QUILTING MACHINE WITH ADJUSTABLE PRESSER PLATE AND METHOD OF OPERATING THE QUILTING MACHINE

Abstract: A quilting apparatus (20) is provided with a computer controlled presser plate adjusting mechanism. A presser plate rocker shaft (119) is separate from and mechanically connected to a needle rocker shaft (112) and imparts a reciprocating motion to the presser plate (82). The presser plate rocker shaft (119) is adjustable to vary the range of its output link (116) to the presser plate (82), thereby changing the endpoints of its reciprocating path of travel. Certain embodiments have an output end (122) of the presser plate rocker shaft (119) adjustable relative to the input end (120) through a coupling (124) to a different angular position relative to an input end in order to change the upper and lower ends of the range of reciprocation of the pressure plate (82) relative to the needle plate (78). Alternatively, the length of a link (110) between the needle and pressure plate rocker shafts (112, 119) is variable to make the presser plate adjustment. A motor or other actuator (129) changes the coupling (124) or link (110) in response to a signal from the quilting machine controller (100), which can be made instantly, either manually by an operator at the controller interface terminal, by a batch mode program run by the controller to set the machine to the parameters required by products on a product schedule, or automatically in response to measurements from sensors that are interpreted by the controller in determining optimal pressure plate setting.

Description: OUILTTNG MACHINE WITH ADJUSTABLE PRESSER PLATE AND METHOD OF OPERATING THE QUILTING MACHINE In the manufacture of quilted fabrics m which, foi example, a cover, a liner and one or more layers of filling material are joined to form an article such as a quilted furmtuie covei 01 a mattiess cover, automated quiltmg machinery is commonly employed to stitch the layers of matenal togethei, with stitching applied in repeated patterns, or arrays of repeated patterns. High speed and economic pioduction of such quilted fabrics generally requires equipment utilizing arrays of needles, ganged together and driven through a common stitch forming mechanism, to apply a pluiahty of patterns simultaneously in a predetermined array. Between each stitch of the needle, the layers of fabric are moved in unison with respect to the needles in order to place the next stitch at the desired point in the quilting pattern. Further, with each stitch cycle of the needles, a presser plate on one side of the multi-layered fabric is moved toward a needle plate on the other side of the fabric to compact the layers of material between the plates for the stitching process As the needles move out of the matenal, the presser plate is simultaneously lifted oi moved away from the needle plate, thereby permitting the material to be moved for the next stitch. Normally, the needles are mechanically coupled to and driven by a needle bar rocker shaft that, in turn, is mechanically connected to and driven by a continuously rotating drive shaft. The presser plate is also mechanically connected to and driven by the needle bar rocker shaft. The motion of the presser plate is thus mechanically and constantly fixed with respect to the motion of the needle. With every stitch cycle, the presser plate usually starts a stitch cycle at the same uppermost position with respect to the needle plate, moves downwaid to the same lowermost position with respect to the needle plate and then retracts upward to the starting uppermost position. Thus, with each stitch, such a presser plate moves the same distance downward to the same material compaction position and then retracts the same distance to its uppermost starting position. Since the operation of the presser plate is mechanically fixed throughout the quiltmg process, the gap between the presser plate and the needle plate at any given point in the stitching cycle is always the same Therefore, a quilting machine is practically limited to stitching layers of material that have the same thickness. The relative motion of the presser plate is controlled by cams on a rocker shaft. Therefore, it is possible to change those cams in order to provide a different gap between the pressei plate and the needle plate during the stitching cycle. Even though reconfiguring the quilting machine is possible by changing various cams, the task requires many hours of complex and difficult laboi and, therefore is rarely if ever done. Therefore, as a practical matter, if one desires to stitch a thicker quilt, a different quilting machine is generally used which has been configured to have a generally larger gap between the presser plate and the needle plate throughout the stitching cycle. With a thicker quilt, the presser plate must have a higher starting position that allows the thicker quilt to be inserted thereunder and a higher, full compaction position that properly compresses the thicker quilt duπng the stitching piocess The lequiiement that different quiltmg machines must be used to stitch quilts having ditteient thicknesses presents significant disadvantages. For example, for quilt manufacturers who can afford only one quilting machine, their market is limited to those applications for quilts of the single thickness that can be readily produced on that one machine In other situations, the commercial demand or quantity of a quilt of a particular thickness may be relatively small, and therefore, the purchase and maintenance of an automated quilting machine to make such a quilt cannot be economically justified Thus, those maikets must be served by quilts that ha\ e a highei labor content and thus, are moie expensive When quiltmg materials such as mattress covers and boiders on a multi-needle chamstitch-quilting machine, the height of the piessei fool abo\ e the needle plate is cntical to piopei stitch formation, sewing lehabihty and product quality The pressei foot height is determined pπmanly by the thickness and density of the mateπals to be stitched Therefoie, users cuπently adjust quiltmg machines to sew a specific thickness range, depending on expected production lequirements. As a result, when it becomes necessary to sew a different thickness, the machine must be re-adjusted, usually by maintenance personnel in a procedure that involves significant amounts of time. Such personnel must know the proper height setting for any given combination of materials. Consequently theie m a need for an improved quiltmg machine that is more flexible in its operation and reconfiguration so that with an easy adiustment quilts of different thicknesses may be stitched. Summary of the Invention An objective of the present invention is to provide a quilting machine and method that is flexible in its ability to produce quilts of different thicknesses A particulai objective of the invention is to provide for adjustment of presser foot position quilting processes so as to allow a single quiltmg machine to accommodate materials of differing thicknesses Further objectives of the invention include providing the correct presser foot setting for quilted products, particularly where the products are made automatically, and particularly where product thicknesses might change from one product to the next. Additional objectives of the invention are to provide quick presser foot adjustment lequning little opeiator skill oi experience, to leduce error m the making of presser foot adjustments. to provide reliable and repeatable presser foot adjustments, and to piovide automatic presser foot adjustments Particular ob j ectives of the invention are to provide for automatically making presser foot settings appropriate for each particular quilted product without the intervention of an operatoi. including by automatically providing a setting that has been predetermined to be appropriate for the product and by providing a setting that is sensed by the machine to be appropriate for the product Other objectives of the invention are to provide a mechanism foi quickly changing presser foot settings that is durable, and to provide a mechanism by which the height of both the lower and upper presser foot positions and the distance between lowei and upper presser foot positions can be increased with the thickness of the material. The invention achieves various of its objectiv es by making adjustment of the presser foot height totally automatic for