Abstract: A method of preparing a tufting process comprises the steps of: a) providing a pattern representation representative of a fabric to be tufted, b) providing at least one group of tufting aspect instruction layers, each group of tufting aspect instruction layers comprising at least one tufting aspect instruction layer, each tufting aspect instruction layer being associated with a tufting aspect instruction, each tufting aspect instruction referring to a tufting aspect, c) assigning at least one tufting aspect instruction to at least one tufting aspect instruction layer.

Abstract: In a carpet manufacturing method, for a plurality of yarns each having a length, a plurality of marks are provided on each yarn at selected locations along the yarn. In the carpet manufacturing method and in a carpet manufacturing assembly, each yarn is stored on or in an associated storage, and fed from its associated storage to a carpet manufacturing apparatus. For each yarn, the marks on the yarn are detected upstream of the carpet manufacturing apparatus. On the basis of the detection of the marks, the uptake of the yarn by the carpet manufacturing apparatus is controlled, whereafter, in the carpet manufacturing apparatus, the yarns are processed to form at least part of a carpet.

Abstract: A cross-tufting machine and process for manufacturing carpet. The cross-tufting machine includes a sewing head and a tufting gun. The sewing head is movably mounted on support railing and a support platform is provided to support carpet that is to be provided with a tufted secondary pattern. The carpet moves in steps on top of the support platform in a machine direction and the sewing head traverses back and forth in a cross-wise direction wherein the tufting gun forms the tufted secondary pattern in the carpet.

Abstract: The invention relates to a control system for a tufting machine configured for forming tufted carpet. The tufting machine can have a system controller in communication with the tufting machine and with a plurality of yarn feed controllers for controlling operation of yarn feed motors that are configured to supply yarn from a source of yarn to the tufting machine. The system controller is programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted such that, although at least two of the predetermined yarn feed profiles can be different, substantially the same feed length of yarn is used from each of the plurality of yarns.

Abstract: A tufting machine is configured with yarn drives having two spaced apart yarn bearing surfaces each substantially wrapped with a yarn and may have only half the needles and yarn drives customarily employed, with the needles being shifted to cover two gauge positions, thereby providing single and yarn control with reduced capital cost.

Abstract: A tufting machine for forming tufted carpet having means for inserting loops of at least two different yarns into a backing material moving through the tufting machine and means for controlling the deviation of the ratio of different yarns projecting from a top surface of the backing material. It is contemplated that the tufting machine can be used to maintain the color of the tufted carpet at a desired color during the operation of the tufting machine.

Abstract: A capstan roller assembly is provided between the yarn supply and scroll type yarn feed attachments for a tufting machine in order to minimize the underfeeding of yarn to the pattern being tufted due to irregularities in the feeding of the yarn from the yarn supply.

Abstract: The invention concerns an improved tufting machine which comprises a tufting head translatable within said tufting machine in X- and Y-directions with respect to backing fabric by means of a movement system. The tufting head comprises a tufting mechanism having a cyclic mode of operation, a hollow needle mounted in the tufting mechanism that is moveable relative to a cooperating foot in a reciprocating manner to insert a tuft of yam into backing fabric in each cycle, a yarn supply mechanism mounted in the tufting mechanism and operable to supply a length of yam to the hollow needle in each cycle, a yarn cutter mounted in the tufting head that is selectively operable to cut the length of yam in selected cycles to produce loop or cut pile, and a computer-operated motion control system.

Abstract: A system for forming multiple patterned, tufted articles, includes a tufting machine having a series of distinct machine sections each adapted to form a desired patterned, tufted articles and each operable independently of the other machine sections. A system control can be programmed with pattern parameters for each of the patterned tufted articles to be formed, and will control the machine sections to form each of the patterned tufted articles.

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices for feeding each of the yarns to the needles of the tufting machine, and a series of yarn feed controllers that monitor and control the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A yarn feeder for a tufting machine is compact and simple in structure and is still capable of freely changing the heights of piles formed by each pile yarn on a fabric. The yarn feeder includes yarn feed rolls for feeding pile yarns to a row of needles of the tufting machine, and a brake device provided between the feed rolls and the needles. The brake device includes a grooved plate having grooves arranged in the width direction of the grooved plate and each receiving one of the pile yarns that are being fed from the feed rolls to the needles, and presser members each opposing one of the grooves. The presser members are movable toward and away from the respective grooves independently of one another. By pressing selected one or ones of the presser members against the bottoms of the corresponding grooves with yarns sandwiched therebetween, the feed rates of the yarns can be freely changed independently of one another without unduly increasing the size of the yarn feeder or complicating its structure.

