Abstract: An apparatus for a funnel assembly on a tufting machine comprising an exchanger bar, one or more exchanger blocks, a funnel bar or one or more funnel blocks, one or more needle assemblies including a needle having a distal end, one or more means for conveying fluid in a direction toward the distal end of the needle and a means for moving the needle assembly in a direction substantially transverse to the backing of a tufted surface covering. The exchanger bar and the exchanger block are stationary when the needle assembly moves between a retracted position and an extended position. A method comprising providing such a funnel assembly, conveying a strand of yarn in a direction toward the distal end of the needle and moving the needle assembly and funnel bar between a retracted position and an extended position.

Abstract: A tufting machine comprising a yarn applicator adapted to receive feed yarn and penetrate a surface covering backing and a cutting means adapted to cut the feed yarn to produce a stitch. The tufting machine also comprises a yarn control module that includes a yarn feed wheel adapted to guide the feed yarn, an actuator adapted to move the yarn feed wheel between an engaged position and a disengaged position, and a yarn feed gear adapted to engage the feed yarn when the actuator moves the yarn feed wheel into the engaged position. The tufting machine further comprises a power source adapted to move the yarn feed gear and a remote process control computer system adapted to send a first signal and a second signal to the yarn control module. The tufting machine produces a patterned surface covering having a plurality of yarn colors and a plurality of pile heights.

Abstract: A compressed air system adapted for use in connection with a tufting machine having a yarn applicator adapted to penetrate a backing of a surface covering and place a stitch in the backing of the surface covering, a presser foot and a funnel block. The compressed air system comprises an air source adapted to provide air to the compressed air system, a digital presser foot injector adapted to convey compressed air to the presser foot, and a funnel block injector adapted to convey compressed air to the funnel block. The compressed air system is adapted to convey compressed air to the digital presser foot injector and the funnel block injector only when the yarn applicator is in use. The method comprises conveying air to the presser foot only when the yarn applicator is in use, and conveying air to the funnel block only when the yarn applicator is in use.

Abstract: An apparatus and method for detecting the position of a knife on a tufting machine. The apparatus includes a grounded needle, an electrically-insulated knife adapted to send a knife signal, a solenoid adapted to move the knife, and a programmable logic controller adapted to send a pattern signal to the solenoid, receive the knife signal from the knife, compare the knife signal to the pattern signal, and determine if the knife is in the position prescribed by the pattern signal. The method includes providing such an apparatus, inputting the pattern signal into the programmable logic controller, sending the pattern signal from the programmable logic controller to the solenoid, sending a knife signal from the electrically-insulated knife to the programmable logic controller, comparing the knife signal to the pattern signal, determining if the electrically-insulated knife is in the position prescribed by the pattern signal.

Abstract: A tufting machine comprising a yarn applicator adapted to receive feed yarn and penetrate a surface covering backing and a cutting means adapted to cut the feed yarn to produce a stitch. The tufting machine also comprises a yarn control module that includes a yarn feed wheel adapted to guide the feed yarn, an actuator adapted to move the yarn feed wheel between an engaged position and a disengaged position, and a yarn feed gear adapted to engage the feed yarn when the actuator moves the yarn feed wheel into the engaged position. The tufting machine further comprises a power source adapted to move the yarn feed gear and a remote process control computer system adapted to send a first signal and a second signal to the yarn control module. The tufting machine produces a patterned surface covering having a plurality of yarn colors and a plurality of pile heights.

Abstract: An adjustable pile height mechanism for producing a tufted floor covering comprising an adjustable bed plate, a cam shaft, and a plurality of eccentric cams mounted on the cam shaft so as to contact the bed plate. The cam shaft is adapted to be rotated so as to rotate the cams, and the rotational movement of the cams raises and lowers the bed plate so as to adjust the pile height of the floor covering. A method for adjusting the pile height of a floor covering further comprises the steps of loosening the presser foot bracket bolt, raising the presser foot assembly, tightening the presser foot bracket bolt, disengaging the clamp assembly, rotating the cam shaft so as to adjust the bed plate to the desired pile height, engaging the clamp assembly, loosening the presser foot bracket bolt, lowering the presser foot assembly, and tightening the presser foot bracket bolt.