batch mode and automatic operation, with the optimum position of the pressure foot determined by the machine controllei computer based on product database information, motor torque feedback, material oi load sensors and other methods. For manual operation, adjustments can be made instantly with the simple touch of an icon. In accordance \\ ith the principles of the present invention, a quiltmg machine and method are provided with an adjustable drive linkage to quickly change the piessei foot setting The drive linkage is adjusted by a motoi oi other actuatoi, which is in turn lesponsive to a contiol signal produced m lesponse to a controller. The controllei in turn lesponds eithei to an input signal from an operatoi or facility computer or to information in a product database of a batch contiol system The presser foot linkage may operate to move end positions of the presser foot travel during each stitch cycle between two positions, among a plurality of more than two positions, or continuously between maximum and minimum settings Pieteiably, the actuatoi is out of the line of the mam dnve to the piessei foot 01 needle bar to minimize loads on the actuatoi and leduce failure rate of the dm e tram In the various prefeπed embodiments of the inv ention, presser foot settings are changeable by operatoi input by lotatmg a knob 01 othei conti ol element 01 b\ selecting an icon on the touch scieen of a controllei and inputting data to change the setting In othei embodiments, a product data file contains pattern information and othei paiameteis that define each of a pluia ty ol pioducts with such paiameteis including the piessme foot setting appiopnate foi the thickness of the particulai pi oduct In furthei embodiments, sensors measuie oi otherwise respond to forces, torques power demands, compiessed material dimensions or other parameters that change as a function material thickness or density In certain embodiments of the invention, there is provided an apparatus foi stitching fabric to produce a quilted fabi ic The apparatus has a needle plate for supporting the fabric, a presser plate located above the needle plate and a needle, oi piefeiably one or more needle bars, each of which holds a plurality of needles A needle rocker shaft is mechanically connected to the needle or needle bars and imparts reciprocating motion to the needles in response to the displacements, pieferably angular displacements, of the needle rocker shaft Further, a presser plate rocker shaft that is distinct from the needle rocker shatt is mechanically connected to the needle rocker shaft and imparts a reciprocating motion to the presser plate in response to the displacements, preferable angulai displacements, of the piesser plate rocker shaft A presser plate adjusting mechanism controls the range and limits of motion of the presser plate rocker shaft so that the lowermost and uppermost points of travel of the presser plate can each be set to one of a plurality of positions to accommodate fabnc of different thicknesses In certain embodiments of the invention, the piessei foot is driven by a system that eliminates the cams and springs, replacmg them with a separate rocker shaft and lever mechanism for the pressei foot operation that is similar to the system used foi the needles A second, independent rockei shaft is pio ided to drive only the presser foot, while the locker shaft commonly used foi diiving both the needles and the presser plate drives the needle bais The presser foot rocker shaft is pieferably driven by the needle rocker shaft through a lever and link mechanism The presser foot rockei shaft drives a pressei foot lod, which in turn moves the presser foot down and up with a lever and link mechanism The height of the piessei loot above the needle plate is adjusted by adjusting a coupling m the presser plate rocker shaft or by effectively changing the length of the presser foot rocker shaft drive link by adjusting the phase of presser plate rocker shaft In some embodiments of the invention, the piesser plate rocker shaft has input and output shafts that aie easily movable to different relative angular positions to locate the presser plate at a different positions with respect to the needle plate Fust and second positions of the piessei plate piovide, for example, respective fust and second gaps betw een the presser plate and the needle plate, which peimit fabrics of different thicknesses to be quilted In one aspect of the invention the piessei plate locker shaft includes a coupling for moving the input and output shafts of the presser plate lockei shaft to the difteient angulai positions with respect to each othei Thus. the gap between the presser plate and the needle plate can be changed without changing the position of the needle One method of operating a quiltmg machine according to the invention includes setting the presser plate to a fust position with respect to the needle plate loading a fust fabnc having a first thickness, stitching the fust fabnc setting the piessei plate to a second position with lespect to the needle plate without changing cams on the machine, loading a second fabnc having a second thickness, and stitching the second fabric In furthei embodiments of the inv ention, a link is piovided to maintain a fixed component of the angulai position of the pressei plate lockei shaft A vanable actuatoi is provided m the lmk to change the fixed component ^ The piessei lockei shaft oscillates about the fixed component angulai position so that changes in the actuatoi setting changes the uppei and lower positions of the piessei plate dunng its cycles The actuator may be any of a numbei of diffeient motors 01 devices, including, foi example, a two position pneumatic cylmdei, a senes of two position cvlindeis 01 a pneumatic 01 electncal actuatoi having moie than two positions, a stepping or seivo motor, or a continuous drive motor that may be, foi example, a lack and pinion drive or a worm gear, to name a few Where 0 the controller signals the actuator in response to an opeiatoi actuated input control on a tough screen, to load oi other sensors on the quiltmg machine, oi to data in a pioduct database, the data may contain pioduct parameters of batch control systems such as, foi example, those described m U S patent no 5,544,599 or U S patent application senal no 09/301,653. filed Septembei 23, 1999, hereby expressly incorporated by reference herein The present invention provides the advantages of a quiltmg machine and method substantially moie 5 flexible m operation than quiltmg machines and methods of the prior art The present invention permits the quiltmg machine to be easily leconfigured so that diffeient gaps can be easily set between a piesser plate and a needle plate, so that fabric layers of different thicknesses can be stitched on the same machine Thus, the invention permits one machme to serve a great many different maikets foi quilted fabrics Further, small quantities of quilted fabrics of diffeient thicknesses can be economically supplied with a single machine The quiltmg machine of the piesent 0 inv ention pi ovides its usei ith oppoi tunities to suppl v different quilted pi oducts m a way that was not possible in the past with a smgle quilting machme Advantages of vanous embodiments of the invention include improved automation wheieby operators and maintenance personnel aie no longer lequned to do anything to adjust the pressei toot height in batch mode or automatic opeiation The mv ention pi ovides simplicity Manual adjustments can be made with simply the touch of an icon No tools, leveis oi cranks are needed Further, adjustments aie virtually 5 instantaneous Labor intensive and time consuming mechanical adjustments aie eliminated Consistency of pressure foot setting is also provided In batch mode oi automatic operation, for example, the pressei foot will always be m the correct position, without depending on the operatoi to know when adjustments are needed oi what the correct position is for any given combination of matenals Guesswork and sources of error aie eliminated Reliability of machinery and machine components is provided The automatic mechanisms are designed 0 to function within pre-defined ranges It is impossible to ad|ust the presser foot beyond acceptable limits to a point where damage to the equipment could result Furthei, less knowledge is requned of opeiators because they no longer need to be concerned ith piessei foot