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices for feeding each of the yarns to the needles of the tufting machine, and a series of yarn feed controllers that monitor and control the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A tufting machine having a servo driven yarn feed attachment adapted to feed two yarns on each yarn feed roll is provided with a tube bank that allows tufting of two single end patterns on the tufting machine from one set of yarn drives.

Abstract: A tuft forming mechanism including a yarn feed mechanism and a yarn severing means (6, 18), the yarn feed mechanism including a passage (5) along which yarn (2) is guided to said yarn severing means (6, 18) and an intermittently rotatable feed disc (1) which engages the yarn (2) to advance the yarn (2) along the passage (5).

Abstract: The present invention provides a double end yarn drive pattern attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls capable of increased torque to carry multiple yarn ends on a single feed roll, thereby economically retaining many advantages of a single end pattern attachment. The improved attachment utilizes an intermediate gear to provide a relatively high torque drive adaptable between single and plural yarn pattern attachments.

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices for feeding each of the yarns to the needles of the tufting machine, and a series of yarn feed controllers that monitor and control the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices for feeding each of the yarns to the needles of the tufting machine, and a series of yarn feed controllers that monitor and control the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A tuft forming mechanism including a yarn feed mechanism and a yarn severing means (6, 18), the yarn feed mechanism including a passage (5) along which yarn (2) is guided to said yarn severing means (6, 18) and an intermittently rotatable feed disc (1) which engages the yarn (2) to advance the yarn (2) along the passage (5).

Abstract: A tufting machine includes a feed roller assembly formed of a plurality of coaxially aligned and detachable shaft members.

Abstract: A puller roller system for tufting machines having a series of intermeshed puller rolls for tensioning a series of yarns to one or more needles of the tufting machine. According to one embodiment of the invention, the puller roller system includes at least one toothed, driven puller roll in rotating and intermeshing relationship with at least two toothed, floating puller rolls. The spacing between the puller rolls is sufficient to securely engage and tension the yarns to the needles without pinching the yarn.

Abstract: The present invention provides a double end yarn drive pattern attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls capable of increased torque to carry multiple yarn ends on a single feed roll, thereby economically retaining many advantages of a single end pattern attachment. The improved attachment utilizes an intermediate gear to provide a relatively high torque drive adaptable between single and plural yarn pattern attachments.

Abstract: Apparatus for loading a row of tuft retention sites (TRS) in a gripper loom with a row of tufts (T) arranged in a predetermined pattern sequence, the apparatus including a group of yarn sources movable along said row tuft retention sites (TRS), drive means for sequentially moving said group of yarn sources along the guide means (33) and temporarily locating a desired yarn source in registry with a predetermined tuft site (TRS), and selectively operable tuft forming means which, on selection, transfer a tuft (T) from said desired yarn sources to said predetermined tuft site (TR).

Abstract: A yarn feed system, enabling the control of individual yarns to the needles of a tufting machine, and which system can be manufactured as a substantially standardized unit or attachment that can be removably mounted to a tufting machine. The yarn feed unit includes a series of yarn feed devices for feeding each of the yarns to the needles of the tufting machine, and a series of yarn feed controllers that monitor and control the operation of the yarn feed devices to control the feeding of the yarns to the needles according to programmed pattern instructions.

Abstract: A tufting machine includes a feed roller assembly formed of a plurality of coaxially aligned and detachable shaft members.

Abstract: A yarn feed roller assembly for a tufting machine for producing multiple pile heights. The assembly comprises at least two rollers 5,6 driven at different speeds and a plurality of actuators 9, 14, 15 each arranged to bring an end of yarn selectively into driving engagement with either drive roller. The actuator may be switched between the drive rollers at a point during the needle stroke thereby varying the proportion of the stroke spent in contact with one or other drive roller, and hence varying the pile height.

Abstract: The present invention provides a double end yarn drive pattern attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls capable of increased torque to carry multiple yarn ends on a single feed roll, thereby economically retaining many advantages of a single end pattern attachment.

Abstract: The present invention provides a scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by an array of single end yarn drives operated by servo motor controllers, and methods of using such an attachment to create and tuft new carpet patterns.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls while eliminating tube banks typical of tufting machine feed attachments and produces new tufted carpet designs.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by an array of single end yarn drives operated by servo motor controllers, and methods of using such an attachment to create and tuft new carpet patterns.

