Abstract: A quilting machine has at least one needle and looper set for forming chain-stitched patterns on a thick multilayered material such as a mattress ticking, preferably a panel of the continuous web clamped stationary on a frame. The stitch forming elements are mounted on separate heads that move independently transversely relative to the panel on a bridge that moves longitudinally relative to the panel. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate linear servos. The needle and looper are each driven by a linear servo having an armature to which the element is directly fixed to reciprocate without intervening mechanical linkage assemblies. A controller drives the servos to chain-stitch patterns, differentially move the heads transversely to account for transverse needle deflection and to phase the needle and looper to compensate for longitudinal needle deflection.

Abstract: A quilting machine has at least one needle and looper set for forming chain-stitched patterns on a thick multilayered material such as a mattress ticking, preferably a panel of the continuous web clamped stationary on a frame. The stitch forming elements are mounted on separate heads that move independently transversely relative to the panel on a bridge that moves longitudinally relative to the panel. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate linear servos. The needle and looper are each driven by a linear servo having an armature to which the element is directly fixed to reciprocate without intervening mechanical linkage assemblies. A controller drives the servos to chain-stitch patterns, differentially move the heads transversely to account for transverse needle deflection and to phase the needle and looper to compensate for longitudinal needle deflection.

Abstract: The order in which panels 13 are to be quilted, the amount of quilting-induced shrinkage, and the amount of crop between adjacent panels 13 are stored in a machine readable file 13 for use in operating a print line 10. Such information 13 is printed or otherwise placed on the material 11 at the print line 10 so as to be readable by a sensor 22 at a quilting station, where the information 13 is read and used to control the quilter 21. Panels 15 are quilted according to a schedule and in batches in the most efficient manner, and panels are cut according to information read from records on the material. Shrinkage is compensated for and appropriate crops are made between panels. The printing line prints series of panels on a web 11 in rolls 14 that can be fed, last-printed panel first, into the quilter.

Abstract: A machine readable file is prepared for use in operating a print line that produces a layer of material having a series of panels printed thereon for quilting. The file includes information on the order in which panels are to be quilted, the amount of shrinkage that will occur to a panel during quilting and the amount of crop to be made between adjacent panels following quilting. Such information is placed, preferably printed, onto the material at the print line. Such information is readable by a sensor at a quilting station, which reads the information and controls a quilter to quilt in accordance with the information. Panels are then quilted in accordance with a schedule and in batches in a most efficient manner. A panel cutter is also controlled by information read from records on the material. Shrinkage is also compensated for and appropriate crops are made between panels.

Abstract: A quilting machine has at least one needle and looper set for forming chain-stitched patterns on a thick multilayered material such as a mattress ticking, preferably a panel of the continuous web clamped stationary on a frame. The stitch forming elements are mounted on separate heads that move independently transversely relative to the panel on a bridge that moves longitudinally relative to the panel. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate linear servos. The needle and looper are each driven by a linear servo having an armature to which the element is directly fixed to reciprocate without intervening mechanical linkage assemblies. A controller drives the servos to chain-stitch patterns, differentially move the heads transversely to account for transverse needle deflection and to phase the needle and looper to compensate for longitudinal needle deflection.

Abstract: A quilting system that includes a multiple needle quilting machine is provided with batch processing capability by the addition of a panel cutter in-line with and downstream of the quilting machine. The panel cutter is equipped with a programmed controller that is loaded with batch information for the production, on the quilting machine, of a plurality of quilts by stitching patterns on a multilayered web of fabric. The batch information includes information of a number of quilts to be quilted as well as the patterns to be quilted on each quilt and the composition of the material on which the patterns are to be quilted. Information is derived by the panel cutter controller from sensors on the panel cutter, which information is used to control the quilting machine by adjusting the length of quilted material from the quilter.

Abstract: A quilting machine is provided having at least one set of single needle stitch forming elements for forming chain stitched patterns on a thick multilayered material such as a mattress cover. The machine is preferably web-fed, with a panel of the continuous web being clamped and held stationary on a frame. The stitch forming elements include a needle and a looper mounted on separate heads that are independently moveable on a bridge transversely relative to the panel, which is moveable longitudinally relative to the frame. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate servos. The stitching elements on each head are driven by separate servos. A controller drives the servos to chain stitch patterns and differentially move the heads transversely to account for transverse needle deflection. The drives of the needle and looper are phased to compensate for longitudinal needle deflection. The controller determines or predicts needle deflection.

Abstract: A quilting apparatus is provided with a computer controlled presser plate adjusting mechanism. A presser plate rocker shaft is separate from and mechanically connected to a needle rocker shaft and imparts a reciprocating motion to the presser plate. The presser plate rocker shaft is adjustable to vary the range of its output link to the presser plate, thereby changing the endpoints of its reciprocating path of travel. Certain embodiments have an output end of the presser plate rocker shaft adjustable relative to the input end through a coupling to different angular positions relative to an input end in order to change the upper and lower ends of the range of reciprocation of the pressure plate relative to the needle plate. Alternatively, the length of a link between the needle and pressure plate rocker shafts is variable to make the presser plate adjustment.