settings Less skill is required of maintenance personnel because critical mechanical adjustments are eliminated These and other objects and advantages of the present invention will become moie leadily appaient dunng the following detailed description together with the drawings herein ς Brief Description of the Drawings Fig. 1 is an elevation view of a quiltmg machine embodying the principles of the present invention Fig. 2 is a plan view of the front side of a fabnc quilted with an airay of disciete 360° patterns quilted on the quilting machine of Fig. 1 Fig. 3 is a diagiammatic disassembled peispectiv e view of the pressei foot operating and related components of one embodiment of the quilting machine of Fig. 1. illustrating the relationships of actuatoi s and drives of the quiltmg station of the machine. Fig. 4 is a cioss-sectional end view of the quilting station embodiment of Fig. 3 illustrating the various interconnecting drives Fig. 5 is a perspective view of one set of the mechanical linkages used to operate the presser plate and needle bars of the embodiment of Fig. 3. Figs. 6A and 6B aie diagiammatic views lllustiatmg the uppermost and lowermost positions of the presser plate and needle with the pressei plate adjusted to stitch fabric having a lesser thickness in accordance with the embodiment of Fig. 3. Figs. 7A and 7B are diagrammatic views illustrating the uppermost and lowermost positions of the presser plate and needle with the piessei plate adjusted to stitch fabnc having a greater thickness in accordance with the embodiment of Fig. 3. Fig. 8 is a diagrammatic perspective view, similar to Fig. 3, illustrating presser foot adjusting system and related components of alternative embodiments of the invention and the relationship of actuators and drives. Fig. 8A is a cross-sectional view along line 8A-8A of Fig. 8 illustrating the presser plate drive linkage with the presser plate in its raised position and adjusted for minimum presser plate distance from the needle plate. Fig. 8B is a cross-sectional similar to Fig. 8A but with the presser plate adjusted for maximum presser plate distance from the needle plate Fig. 9 is a diagrammatic perspective view illustrating the variable linkage of the pressure foot adjusting system of Fig. 8. Fig. 9A is a diagrammatic perspective view of the variable linkage of Fig. 9. Detailed Description of the Invention Referring to Fig. 1, a double lock chain stitch quiltmg machine 20 according to one embodiment of the present invention is illustrated. The machine 20 includes a frame 22 assembled in one or more components on a plant flooi 24. Assembled to the frame 22 is a fabric material supply station 26 at the upstream end of the frame 22, a quilt take-up station 28 at the downstream end of the frame 22, and a quiltmg station 30 between the supply station 26 and the take-up station 28 At the quiltmg station 30. a stitch pattern is applied to a multiple layered fabric 32 to form a quilt 34. which then passes to the take-up station 28 where it is wound upon a take-up roll 36, which is rotatably supported on a transverse axle to the fiame 22 at the take-up station 28. The fabnc 32 is formed of one or more layers of fillei material 38 from supply rolls 40 mounted on horizontal transv erse axles to the frame 22 at the supply station 26 The filler material 38 is fed downsπ'eam from the supply station 26 around guide rollers 42 and between two layers of cover material, including an outei cover 44 from a supply roll 46 lying in a trough mounted to the frame 22 above the flights of filler material 38 at the entry end 48 of the quilting station 20, and a lmer or backing 50 from a supply roll 52, rotatably mounted on a transverse axle to the frame 22 below the filler material 38 at the entry end 48 of the quilting station 30 The layeis of matenal 38 44 and 50 aie biought togethei at a rollei station 54 at the entiy end 48 of the quiltmg station 30 to foi the fabnc 32 The lollei station 54 includes tw o pan of tiansv eisely extending trans eisely shiftable rev ersible feed iollers 56 ^8 Rolleis 56 aie adiacent the entiy end 48 of the quiltmg station 30 and leceiv e the fabnc 32 befoie it enteis the quiltmg station 30 The entiy feed lolleis 56 aie dnven in s nchionism with coopeiating exit feed lolleis ^8 at the exit end 60 of the quilting station 30 rotating oi tiansveisel shifting togethei to advance, leveise and tiansveisely shift the fabnc 32 as it moves thiough the quiltmg station 30 At the quilting station 30, the fabnc 32 is se n, ith a stitch forming mechanism into an ays 62 of a quilted pattern 64 (Fig. 2) fiom a pluiahty of needle thieads 68 horn a pluiahty of needle thread spools 70 mounted on the frame 22 near the supply station 26, and a pluiahty of looper threads 72, from a plurality of looper thread spools 74 mounted on the frame 22 beneath the quiltmg station 30 In a known mannei. the needle thieads 70 pass thiough a bank of thread tension adjusteis at the front side of the name 22 at the quiltmg station, pπoi to passing to the quiltmg station 30 These adjusters are mechanically settable to piovide piopei thiead tension They aie also contiolled by pneumatic solenoid contiolled actuators to switch between a tension state, at which the set tension is applied to the needle threads 70, and a release state, at which no tension or minimum tension is applied to the thieads 70 Alternatively, separate thread clamps may be provided at a position along the thiead close to the needles, however, then exact location is dependent on the elasticity of the thiead and is selected to avoid thiead snap-back and unthieadmg of the needles Other details of the quiltmg machine 20 lllustiated in Fig. 1 aie set forth in U S Patent No 5, 154.130 hereby mcorpoiated by leference heiein Furthei, such machines aie commeiciallv available horn Gnbetz International of Sunrise, Florida As illustrated in Figs. 3 and 4, a needle plate 78 supports the fabric 32 as patterns, such as pattern 64 (Fig. 2), are stitched on it to form the quilt 34 Needle plate 78 has a matrix of needle recei ing holes 80 spaced appioximately one inch apart in paiallel rows that aie spaced about six inches apart A presser foot or plate 82, located above the needle plate 78, moves down to piess the fabnc 32 against the needle plate 78 to hold the fabnc as needles 84 extend through it. and the pressei plate 82 mov es up to allow the fabnc 32 to be moved The pressei plate 82 also has a matiix of holes 86 which coπespond to the matnx of needle holes 80 in the needle plate 78 Positioned abov e the piesser plate 82 is a set of paiallel tiansversely onented and longitudinally spaced needle support bars 88, each having a matrix of needle holdeis 90 thereon corresponding to. and spaced directly abo e, each of the holes 86, 80 in respective presser and needle plates 82, 78 Each of the holders 90 includes a vertical groove and a clamping screw positioned in a fhieaded hole beside the groove to clamp the needle securely in position The needles 84 are mounted in an an ay on the needle bais 88 to define the relative spacings of patterns such as pattern 64 in pattern aπay 62 (Fig. 2) The needle bais 88 aie ganged through cioss membeis 92 mounted to reciprocate vertically on the frame 22 at quiltmg station 30 to mov e up and down on the frame 22, as shown by the aιτow 94. so that each of the needles 84 passes thiough conespondmg holes 86, 80 m the respectiv e presser and needle plates 82, 78 The array 62 of disci ete patterns such as the pattern 64 of Fig. 2, is achieved by programmed motion of the fabric 32 transverseh and longitudmallv bv motion of the feed lolleis 56 and 58 moving synchiomsm with the operation of the piessei plate 82 and needle bai s 88 to foim stitches preferably of equal length in the pattern shape. The 360° patterns 64 of the an ay 62 aie accomplished by forwaid and leverse lotation of the feed lolleis 56 and 58 as well as transveise lecipiocatmg motion of the rolleis 56 and 58 The disciete charactei of the patterns 64 of Fig. 2 involves the formation of sev eial tack stitches upon the completion of a pattern 64. a cutting of at least the top or needle threads 68. and a lepositionmg of the fabric 32 under the needles 84 for the beginning 5 of the next pattern The feed rollers 56 and 58 aie dnven in synclnomsm by the a feed roller movement mechanism that includes a l oiler leveisible lotaiv d ve 96. sho n schematically in Fig. 3 The reversibility of the drive 96. and the ability to pull the fabnc 32 fiom the fiont by lolleis 58 as well as from the back by rollers 56, provides an ability to form 360° patterns such as pattern 64 During the stitching piocess, the fabric 32 feeds generally in the direction of the arrow 99. 