Tangential drive needle bar shifter for tufting machines

• US 5,794,551 A
• Filed: 11/08/1996
• Issued: 08/18/1998
• Est. Priority Date: 09/14/1994
• Status: Expired due to Fees

• Current Assignee: Modern Techniques, Inc.
• Original Assignee: Modern Techniques, Inc.
• Inventors: Morrison, Gerald, Berger, M. Steven
• Primary Examiner(s): LEWIS, PAUL
• Application Number:
  US08/746,406
• Time in Patent Office: 648 Days
• Field of Search: 112/80.01, 112/80.23, 112/80.41, 74/89.22, 74/813 L, 198/832.2, 198/832.1, 198/571, 198/572
• US Class Current: 112/80.41
• CPC Class Codes: D05C 15/30 by moving the tufting tools laterally

Abstract

A tangential drive needle bar shifter for tufting machines. The tangential drive needle bar shifter includes a computer system for creating and storing selected carpet patterns and for controlling the operation of at least one motor which drives the needle bar. The motor includes an output shaft which rotates through a selected degree of rotation in a selected direction. At least one belt is driven by the rotation of the shaft to create lateral displacement of an engagement device is secured thereto. Displacement of the engagement device ultimately creates a shift of the needle bar. As the motor is actuated, the needle bar is shifted a distance proportional to the degree of rotation of the output shaft. A position locking mechanism, or indexer, is provided for preventing the needle bar from shifting farther then required and thus preventing the needles from colliding with the corresponding hooks.

Claims

1. A needle bar shifter for shifting one conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, more than one said needle bar shifter being used with more than one conventional needle bar to shift each conventional needle bar independently of each other conventional needle bar with respect to a direction and a distance of travel thereof, said needle bar shifter comprising:

a rotation imparting device including a pinion member;

a flexible member engaging said rotation imparting device proximate said pinion member and a support device, said flexible member being oscillated in a path about at least a portion of each of said rotation imparting device and said support device to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said flexible member defined between said rotation imparting device and said support device being disposed in a substantially linear configuration, said portion of said flexible member being substantially parallel to the direction of travel of the needle bar; and

a single attachment member adapted to be disposed between said flexible member and the needle bar, said attachment member being secured to said portion of said flexible member and being adapted to be secured to the needle bar.

2. The needle bar shifter of claim 1 further comprising a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance.

3. The needle bar shifter of claim 1 further comprising a computer-operated controller.

4. A needle bar shifter for shifting one conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, more than one said needle bar shifter being used with more than one conventional needle bar to shift each conventional needle bar independently of each other conventional needle bar with respect to a direction and a distance of travel thereof, said needle bar shifter comprising:

a rotation imparting device including a first pinion member;

a transmission shaft carrying a first gear member at a proximal end and a second pinion member at a distal end;

a first flexible member engaging said rotation imparting device proximate said first pinion member and said transmission shaft proximate said first gear member, said first flexible member being oscillated in a path about said first pinion member and said first gear member;

a support member adapted to be carried by a portion of the housing of the tufting machine, said support member having a second gear rotatably mounted thereto proximate a distal end;

a second flexible member secured between said second pinion member and said second gear member, said second flexible member being oscillated in a path about at least a portion of each of said second pinion member and said second gear member to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said second flexible member defined between said second pinion member and said second gear member being disposed in a substantially linear configuration, said portion of said second flexible member being substantially parallel to the direction of travel of the needle bar; and

a single attachment member adapted to be disposed between said second flexible member and the needle bar, said attachment member being secured to said portion of said second flexible member and being adapted to be secured to the needle bar.

