System and method of producing multi-colored carpets

• US 7,333,877 B2
• Filed: 03/14/2006
• Issued: 02/19/2008
• Est. Priority Date: 02/27/2004
• Status: Active Grant

• Current Assignee: Aladdin Manufacturing Corporation (Mohawk Industries Incorporated)
• Original Assignee: Mohawk Carpet Corporation (Mohawk Industries Incorporated)
• Inventors: Dabrowa, Paul M., Kuhels, Katrina, Thompson, Charlie, Swift, Ashlee, Poindexter, Dina
• Primary Examiner(s): WORRELL JR, LARRY D
• Application Number:
  US11/375,185
• Publication Number:
  US 20060149409A1
• Time in Patent Office: 707 Days
• Field of Search: 112/102.5, 112/410, 112/2.2, 112/80.01, 112/470.01, 112/475.23, 112/80.23, 700/136, 700/138, 700/131
• US Class Current: 700/138
• CPC Class Codes: D05C 15/34 by inserting loops of different nature or colour

Abstract

A system and method for producing multi-colored carpets using a tufting machine. The present invention features a system and method for: providing a multi-colored pattern which is analyzed for validity with reference to a particular tufting machine; collecting parameters concerning a particular tufting machine; determining the colors of yarn to load with each needle of the particular tufting machine; and generating a report including a palette of colors used within the pattern, a chart indicating which color of yarns are used within each needle position, and a summary of the number of yarn cones needed to create a carpet of a predetermined size with the particular tufting machine.

Claims

1. A method of generating a report for a tufting machine, the method comprising:

receiving digital image data from a pattern storage unit, wherein the digital image data represents a pattern having multiple colors;

receiving operational characteristics of a tufting machine;

validating the pattern for the tufting machine, based on the operational characteristics;

generating a report designating at least one color of the pattern with at least one needle of the tufting machine, wherein the report includes yarn loading instructions of the tufting machine, such that when loaded the tufting machine can create a product having the pattern.

2. The method of claim 1, wherein generating a report with yarn loading instructions comprises:

determining at least one color of a portion of the pattern, wherein the portion of the pattern corresponds to at least one needle of the tufting machine; and

designating the at least one color with the at least one needle of said tufting machine.

3. The method of claim 2, wherein determining at least one color comprises:

analyzing at least one pixel of the portion of the pattern; and

identifying at least one color of the at least one pixel.

4. The method of claim 1, wherein the report further includes a color palette indicating a percentage of each color used within the pattern.

5. The method of claim 4, wherein generating a report having a color palette comprises:

determining at least one color of the pattern by analyzing at least one pixel of the pattern; and

determining a percentage that the at least one color is used in the pattern.

6. The method of claim 1, wherein the report further includes a cone count summary indicating a number of yarn cones required for the at least one needle of the tufting machine.

7. The method of claim 1, wherein validating the pattern for the tufting machine comprises:

determining a number of colors of a portion of the pattern, wherein the portion of the pattern corresponds to at least one needle of the tufting machine;

determining whether the number of colors is greater than a predetermined number of colors associated with the at least one needle of the tufting machine, wherein the operational characteristics include the predetermined number of colors; and

if the number of colors is greater than the predetermined number of colors, determining that the pattern may not be implemented on the tufting machine; and

if the number of colors is not greater than the predetermined number of colors, determining that the pattern may be implemented on the tufting machine.

8. The method of claim 7, wherein determining a number of colors of a portion of the pattern comprises:

analyzing at least one pixel of the portion of the pattern; and

enumerating at least one color of the at least one pixel.

9. A method of generating a report for a tufting machine, the method comprising:

receiving digital image data from an input device representing a pattern having a plurality of colors;

receiving operational characteristics of a tufting machine, wherein the operational characteristics include a number of needles of the tufting machine and a number of colors associated with each needle;

validating the pattern for the tufting machine, based on the operational characteristics;

generating a report via a report generator unit, wherein the report designates at least one color of the pattern with at least one needle of the tufting machine, wherein the report includes yarn loading instructions of the tufting machine, such that when loaded the tufting machine can create a product having the pattern.

10. The method of claim 9, wherein the report further includes a color palette indicating a percentage of each color used within the pattern, such that an amount of each corresponding color of yarn necessary to create the product having the pattern can be determined.

11. The method of claim 9, wherein the report further includes a cone count summary indicating a number of yarn cones required for the at least one needle of the tufting machine.

12. The method of claim 9, wherein validating the pattern for the tufting machine comprises:

determining a number of colors of a portion of the digital image data, wherein the portion of the digital image data corresponds to at least one needle of the tufting machine;

determining whether the number of colors of the portion is greater than the number of colors associated with each needle; and

if the number of colors of the portion is greater than the number of colors associated with each needle, determining that the pattern may not be implemented on the tufting machine; and

if the number of colors of the portion is not greater than the number of colors associated with each needle, determining that the pattern may be implemented on the tufting machine.

13. A computer-readable medium comprising computer-executable instructions for generating a report for a tufting machine, the computer-executable instructions comprising:

receiving digital image data from a pattern storage unit, wherein the digital image data represents a pattern having multiple colors;

receiving operational characteristics of a tufting machine;

validating the pattern for the tufting machine, based on the operational characteristics, comprising;

determining a number of colors of a portion of the pattern. wherein the portion of the pattern corresponds to at least one needle of the tufting machine;

determining whether the number of colors is greater than a predetermined number of colors associated with the at least one needle of the tufting machine, wherein the operational characteristics include the predetermined number of colors; and

if the number of colors is greater than the predetermined number of colors, determining that the pattern may not be implemented on the tufting machine; and

if the number of colors is not greater than the predetermined number of colors, determining that the pattern may be implemented on the tufting machine; and

generating a report designating at least one color of the pattern with at least one needle of the tufting machine, wherein the report includes yarn loading instructions of the tufting machine, such that when loaded the tufting machine can create a product having the pattern.

14. The computer-readable medium of claim 13, wherein generating a report with yarn loading instructions comprises:

determining at least one color of a portion of the pattern, wherein the portion of the pattern corresponds to at least one needle of the tufting machine; and

designating the at least one color with the at least one needle of said tufting machine.

15. The computer-readable medium of claim 14, wherein determining at least one color comprises:

analyzing at least one pixel of the portion of the pattern; and

identifying at least one color of the at least one pixel.

16. The computer-readable medium of claim 13, wherein the report further includes a color palette indicating a percentage of each color used within the pattern.

17. The computer-readable medium of claim 16, wherein generating a report having a color palette comprises:

determining at least one color of the pattern by analyzing at least one pixel of the pattern; and

determining a percentage that the at least one color is used in the pattern.

18. The computer-readable medium of claim 13, wherein the report further includes a cone count summary indicating a number of yarn cones required for the at least one needle of the tufting machine.

19. The computer-readable medium of claim 13, wherein determining a number of colors of a portion of the pattern comprises:

analyzing at least one pixel of the portion of the pattern; and

enumerating at least one color of the at least one pixel.