10 The lollers 56 and 58 are also shiftable tiansveisely. in synchronism with each other, by transverse rollei drive 98 These roller drives 96 and 98 aie electronically linked to the operation of the presser plate 82 and needle bars 88 by a controller 109 The rotary feed drive 96 is driven by feed motor 102 while the transverse drive 98 is driven by shift motoi 104. The latio and relative dnection of the drives 96 and 98 and operation of the presser plate 82 and needle bars 88 is controlled m response to a computer, containing a pattern program, within the controller 15 100. The controller 100 permits the drives 96 and 98 and the motors 102 and 104 can be driven in synchronism with, or disengaged from, the presser plate 82 and needle bars 88, which are driven by a separate drive motor 106. Each of the motors 102, 104. 106 can be locked in position while the others are activated, under control of the controller 100. The controller 100 furthei contiols needle and looper thread tensioners 101 and responds to the states of door interlocks 103 in a know n mannei 0 An output shaft of the motoi 106 is connected to a main drive shaft 108 that extends transversely to the fabric feed direction along the length of the quilting station 30 The main drive shaft 108 lotates continuously but by means of an eccentric coupling, imparts a linear oscillating motion to a mechanical linkage 110 that drives a needle bar and presser plate leciprocatmg assembly 1 15 The mechanical linkage 1 10 reciprocates as illustrated by arrow 107 to impart angulai oscillations to the needle bar locker shaft 1 12 as indicated by the aπow 1 14 and 5 operate the needle bar and presser plate reciprocating assembly 1 15. The angular displacement or amplitude of the angular oscillation is determined by the eccentric drive coupled to the mam drive shaft 108 and the mechanical linkage 110 interconnectmg the needle rocker shaft 1 12 with the main drive shaft 108. The needle rocker shaft 112 extends transversely to the fabric feed direction along the length of the quilting station 30. At selected locations, mechanical linkage 1 16 mteiconnects the needle bars 88 with the needle locker shaft 1 12 and functions to convert the l ecipi ocatmg angulai oscillations of the needle bai rocker shaft 1 12 into a vertical reciprocatmg motion of the needle bars 88 as indicated by the arrow 1 17. The linear displacement or amplitude of the reciprocatmg motion of the needle bars 88 is a function of the magnitude of the oscillation of the needle bai rocker shaft 112 and the mechanical linkage 1 16. Mechanical linkage 1 18 connects a piessei plate locker shaft 1 19 with the needle bai lockei shaft 1 12 5 The piesser plate rockei shaft 1 19 is comprised of an assembly of a presser plate input rocker shaft 120, a pressei plate output rockei shaft 122 and a static phase adjusting coupling 124 connected between the shafts 120, 122. The static phase adjusting coupling 124 pι ides angulai adjustment between the input and output presser plate lockei shafts 120 and 122 and provides the presser plate adjustment which determines the spacing between the presser plate 82 and the needle plate 7 8 at the low ei most and uppei most positions of the piessei plate 82 m each stitch cycle With the coupling 124 set any position, in the couise of the stitching cycles, the piesser plate rockei shaft 1 19 oscillates through an angular displacement repiesented by the arrow 123. and that displacement is temporally identical with the angular oscillations of the needle bai locker shaft 112 The magnitude or angulai displacement with each oscillation of the pressei plate lockei shaft 1 19 is a function of the amphmde of the oscillation of the needle bar locker shaft 1 12 and the mechanical linkage 1 18 interconnecting the shafts 1 12,120. Mechanical linkage 126 mtei connects the output pressei plate lockei shaft 122 with the presser plate 82 and imparts a reciprocating vertical motion to the pressei plate 82. as indicated by aπovv 125. in response to the angulai oscillations of the output presser plate rocker shaft 122. The linear displacement or amplitude of each reciprocation of the presser plate 82 is a function of the angulai displacement of the oscillation of the output presser plate locker shaft 122 and the mechanical linkage 126 Thus, the opeiation of the drive motor 106 causes the presser plate 82 to move through a vertically hneai reciprocating motion that is synchronized with a vertically linear reciprocating motion of the needle bars 88, thereby permitting the fabric 32 to be moved by the feed rollers 56. 68 and the drive 96 to desired different locations between each stitching cycle. A manually operable version of the static phase adjusting coupling 124 is a 360° positioner commercially available from Candy Controls of Niles, Illinois. The phase adjusting coupling 124 is used to change the relative angular position of the output presser plate rocker shaft 122 with respect to the mput presser plate rocker shaft 120, thereby changmg the amplitude of the reciprocating linear motion of the presser plate 82 as well as the location of that reciprocating motion with respect to the needle plate 78 By changmg the location of the reciprocating motion, the gap between the presser plate 82 and needle plate 78 is thereby adjustable to permit quilts of different thicknesses to be stitched by the quilting station 30. This adjustment of the coupling 124 may be made by a servo motoi 129 opei ating m l esponse lo a signal fiom the conti ollei 100. or may be made manually, by turning an adjustment ring, foi example. Figs. 3-5 illustrate furthei details of the drive mechanisms for the presser plate 82 and needle bais 88. In Figs. 3-5, many structural details of the quiltmg station 30 are not illustrated to clarify the operation of the drive mechanism. Further, drive shaft 108 and lockei shafts 1 12. 1 19 extend ttansversely to the direction of feed of the fabric 32 across the full length of the quilting station 30 and are supported by bearings at both ends of the shafts The linkage 110 connecting the drive shaft 108 to the needle bar rocker shaft 1 12 is normally located at one end of the shaft 108. One or moie mechanical linkage 1 10 can be used to mechanically couple the shaft 108 to the needle bar rockei shaft 112. Foi example, identical mechanical linkage 1 10 can be located at opposite ends of the drive shaft 108. The mechanical linkage 1 18 interconnecting the needle bar rocker shaft 1 12 with the presser plate rocker shaft 119 may be located at any point on the drive shaft 108 but normally is located close to one end of the drive shaft 108 and mside of the mechanical linkage 1 10. Typically, a number of mechanical linkages 1 16 interconnecting the needle bai locker shaft 112 to the needle bars 88 are equally spaced over the length of the quiltmg station 30 Normally, a mechanical linkage 126 interconnecting the presser plate rockei shaft 1 19 with the pressei plate 82 is located ovei the length of the piessei plate locker shaft 1 19 adjacent to each of the mechanical linkdues 1 16 Retell ing lo F igs. 3 and 4. the main di n e shall 108 includes an eccentnc cam 128 The mechanical linkage 1 10 is comprised of a connecting lod 130 jouinalled at one end aiound the mam drive shaft 10S and eccentric 128. The connecting lod 130 is pivotally connected at its opposite end to the distal end of a needle bai rocker lever 132. The pioximal end of " the level 132 is clamped oi othei wise mechanically fixed onto the needle bai lockei shaft 1 12 Thus, lotation of the din e shaft 108 by motoi 106 (Fig. 3) causes the connecting rod to reciprocate in a direction parallel to its longitudinal center line. The hneai displacement oi amplitude of each reciprocation is a function of the eccentricity of the eccentnc cam 128. The mechanical linkage 1 18 connecting the needle bar rocker shaft 1 12 with the input presser plate rockei shaft 120 is comprised of a first driving lever 133 and a connecting link 135 and a driven lever 137. The proximal end of the driving lever 133 is clamped or otherwise mechanically fixed to the needle bar rocker shaft 1 12. The distal end of the