5. The needle bar shifter of claim 4 further comprising a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance.

6. The needle bar shifter of claim 4 further comprising a computer-operated controller.

7. A needle bar shifter for shifting a conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, said needle bar shifter comprising:

a rotation imparting device including a pinion member;

an endless loop member engaging said rotation imparting device proximate said pinion member and a support device, said endless loop member being oscillated in a path about said rotation imparting device and said support device, at least a portion of said endless loop member defined between said rotation imparting device and said support device being disposed in a substantially linear configuration, said portion of said endless loop member being substantially parallel to the direction of travel of the needle bar;

an attachment member adapted to be disposed between said endless loop member and the needle bar, said attachment member being secured to said portion of said endless loop member and being adapted to be secured to the needle bar;

a shifting bar connected between said attachment member and the needle bar;

a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance, said position locking mechanism including a piston carried by a distal end of said shifting bar, and an outer sleeve rotatably receiving said piston, a timing belt being disposed about said outer sleeve and a drive mechanism incorporated in the tufting machine, said outer sleeve being timed to rotate through one revolution during one tufting cycle of the tufting machine, said piston defining a plurality of equidistantly spaced walls having annular grooves defined therebetween, a length of said walls being proportionate to a portion of the tufting machine cycle defined when the needles carried by the needle bar penetrate the backing material until the needles exit the backing material, said outer wall being provided with at least one guide for being closely received in said grooves, said guide moving freely in a lateral direction when the needles are above the backing material in order to allow shifting of the needle bar, each of said plurality of walls being tapered to a leading edge, said guide defining a leading edge having tapered sides such that as said outer sleeve is rotated and said guide leading edge approaches said wall leading edge, the needle bar is shifted until properly aligned within the tufting machine, thus preventing failure within said position locking mechanism; and

a computer-operated controller.

8. A needle bar shifter for shifting one conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, more than one said needle bar shifter being used with more than one conventional needle bar to shift each conventional needle bar independently of each other conventional needle bar with respect to a direction and a distance of travel thereof, said needle bar shifter comprising:

a rotation imparting device including a pinion member;

a flexible member engaging said rotation imparting device proximate said pinion member and a support device, said flexible member being oscillated in a path about at least a portion of each of said rotation imparting device and said support device to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said flexible member defined between said rotation imparting device and said support device being disposed in a substantially linear configuration, said portion of said flexible member being substantially parallel to the direction of travel of the needle bar;

an attachment member adapted to be disposed between said flexible member and the needle bar, said attachment member being secured to said portion of said flexible member and being adapted to be secured to the needle bar;

a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance, said position locking device including a piston member and a sprocket member defining a plurality of recesses about a perimeter, said piston member having a selectively-extendable pin for engaging one of said plurality of recesses.

9. The needle bar shifter of claim 8 further comprising a computer-operated controller.

10. The needle bar shifter of claim 8 wherein said piston member is oriented in a direction parallel to an axis of rotation of said sprocket member.

11. A needle bar shifter for shifting one conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, more than one said needle bar shifter being used with more than one conventional needle bar to shift each conventional needle bar independently of each other conventional needle bar with respect to a direction and a distance of travel thereof, said needle bar shifter comprising:

a rotation imparting device including a pinion member;

a flexible member engaging said rotation imparting device proximate said pinion member and a support device, said flexible member being oscillated in a path about at least a portion of each of said rotation imparting device and said support device to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said flexible member defined between said rotation imparting device and said support device being disposed in a substantially linear configuration, said portion of said flexible member being substantially parallel to the direction of travel of the needle bar;

an attachment member adapted to be disposed between said flexible member and the needle bar, said attachment member being secured to said portion of said flexible member and being adapted to be secured to the needle bar;

a shifting bar connected between said attachment member and the needle bar; and

a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance, said position locking device including a piston carried by a distal end of said shifting bar and an outer sleeve rotatably receiving said piston, a timing belt being disposed about said outer sleeve and a drive mechanism incorporated in the tufting machine, said outer sleeve being timed to rotate through one revolution during one tufting cycle of the tufting machine, said piston defining a plurality of equidistantly spaced walls having annular grooves defined therebetween, a length of said walls being proportionate to a portion of the tufting machine cycle defined when the needles carried by the needle bar penetrate the backing material until the needles exit the backing material, said outer wall being provided with at least one guide for being closely received in said grooves, said guide moving freely in a lateral direction when the needles are above the backing material in order to allow shifting of the needle bar.

12. The needle bar shifter of claim 11 further comprising a computer-operated controller.

13. The needle bar shifter of claim 11 wherein each of said plurality of walls being tapered to a leading edge, and wherein said guide defines a leading edge having tapered sides such that as said outer sleeve is rotated and said guide leading edge approaches said wall leading edge, the needle bar is shifted until properly aligned within the tufting machine, thus preventing failure within said position locking mechanism.