Abstract: A tufting machine has a yarn feed roller assembly with a plurality of rotatable driver rollers driven at different speeds and a plurality of actuators in the form of a pivotable arm having in one embodiment a pair of yarn feed reels one of which is arranged to selectively press yarn into engagement with one of the drive rollers and the other arranged to selectively press yarn into engagement with another drive roller. Yarn is engaged by each actuator and a selected drive roller for a period of time determined by a pattern. The longer the actuator engages the high speed roller during the stroke of a tufting machine needle the greater will be the pile height of the tufts produced and alternatively the longer the actuator engages the lower speed roller during the needle stroke the lower will be the pile height. Pile height variations between a high pile and a low pile may be obtained by controlling the proportion of time during the stroke that the yarn engages with the high and low speed rollers.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls while eliminating tube banks typical of tufting machine feed attachments to produce new tufted carpet designs.

Abstract: Apparatus for feeding yam from a yam supply to a reciprocating needle of a multicolored patterned tufting apparatus comprising a dual yarn feeder for increased productivity of the tufting apparatus or increasing the number of different yams or both. The dual yam feeder includes two yam feeder components which are selectively and independently movable in and out of engagement with a driven roller.

Abstract: A tufting machine has a yarn feed roller assembly with a plurality of rotatable driver rollers driven at different speeds and a plurality of actuators in the form of a pivotable arm having in one embodiment a pair of yarn feed reels one of which is arranged to selectively press yarn into engagement with one of the drive rollers and the other arranged to selectively press yarn into engagement with another drive roller. Yarn is engaged by each actuator and a selected drive roller for a period of time determined by a pattern. The longer the actuator engages the high speed roller during the stroke of a tufting machine needle the greater will be the pile height of the tufts produced and alternatively the longer the actuator engages the lower speed roller during the needle stroke the lower will be the pile height. Pile height variations between a high pile and a low pile may be obtained by controlling the proportion of time during the stroke that the yarn engages with the high and low speed rollers.

Abstract: A yarn feed roller assembly for a tufting machine for producing multiple pile heights. The assembly comprises at least two rollers 5, 6 driven at different speeds and a plurality of actuators 9, 14, 15 each arranged to bring an end of yarn selectively into driving engagement with either drive roller. The actuator may be switched between the drive rollers at point during the needle stroke thereby varying the proportion of the stroke spent in contact with one or other drive roller, and hence varying the pile height.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls while eliminating tube banks typical of tufting machine feed attachments and produces new tufted carpet designs.

Abstract: The present invention provides a single end scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of yarn feed rolls while eliminating tube banks typical of tufting machine feed attachments and produces new tufted carpet designs.

Abstract: A tufting machine with a pair of closely spaced apart needle bars which reciprocate together but the needles carried by one bar may be controlled selectively to be either in a position to form pile or be retracted to a position where they do not form pile when the needle bars are driven toward the backing material selectively. A control system is provided to control the selection of the needles of the one needle bar and also the feeding of yarn to the needles of the one needle bar so that yarn from needles which are not tufting is drawn tight on the backing. The needles may be mounted in modules and selected needle modules may be independently controllable by pneumatic cylinders so that various overtufted patterns may be made by the controlled needles in a background formed by the needles in the other bar that tuft on every stitch.

Abstract: The present invention provides a scroll-type yarn feed attachment for tufting machines characterized by independent servo-motor control of sets of yarn feed rolls, an improved tube bank, and a software design system to facilitate use of the attachment.

Abstract: A tufting machine having a yarn feed roll attachment wherein the rolls are driven by a chain drive and having an adjustable tension applying device including a housing having a yoke defined by two arms separated by a slot. The arms of the yoke include planar interior surfaces which cooperate with a planar support plate and at least one connector which locates the housing of the device in a fixed position relative to the support plate. At a second end of the housing is a guide which preferably rotates about a guide axis. The guide axis is preferably perpendicular to the plane of the support plate, when installed.

Abstract: A tufting machine has a yarn feed pattern assembly including a housing having a mounting plate for mounting a multiplicity of yarn feed rollers from the exterior of said mounting plate and a multiplicity of servo motors connected to said mounting plate on the interior of said housing. Each servo motor is connected to a respective feed roller. A multiplicity of tubes extend within said housing, half the tubes directing yarn from a source to respective rollers and half of the tubes directing yarn from the rollers to respective needles. The guide tubes direct yarn from the interior of said housing through said mounting plate where the yarn is trained about a respective roller and directed back into the yarn guide leading toward the needles of said tufting machine.

Abstract: Apparatus for feeding yarn from a yam supply to a reciprocating needle of a multi-color pattern carpet tufting apparatus comprises a yarn pullback mechanism mechanically linked to a yarn feeder such that when the yarn feeder moves out of engagement with a driven roller, the yarn pullback mechanism draws the yarn back from the reciprocating needle. When the yarn feeder moves back into engagement with the driven roller, the yarn pullback mechanism shortens the path between the yarn feeder and the reciprocating needle.