Tufting Machine Yarn Entanglement Compensation
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Solution Overview
Problem
Tufting machines face issues with yarn entanglement and uneven yarn feed, leading to short tufts and messy back surfaces due to the complex paths of yarns between tufts, which result in inconsistent pile height and visibility problems in finished carpets.
Innovation Solution
A controller in the tufting machine actively calculates and compensates for points of entanglement by adjusting yarn feed based on the actual path of yarns between tufts, rather than assuming a straight path, and may perform additional iterations for increased accuracy, using a yarn feed mechanism with servo motors and puller rolls to manage tension and slack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If yarn feed is calculated based on direct path between adjacent tufts, then yarn feed amount is reduced, but yarn entanglement occurs and causes short tufts
Solution Approach 1:
The controller proactively calculates the actual yarn path and determines the required yarn feed amount before the tufting process begins. By pre-computing the yarn consumption based on the complex path between adjacent tufts, the system ensures adequate yarn supply without entanglement, preventing short tufts before they occur.
Solution Approach 2:
The system uses pattern data and needle position information to continuously monitor and calculate the actual yarn path. This feedback mechanism allows the controller to adjust yarn feed amounts dynamically based on the calculated path length, ensuring consistent tuft length despite variations in yarn routing.
2Device complexity
If yarn path is assumed to be straight between tufts, then calculation is simplified, but yarn entanglement occurs on back surface
Solution Approach 1:
The controller pre-calculates the actual yarn path considering the complex routing between adjacent tufts before the tufting process begins. By determining the true path length in advance, the system avoids yarn entanglement without requiring complex real-time calculations during operation.
3Adaptability or versatility
If multiple colours of yarn are used in pattern, then design versatility is improved, but yarn entanglement increases on back surface
Solution Approach 1:
The controller receives pattern data specifying multiple yarn colours and calculates the actual path for each colour's yarn between adjacent tufts. This feedback mechanism allows the system to compensate for the increased entanglement risk by adjusting yarn feed amounts based on the specific path length for each colour, maintaining uniform tuft length despite multiple yarn colours.
Data Source
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AI summary
A pattern data processing system configured to determine and compensate for any points of entanglement between different yarns. A point of entanglement is defined as a point where the yarn from one needle crosses and traps the yarn from another needle on the back face of the backing medium. The pattern data processing system is configured to calculate the additional length of back stich caused by each point of entanglement by subtracting an ideal back stich length, calculated as the path which would have been taken by the yarn had it not been entangled in another yarn, from an actual yarn path, calculated as the actual length of the entangled yarn. A controller is configured to include in the amount of yarn fed by a respective yarn feed mechanism for each stitch an amount equivalent to the additional length of back stitch. The invention also includes a tufting machine and method of operating the tufting machine with the pattern data processing system.