14. A needle bar shifter for shifting a conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, said needle bar shifter comprising:

a rotation imparting device including a first pinion member;

a transmission shaft carrying a first gear member at a proximal end and a second pinion member at a distal end;

a first flexible member engaging said rotation imparting device proximate said first pinion member and said transmission shaft proximate said first gear member, said first flexible member being oscillated in a path about said first pinion member and said first gear member;

a support member adapted to be carried by a portion of the housing of the tufting machine, said support member having a second gear rotatably mounted thereto proximate a distal end;

a second flexible member secured between said second pinion member and said second gear member, said second flexible member being oscillated in a path about at least a portion of each of said second pinion member and said second gear member to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said second flexible member defined between said second pinion member and said second gear member being disposed in a substantially linear configuration, said portion of said second flexible member being substantially parallel to the direction of travel of the needle bar; and

an attachment member adapted to be disposed between said second flexible member and the needle bar, said attachment member being secured to said portion of said second flexible member and being adapted to be secured to the needle bar;

a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance, said position locking device including a piston member and a sprocket member defining a plurality of recesses about a perimeter, said piston member having a selectively-extendable pin for engaging one of said plurality of recesses.

15. The needle bar shifter of claim 14 further comprising a computer-operated controller.

16. The needle bar shifter of claim 14 wherein said piston member is oriented in a direction parallel to an axis of rotation of said sprocket member.

17. A needle bar shifter for shifting one conventional needle bar of a tufting machine in a lateral direction with respect to a direction of travel of material being tufted by the tufting machine, more than one said needle bar shifter being used with more than one conventional needle bar to shift each conventional needle bar independently of each other conventional needle bar with respect to a direction and a distance of travel thereof, said needle bar shifter comprising:

a rotation imparting device including a first pinion member;

a transmission shaft carrying a first gear member at a proximal end and a second pinion member at a distal end;

a first flexible member engaging said rotation imparting device proximate said first pinion member and said transmission shaft proximate said first gear member, said first flexible member being oscillated in a path about said first pinion member and said first gear member;

a support member adapted to be carried by a portion of the housing of the tufting machine, said support member having a second gear rotatably mounted thereto proximate a distal end;

a second flexible member secured between said second pinion member and said second gear member, said second flexible member being oscillated in a path about at least a portion of each of said second pinion member and said second gear member to impart movement of one needle bar in a direction tangential to said rotation imparting device, at least a portion of said second flexible member defined between said second pinion member and said second gear member being disposed in a substantially linear configuration, said portion of said second flexible member being substantially parallel to the direction of travel of the needle bar;

an attachment member adapted to be disposed between said second flexible member and the needle bar, said attachment member being secured to said portion of said second flexible member and being adapted to be secured to the needle bar;

a shifting bar connected between said attachment member and the needle bar; and

a position locking device for arresting movement of the needle bar when the needle bar has traveled a selected distance, said position locking mechanism including a piston carried by a distal end of said shifting bar and an outer sleeve rotatably receiving said piston, a timing belt being disposed about said outer sleeve and a drive mechanism incorporated in the tufting machine, said outer sleeve being timed to rotate through one revolution during one tufting cycle of the tufting machine, said piston defining a plurality of equidistantly spaced walls having annular grooves defined therebetween, a length of said walls being proportionate to a portion of the tufting machine cycle defined when the needles carried by the needle bar penetrate the backing material until the needles exit the backing material, said outer wall being provided with at least one guide for being closely received in said grooves, said guide moving freely in a lateral direction when the needles are above the backing material in order to allow shifting of the needle bar.

18. The needle bar shifter of claim 17 further comprising a computer-operated controller.

19. The needle bar shifter of claim 17 wherein each of said plurality of walls being tapered to a leading edge, and wherein said guide defines a leading edge having tapered sides such that as said outer sleeve is rotated and said guide leading edge approaches said wall leading edge, the needle bar is shifted until properly aligned within the tufting machine, thus preventing failure within said position locking mechanism.