driving lever 133 is pivotally connected to one end of the connecting link 135 and the opposite end of the connecting link 135 is pivotally connected to the distal end of the driven lever 137. The proximal end of the driven levei 137 is clamped oi otherwise mechanically fixed to the input presser plate rocker shaft 120. Referring to Figs.3-5. the mechanical linkage 1 16 connecting the needle bar rocker shaft 112 to the needle bars 88 is comprised of a needle bar drive lever 134 and a needle bar connecting rod 136. The proximal end of the needle bar drive lever 134 is clamped or otherwise mechanically fixed to the needle bar rocker shaft 1 12. and the distal end of the needle bar drive lever 134 is pivotally connected to an upper end of the needle bar connecting rod 136. The lower end of the needle bar connecting rod is pivotally connected with respect to a cross member 92 that is clamped or otherwise rigidly connected to the needle bars 88 The cross member 92 has a guide rod 158 extending vertically upward through a name member 140 to ensure that the needle bars 88 reciprocate m a vertical direction. Thus, angular oscillations of the needle bar locker shaft 112 are converted by mechanical linkage 1 16 into vertical reciprocating motion of the needle bars 88 The mechanical linkage 126 connecting the output presser plate rocker shaft 122 to the presser plate 82 includes a presser plate lever 138. a pressei" plate dnve link 141 and a piesser plate guide rod 142 The pioximal end of the presser plate lever 138 is clamped or otherwise mechanically secured to the output presser plate rocker shaft 122. The distal end of the presser plate level 138 is pivotally connected to an upper end of the presser plate drive link 141. The presser plate guide rod 142 is mounted withm bearings (not shown) that m turn are supported by a frame member 150. The lowei end of the presser plate drive link 141 is pivotally connected to a presser plate block 142 that is clamped or otherwise mechanically secured to an upper end of a presser plate guide lod 144. The lower end of the presser plate guide lod terminates into a presser plate mounting block 146 that is secured to the presser plate 82 by fasteneis 148 or othei means Thus, oscillations of the needle bar rocker shaft 112 are transmitted via the mechanical linkage 1 18 to the pressei plate rockei shaft 1 19 Angular oscillations of the pressei plate locker shaft 119 aie tiansfeπed via mechanical linkage 126 to vertical reciprocations of the presser plate 82 In use. the quiltmg machine 20 is illustrated as set up to establish a gap between the presser plate 82 and the needle plate 78 that is suitable to stitch layers of fabric 32 that are relatively mm. In Fig. 6A, the presser plate 82 is located approximately 0.25 inches above the needle plate 78, and a first fabric 32 having a first thickness is loaded into the quilt g station 30 and located betw een the piesser plate 82 and the needle plate 78 As the needle bar rocker shaft 112 besjms its oscillation in the ireneiallv clockwise direction, mechanical linkage 116 shown m Figs. 3-5 causes the needle 84 to begin tiavehng vertically downwaid as pieviously described. Furthei. the pressei plate l ckei shall 1 19, being mechanically linked to the needle bai lockei shaft 1 12 bv mechanical linkage 1 18. also begins to rotate in the clockwise duection Clockw lse lotation of the piessei plate locker shaft moves the pressei plate 82 vertically downwaid to compact the fabnc 32 The presser plate 82 and needle 84 continue their downward motion until the needle bar lockei shaft 1 12 lotates thiough an angular displacement of appioximately 40° to the position illustrated in Fig. 6B The mechanical linkage 118 causes the piesser plate rocker shaft 1 19 to rotate thiough an angulai displacement of appioximately 25° to the position illustrated in Fig. 6B. At that point, the piessei plate 82 and needle 84 will be at then loweimost positions pioviding the smallest gap between the pressei plate 82 and the needle plate 78. Thus, the presser plate 82 has moved downward through a stroke of 0 125 inches. thereby causing the presser plate 82 to compact the material 32 to a thickness of approximately 0.125 inches. The needle bar locker shaft 112 then reverses direction and rotates back through the 40° angular displacement to the position illustrated m Fig. 6A, thereby retracting the needle 84 from the material 32 and rotating the presser plate rocker shaft 1 19 and lifting the presser plate 82 to then lespective original positions. The feed rollers 56, 58 and transverse drive 96 then move the material 32 to an appropriate location for the next stitch as required, for example, by the pattern 64. It should be noted that in Fig. 6B. the pivot axes of the presser plate rocker shaft 1 19, presser plate lever 138 and pressei plate dnve link 141 foi m a geneially straight line The toggle formed at the pivot 143 interconnecting the presser plate lever 138 and pressei plate drive link 141 functions to provide a dwell time for the presser plate 82 in its lowermost, full compaction position. Preferably, the presser plate rocker shaft 1 19 rotates several degrees beyond the m-line position to "toggle-over" the pivot 143. The net result is that the presser plate rocker shaft 119 rotates clockwise through a small angle to toggle-over the pivot joint 143. reverses direction and moves in a counterclockwise direction thiough the same angulai displacement without the presser plate 82 experiencing significant vertical motion Thus, during the time lequired for the presser plate rocker shaft 22 to move thiough those angular displacements to toggle-ovei and retract the pivot 143. the presser plate 82 dwells in a stationary position, thereby maintaining the material 32 in its fully compressed state while the needle 84 is retracting from the material. If a thicker quilt is to be stitched, the quiltmg machine is stopped; and the static phase adjusting coupling 124 is utilized to change the height of the piessei plate 82. theieby changing the gap between the presser plate 82 and the needle plate 78. The coupling 124 has an outer ring 131 which is unlocked by activation of a solenoid 139 in response to a signal from controller 100 Then, the ring 131 rotated in a direction causing the presser plate rocker shaft 1 19 to turn counteiclockwise as viewed in Fig. 7A Thus, by rotating the outer ring of the static phase couplmg 124. the input piesser plate locker shaft 120 lemains stationary, but the output presser plate rocker shaft 122 will rotate, for example, counterclockwise, as viewed in Fig. 7A. Each revolution of the outer ring of the phase coupling 124 results in a rotation of approximately 3 6° of the outer presser plate rocker shaft 122. If it is desired to provide a gap between the presser plate 82 and needle plate 78 of approximately 0.6275 inches as illustrated m Fig. 7A. the output piesser plate locker shaft 122 will have to be moved approximately 24° m the counterclockwise duection Thus, the outei nng of the phase adjusting coupling 124 must be mov ed through appioximately 6 7 revolutions When rotation of the outer collar of phase couplmg 124 results m the presser plate 82 having the desned gap or distance fiom the needle plate 78. the outei ring of the phase coupling 124 is then locked into position, and the stitching cycle may be initiated In this example, using the coupling 124. the gap between the presser plate 82 and the needle plate 78 is easily mcieased to approximately 0.6275 inches as illustrated in Fig. 7A. Thereaftei, a second fabric 32 having layeis of a second thickness aie loaded mto the quiltmg machine 20. 