simple.

Inventive Principle:

Principle #4Asymmetry

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

This solution significantly reduces vibration and distortion, enhances the stability of the needle holders, and eliminates the need for regular maintenance by using magnets and cushioning to manage impacts, improving the overall performance and longevity of the tufting machine.

Implementation Method 1

magnets are provided in order to hold the non-latched needle holder in its topmost position

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Implementation Method 2

There is provided a cushioning member attached to the magnet facing the top of each needle bar

Methodology Applied

Scientific EffectImpact absorption: Damping

Data Source

PatentUS11492739B2Tufting machine

Publication Date: 2022.11.08 VANDEWIELE NV

AI summary

A tufting machine comprising a plurality of needle holders (11) associated with a needle bar (5) and slidably supported in a frame for reciprocation in a needle reciprocation direction. A respective needle (10) is attached to each needle holder (11), each needle holder having an engagement portion. The needle bar (5) has means (7, 13) for selectively latching with the engagement portion of each selected needle holder so as to selectively drive latched needle holders in the needle reciprocation direction. A stop bar (21) is positioned to limit the upward movement of the needle holders (11). At least one magnet (20) retains non-latched needle holders in its uppermost position as the needle bar is reciprocated. The magnets (20) are embedded in the stop bar (21). The machine further comprises a cushioning member (27) attached to the magnet (20) and facing the top of each needle holder (11).