5 and the operation of the quiltmg machine is started In this example, a stitching cycle is executed corresponding to that shown m Figs. 7A, 7B which, except for the size of the gap between the piesser plate 82 and the needle plate 78, is substantially the same as the cycle lllustiated in Figs. 6A, 6B. That is. from the highest, fully retracted position of the piesser plate 82 and needle 84 lllustiated in Fig. 7A to the fully extended, lowermost position of the piesser plate 82 and needle 84 lllustiated in Fig. 7B. the needle bar rocker shaft 1 12 rotates through approximately 10 40°. The mechanical linkage 118 with the piesser plate rocker shaft 1 19 causes the presser plate rocker shaft 1 19 to rotate clockwise through an angulai displacement of appioximately 25° That angular displacement of the presser plate rocker shaft 119 causes the presser plate 82 to move downward through a compression stroke of approximately 0.375 mches to provide full compression with a gap of appioximately 0.25 inches between the presser plate 82 and needle plate 78. The needle bai locker shaft 1 12 then leveises direction and rotates counterclockwise through an 15 angular displacement of approximately 40° to move the linkages of presser plate 82 and needle 84 to the fully retracted positions illustrated in Fig. 7A. Thus, the present invention provides a quiltmg machine and method that is substantially more flexible in its operation The quiltmg machine of the present invention permits different gaps between the presser plate 82 and the needle plate 78 to be easily set, so that fabric layers of different thicknesses can be stitched on the same machine. 0 The gap between the presser plate 82 and the needle plate 78 is adjusted simply in seconds by changing the setting of the static phase coupling 124, and it is not necessary to exchange cams or other mechanical components which requires many hours of complex and difficult labor to accomplish. The quiltmg machine of the present invention pi ovides its user with oppoi amities to supply diffeient quilted products in a way that was not possible in the past with a single quilting machine. 5 Additional advantages and modifications to the above embodiment will readily appear to those who are skilled in the art. For example, as illustrated in Fig. 3, a lever arm 132 is utilized to impart angulai oscillations to the needle bar rocker shaft 1 12. Similarly, a second lever arm 133 is used to transmit an angular oscillation from the needle bar rocker shaft 112 to the presser plate locker shaft 1 19 As will be appreciated, the levers 132 and 133 may be integrated into a single unitary lever that extends fiom either one side or both sides of the needle bar rocker 0 shaft 1 12 Further, the disclosed embodiment in Fig.3 illustrates the motor 106 directly driving the drive shaft 108 As will be appreciated, the motor 106 and drive shaft 108 may be mechanically coupled with other devices, foi example, timing belts, chains, etc., in a know n mannei Further, the quilting station 30 illustrated in Figs. 3-5 provides two needle bars 88. Different numbers of needle bars 88 may be utilized by the quiltmg station. The use 5 of the static phase coupling 124 to change the lelative angular positions of the input and output presser plate rockei shafts 120. 122 may be used with any type and style of quiltmg machine Further, the application of the static phase coupling 124 is independent of the lelative degiee of automation of the quiltmg machine Othei embodiments aie lepiesented by Figs. 8 thiough 9B, in which an alternative needle bar and piessei plate lecipiocatmg assembly 215 is piovided having a vanable linkage 218 which replaces the linkage 1 18 and provides the pressuie plate adjustment function provided by the assembly of the split shaft 119 and the static phase adjusting coupling 124 thei eof The variable linkage 218 connects the needle bar rocker shaft 1 12 with a solid one 5 piece presser plate rocker shaft 219, and includes a first driving lever block assembly 233, a connecting link 235 and a driven lever block assembly 237 The proximal end of the driving lever block assembly 233 is clamped oi otherwise rigidly attached fixed to the needle bar rocker shaft 1 12. The distal end of the driving lever block assembly 233 is pivotally connected to one end of the connecting link 235 and the opposite end of the connecting link 235 is pivotally connected to the distal end of the dnven lever block assembly 237 The proximal end of the 10 driv en lever 237 is clamped oi otherwise ngidly attached to the presser plate rockei shaft 219 The mechanical linkage 126 connects the presser plate rocker shaft 219 to the presser plate 82 and includes the presser plate lever 138, the piesser plate dnve link 141 and the presser plate guide rod 142. The proximal end of the piessei plate level 138 is clamped oi otherwise mechanically secured to the presser plate rocker shaft 219 The distal end of the presser plate lever 138 is pivotally connected to an uppei end of the piesser plate drive link 15 141. The presser plate guide rod 142 is mounted within bearings (not shown) that in turn are supported by a frame member 150. The lower end of the presser plate drive link 141 is pivotally connected to a presser plate block 142 that is clamped or otherwise mechanically secured to an upper end of a presser plate guide rod 144. The lower end of the presser plate guide rod terminates into a presser plate mounting feet 146 that is secured to the presser plate 82 by fasteners or other means Thus, oscillations of the needle bar rocker shaft 1 12 are transmitted via the variable 20 linkage 218 to the presser plate rocker shaft 219 Angulai oscillations of the presser plate rocker shaft 219 are transferred via mechanical linkage 126 to vertical reciprocations of the presser plate 82. The variable linkage 218 tiansmits the oscillating motion of the needle rocker shaft 1 12 to the presser plate rocker shaft 219 to drive the piesser plate 82 between it's lo ermost point of travel closest to the needle plate 78. wheie it compiesses the matenal to its maximum state of compiession for sewing a stitch, and its uppermost point 25 of travel farthest from the needle plate 78, where the matenal is capable of being moved horizontally parallel to the plates and relative to the paths of travel of the needles. The variable linkage 218 is adjusted by effectively varying the length of the linkage 218 to change the lowermost and uppermost points of travel of the presser plate 82. The length of the linkage is varied by moving the axis of pivot between the connecting link 235 and the driven lever block assembly 237 to effectively change the length of " the connecting link 235 and the angular adjustment of shaft 30 219. The axis is the centerlme of an eccentric lobe 226, which, when rotated, increases or decreases the distance between the actual pivot points of the link 235 in the block assembly 237. This results in a corresponding change in the presser foot height The eccentnc lobe 226 is mounted with bearings 231, 232 in both the lever block assembly 237 and the link 235. lespectively A mechanism that includes a geai 227 on one end of the shaft of the eccentric lobe 226 and a geaied lev ei 228 mechanism pivotally mounted on the block assembly 237 rotates the 35 eccentric lobe 226. The geared lev ei 228 lotates on beaiing 239 about the pressei foot rocker shaft 219 and is held in place with a collai 234. A hneai motoi or actuator 229, described here as a two position bidirectional pneumatic cylindei. is mounted on the block assembly 237 and actuates the mechanism of gear 227 and lever 228. forcing a stop levei 230 against a mechanical stop 235 at either end of the rotary travel of " the eccentric lobe 226. The geai 227 and stop lever 230 are keyed to the eccentnc shaft 226 w ith a key 236. A pneumatic contiol v alve (not shown) actuates the cylmdei. The machine contiollei 100 opeiates the pneumatic contiol alv e and thereby toggles the pressure foot setting between a highei and lower setting The mechanical parts can be divided into two categories. One category includes the force transmitting parts, which aie levei block 233. link 235. eccentnc lobe 226. bearings 231 and 232 and lever block 237. which transmit the heavy forces lequned to be tiansmitted from the rockei shaft 1 12 to the presser foot rocker shaft 219. The other categoiy includes position holding parts and parts that provide adjustability, which are pneumatic cylinder 229. gear lever 228, bearing 239, lock ring 234, gear 227. stop lever 230. stop 240 and key pin 236, which hold the foice transmitting parts then piopei positions, but do not tiansmit the heavy foices themselves. The actuatoi oi motoi 229 can be in the form of a double acting two position pneumatic cylinder, solenoid or other double acting motor, or it may be in the form of a multiple position motor that can adjust the linkage among a plurality of discrete positions or infinitely over a range. For example, greater adjustability than is provided by a smgle double actmg actuatoi can be achieved by adding a second eccentric system into the linkage 218 in series with the first eccentric lobe element 226, for example by adding a similar lobe m place of pivot shaft 444 on the other end of the link 235. An additional double acting actuator 229 would be provided to switch this lobe between two positions, thereby producing a total of four adjustments or presser foot positions rather than two, depending on which actuator 229 were actuated: one, the other, neither, or both. Infinite adjustability could be provided by using, instead of a two position cylinder for the actuator 229, using a multiple position actuator to rotate the eccentric to more than only two positions This can be achieved by incorporating a motor such as a stepping motor or other device capable of stopping and holding the eccentric in either a plurality of discrete positions or an infinite number of positions within its range of travel. The actuator may be controlled to adjust the presser foot height in several ways. Preferably, several modes of control aie provided, including a manual mode, hich gives an operator the flexibility to set or change the pressei foot height, a batch mode, in w hich the contioller signals the actuatoi to make set the height that has been predetermined to be appropriate for the product being quilted, and an automatic mode in which sensors measure one or more parameters during the quilt g operation to determine the height setting appropriate for the material bemg quilted. In each mode, the controller 100 sends a signal to the actuator 229 to execute the adjustment. Similar control modes can be used for the actuatoi 129 in the embodiment of Figs. 3-7B discussed above In the manual mode, a touchscieen icon foi selecting manual operation of the presser foot setting is incorporated into the opeiator interface of the controller 100 When the icon is selected, screen contiols aie presented to the operator by which a pressei foot setting oi setting change can be entered to the controller 100. The manual setting is preferably made when the machine is stopped for adjustment so that the high forces present during high speed quilting are not encounteied during adjustment. Automated setting can be synchronized to those points m the quiltmg machine cycle when the adjustments can be made. In the batch mode operation, information regarding proper presser foot height is included in a product database that includes data for all of the automatic parameter settings to produce each product scheduled on the quilting machine. Adjustments aie made automatically by the controllei 100 at the correct time in the quiltmg process as the materials are in tiansition undei the piesser foot More detailed explanations of batch mode contiol aie set forth m Foi ' batch mode" U S Patent No 3 ~>44 ^99 and U S Patent Application Senal No 09/301 6:>3 filed April 28 1999 bv Fiazei et al entitled Quilt Making Automatic Scheduling Sv stem and Method, both heiebv expiessly mco orated by refeience herein In automatic mode, automatic adjustments aie made based on leal time sensing of one or moie vanables such as the thickness of the matenal oi the density of the matenal This sensing can be made by gages oi othei thickness or density sensing devices (for example thickness gage 260 as lllustiated in Fig. 3) to measuie these quantities dnectly but is most easily accomplished by electionically monitoring machine paiameteis directly affected by those vanables, such as the load and consequential inci eased toique demands being placed on the machine (foi example, thiough feedback 261 from the din e motoi 106 to the conti oiler 100 as illustrated in Fig. 3) oi by physical load measunng devices The invention is not limited to the specific details shown and descnbed herein Departures may be made from the details described herein without departing fiom the spirit and scope of the claims hich follow

Claims: What is claimed is 1. A quiltmg appaiatus comprising a needle plate foi supporting a fabnc to be quilted, a piessei plate paiallel to the needle plate and moveably mounted to lecipiocate, dunng each of a plurality of " stitching cycles, between a matenal clamping position spaced fiom and lelatively proximate to the needle plate and a material releasing position spaced from and lelatively remote fiom the needle plate, a ganged needle array located opposite the piesser plate from the needle plate having thereon a plurality of needles each positioned to pass thiough aligned an ays of holes in the piessure plate and needle plate to stitch material clamped between the needle plate and the piessuie plate when the pressure plate is in its clamping position, a needle rocker shaft linked to the needle an ay and mounted to oscillate thiough angulai displacements to impart lecipiocatmg motion to the needles of the anay, a presser plate rockei shaft linked to the presser plate and mounted to oscillate through angular displacements to impart reciprocatmg motion to the piesser plate in response to the angular displacements of the needle locker shaft, a drive motoi having an output connected to the needle rockei shaft to drive the needles of the array m their reciprocating motion and to thereby drive the presser plate in its reciprocating motion, an adjustable element connected in series with the presser plate rocker shaft between the needle rocker shaft and the presser plate wheieby the range of the lecipiocatmg motion of the pressei plate can be adjusted, an adjustment motoi having an output connected to the adjustable element, and a controllei having a contiol signal output connected to the adjustment motor to contiol the motoi to move the adjustable element to thereby adjust the lange of the reciprocating motion of the presser plate 2. A quilting appaiatus compnsing a needle plate for supporting a fabnc to be quilted, a presser plate parallel to the needle plate and moveably mounted to recipiocate, during each of a plurality of stitching cycles of the apparatus, between a matenal clamping position spaced fiom and lelatively pioximate to the needle plate and a material releasing position spaced from and relatively remote from the needle plate, a drive motor for driving the appaiatus through the plurality of cycles, a presser plate dnve linkage connecting the piessei plate to an output of the drive motor, the linkage having a variable element theiein moveable to and fiom each of a plurality of settings to thereby vary the spacing between the needle plate and the pressure plate when its matenal clamping position, an actuator having an output connected to the vanable element and opeiable in lesponse to a contiol signal to selectively move the element to and each of the settings, and a controller operable to send the contiol signal to the actuator to change the pressure plate setting 3. The quilting appaiatus of claim 2 furthei comprising a sensor responsiv e to the thickness or density of the fabnc, and the conti oiler having an input connected to the sensor and being programmed to automatically determine a pressure plate setting appiopriate foi quiltmg the fabnc and being operable to send the control signal to the actuator to change the piessure plate setting to the determined setting. 4. The quiltmg apparatus of claim 2 wherein. the contiollei has a memoiy associated theiewith hav ing stoied therein data of machine parameters for the quiltmg of a plurality of different quilted fabrics, the data including the piesser plate setting appropriate for quiltmg each respective product; and the controller is operable in response to the data stored in the memory to control parameters of the apparatus to produce each of the different quilted products, including to generate the control signal to the actuatoi to cause the actuator to affect the piessuie plate settings appropriate to respectively quilt each of the products 5. The quiltmg apparatus of claim 2 wherein. the controller has an input associate theiewith for receiving a piesser plate setting command from an operator; and the controller is operable m response to a presser plate setting command from received on the input from the operator to generate the control signal to the actuator to cause the actuator to set the pressure plate spacing m accordance with the received command 6. The quilting apparatus of claim 2 wherein; the piesser plate dnve linkage includes a presser plate rocker shaft having an input link connected thereto and driven by the motor and an output link connected to the presser plate; the presser plate rockei shaft having a coupling therein that is adjustable to vary the phase angle between the input link and the output link to thereby vary the presser plate setting; and the actuator is operably connected to the coupling to vary the coupling in response to the control signal. 7. The quiltmg apparatus of claim 2 wherein the presser plate drive linkage includes a presser plate rocker shaft having an input link connected thereto and driven by the motoi and an output link connected to the presser plate; the input link has a vanable element theiein that is adjustable to vaiy the range of oscillation of the presser plate rocker shaft to thereby vary the presser plate setting; and the actuator is opeiably connected to the variable element to vary the coupling in response to the control signal. 14. A quilting method comprising setting the piessei plate to a first position spaced from the needle plate, loading a first fabric of a first thickness into the quilting machine, reciprocating a needle holder relative to the fust fabric while reciprocating the presser plate to and from the first position to cause a synchronized opeiation of the needle and the presser plate, thereby quilting the first fabric, then loading a second fabric of a second thickness into the quilting machine and generating a control signal to drive an adjustment motor to set the presser plate to a second position spaced from the needle plate, and reciprocating a needle holder relative to the second fabric while reciprocating the presser plate to and from the second position to cause a synchronized operation of the needle and the presser plate, thereby quilting the second fabric 15 An apparatus for stitching fabric to pioduce a quilted fabric comprising a needle plate for supporting the fabric, a presser plate located at a first position above the needle plate and supported for linear motion. a needle located above the piesser plate and supported for linear motion, a needle rocker shaft mounted for rotational motion and rotationally oscillating through angular displacements, the needle rocker shaft being mechanically connected to the needle and imparting a reciprocating motion to the needle in response to the angular displacements of the needle rocker shaft, a presser plate rocker shaft mounted for rotational motion, mechanically connected to the needle rocker shaft and imparting a lecipiocatmg motion to the presser plate in response to the angular displacements of the needle rocker shaft, the presser plate rocker shaft having an output shaft movable from a first to a second lelative angular position with respect to an input shaft, thereby locating the presser plate at a second position with respect to the needle plate and permitting quilts of different thicknesses to be stitched 16 An apparatus for stitching fabric to produce a quilted fabnc comprising a needle plate foi supporting the fabric. a presser plate located above the needle plate and supported for linear motion, a needle located above the pressei plate and supported for lineai motion, a needle rockei shaft mounted for rotational motion and rotationally oscillating through angular displacements the needle locker shaft being mechanically connected to the needle and imparting a reciprocating motion to the needle in response to the angular displacements of the needle rocker shaft, a presser plate rocker shaft mounted for rotational motion the presser plate rocker shaft including drive linkage imparting a reciprocating motion to the pressei plate, in synchronized relationship to the angulai displacements of the needle l ocker shaft towaid and away from the needle plate, and an adjustment device linked to the presser plate l ockei shaft for changing the range of rotational motion of the presser plate rocker shaft to cause it to reciprocate the presser plate to different locations with respect to the needle plate thereby pei mitting quilts of diffeient thicknesses to be stitched 14. A quilting method compnsing setting the piessei plate to a first position spaced fiom the needle plate loading a fust fabnc of a fust thickness into the quilt g machine, lecipiocatmg a needle holdei lelative to the fust fabnc while lecipiocatmg the piessei plate to and from 5 the first position to cause a synchionized opeiation of the needle and the piesser plate, theieby quiltmg the fust fabnc, then loadmg a second fabric of a second thickness into the quiltmg machine and geneiating a contiol signal to dnve an adjustment motoi to set the piessei plate to a second position spaced fiom the needle plate, and recipiocating a needle holdei lelati e to the second fabnc while lecipiocatmg the pressei plate to and from 10 the second position to cause a synchronized opeiation of the needle and the pressei plate, thereby quilting the second fabnc 1 :> An appaiatus foi stitching fabnc to pioduce a quilted fabnc compnsing a needle plate for supporting the fabnc, a pressei plate located at a first position above the needle plate and supported foi lmeai motion, 15 a needle located above the pressei plate and supported foi lmeai motion a needle rocker shaft mounted for lotational motion and rotationally oscillating thiough angulai displacements, the needle lockei shaft being mechanically connected to the needle and imparting a lecipiocatmg motion to the needle in response to the angulai displacements of the needle rocker shaft, a piesser plate rockei shaft mounted foi lotational motion, mechanically connected to the needle lockei 20 shaft and imparting a reciprocating motion to the piessei plate in response to the angular displacements of the needle rocker shaft, the presser plate rocker shaft having an output shaft movable from a first to a second lelative angulai position w ith respect to an input shaft theieby locating the piessei plate at a second position w ith lespect to the needle plate and permitting quilts of diffeient thicknesses to be stitched 16 An apparatus for stitching fabric to produce a quilted fabnc comprising 25 a needle plate for supporting the fabnc, a piessei plate located abo e the needle plate and supported foi lmeai motion, a needle located above the pressei plate and supported foi lmeai motion a needle rocker shaft mounted for lotational motion and rotationally oscillating thiough angulai displacements, the needle lockei shatt being mechanically connected to the needle and imparting a lecipiocatmg ^0 motion to the needle in lesponse to the angulai displacements of the needle locker shaft a piessei plate lockei shaft mounted foi lotational motion the piessei plate lockei shaft including dnve linkage imparting to the piessei plate in synchionized lelationship to the angulai displacements of the needle rockei shaft, a reciprocating motion between locations lelativelv towaid and away from the needle plate, the presser plate rocker shaft including an adjustment dev ice foi changing the rotational motion of the piesser plate rocker shaft to 35 change said locations and to theiebv move the piessei plate to diffeient locations vv ith respect to the needle plate theiebv permitting quilts of diffeient thicknesses to be stitched 17. A method of " stitching fabric on a quilting machine having a needle plate, a presser plate located above the needle plate, a needle located abov e the pressei plate, a rotationally oscillating needle rocker shaft, and a pressei plate rocker shaft mechanically connected to the needle rocker shaft, the method comprising, setting the presser plate to a first position above the needle plate; loading a fu st fabric of a first thickness into the quilting machme. oscillating the needle rocker shaft to impart an oscillation to the presser plate rocker shaft and cause a synchronized operation of the needle and the presser plate, thereby stitching the first fabric; stopping the needle rocker shaft; setting the pressei plate to a second position above the needle plate without changing cams on the machine, loading a second fabric of a second thickness into the quiltmg machine: and oscillating the needle rocker shaft to impart an oscillation to the presser plate rocker shaft and cause a synchronized operation of the needle and the presser plate, thereby stitching the second fabric.

Inventors: BONDANZA JAMES, CODOS RICHARD N, JAMES MICHAEL, KAETTERHENRY JEFF, LEAVIS GLENN, BONDANZA, JAMES, CODOS, RICHARD, N., JAMES, MICHAEL, KAETTERHENRY, JEFF, LEAVIS, GLENN
Applicants: L & P PROPERTY MANAGEMENT CO, L & P PROPERTY MANAGEMENT COMPANY
Application year: 2000
Main classification: D05B11
IPC codes: D05B11, D05B19, D05B29