Patent Description:
The disclosed invention relates to tufting machines and, in particular, to apparatus and methods for adjusting the needle bars of tufting machines.

Tufting machines, such as, for example, conventional Card-Monroe tufting machines, comprise a needle bar having a plurality of needles that are reciprocally plunged through backing to make a tufted article. A corresponding hook bar can comprise a plurality of hooks, or "loopers," that engage the yarn from respective needles to form yarn loops. A needle bar shifter assembly can be coupled to each needle bar to shift the needle bar transversely to the movement direction of the backing material in order to form patterns in the tufted article. The needle bar shifter assembly can comprise a slide assembly that is coupled to a carriage assembly, and the needle bar can, in turn, be coupled to the carriage assembly. An actuator can shift the slide assembly transversely, thereby driving the carriage assemblies transversely. One embodiment of a shifter assembly is disclosed in <CIT> Further examples are disclosed in <CIT> and <CIT>.

Conventional needle bar assemblies used in shifted tufting processes require periodic position adjustment relative to the hook bar in order to maintain a select positioning of the needles relative to the respective hooks. The desired spatial relationship between the needles and respective hooks can change based on the different types of yarn being used.

Although tufting machines typically have an adjustment (tensioning) system, a technician using a standard wrench can only access such tensioning systems from a guarded area, thereby slowing the tensioning process. Moreover, technicians frequently use a hammer and/or punch or specialized (crow's foot) wrenches in order to adjust the tension of the needle bar shifter assembly. However, the use of these tools creates additional safety concerns and damages the shifter shaft of the tufting machine. Moreover, the conventional tensioning system uses a coarse thread pitch, so adjustment via the conventional tensioning machine is correspondingly coarse. Thus, the conventional tensioning system lacks precision.

Described herein, in various aspects, is an apparatus comprising a needle bar shifter of a tufting apparatus. The needle bar shifter has first, second, third, and fourth shaft segments. Each of the first, second, third, and fourth shaft segments has respective first and second ends, the first and second shaft segments being aligned and spaced apart in a longitudinal dimension, the third and fourth shaft segments being aligned and spaced apart in the longitudinal dimension, the first ends of the first and second shaft segments facing one another, the first ends of the third and fourth shaft segments facing one another. The third and fourth shaft segments are offset from the first and second shaft segments in a transverse dimension. The apparatus further comprises a shifter adjustment assembly configured to couple to the needle bar shifter. The shifter adjustment assembly is configured to cause adjustment of a position of a needle bar of the tufting apparatus relative to a hook bar of the tufting apparatus in order to maintain a select positioning of needles of the needle bar relative to respective hooks of the hook bar. The shifter adjustment assembly comprises a first body that is configured to couple to the first ends of the first and third shaft segments. A second body is configured to couple to the first ends of the second and fourth shaft segments. The shifter adjustment assembly comprises a coupling between the first body and the second body. The coupling is configured to releasably secure an axial position of the first body with respect to the second body along the longitudinal dimension. The first body and second body define respective complementary surfaces that are configured for sliding engagement so that movement between the first body and the second body in the transverse dimension is restricted and movement between the first body and the second body in the longitudinal dimension is permitted.

The shifter adjustment assembly can further comprise an adjustment device configured to move the first body with respect to the second body in the longitudinal dimension.

The first body can define a first through-hole that extends through the first body in the longitudinal dimension. The second body can define a second through-hole that extends through the second body in the longitudinal dimension. The first through-hole can define a right-hand thread. The second through-hole can define a left-hand thread. The adjustment device can comprise an elongate rod having a right-hand thread on a first end and a left-hand thread on a second end opposite the first end. The right-hand thread of the first end of the elongate rod can be in engagement with the right hand thread of the first through-hole, and the left-hand thread of the second end of the elongate rod can be in engagement with the left-hand thread of the second through-hole.

The shifter adjustment assembly can further comprise a hexagonal head coupled to the elongate rod.

The adjustment device can further comprise a jam nut that is threadedly movable on the elongate rod and configured to bias against one of the first body or the second body.

The first body can comprise a first portion and a second portion that is coupled to the first portion. The first portion of the first body can define the first through-hole that defines the right-hand thread. The second body can comprise a first portion and a second portion that is coupled to the first portion. The first portion of the second body can define the second through-hole that defines the left-hand thread.

The first portion of the first body can extend upwardly from the second portion of the first body. The first portion of the second body can extend upwardly from the second portion of the second body.

The coupling between the first body and the second body can comprise at least one fastener.

One of the first body and the second body can define at least one slot that is elongate in the longitudinal dimension, wherein each fastener of the at least one fastener extends through a respective slot of the at least one slot.

The first body can define a first longitudinally extending through-bore for receiving the first shaft segment. The first body can define a second longitudinally extending through-bore for receiving the third shaft segment.

The first body can define a first slit that extends between a first side of the first body and the first longitudinally extending through-bore. The first body can define a second slit that extends between a second side of the first body and the second longitudinally extending through-bore. The shifter adjustment assembly can comprise at least one threaded fastener that extends across the first slit of the first body. The at least one threaded fastener that extends across the first slit of the first body can threadedly couple to the first body so that a tightening of the at least one threaded fastener that extends across the first slit of the first body causes the first longitudinally extending through-bore to tighten against the first shaft segment. The shifter adjustment assembly can comprise at least one threaded fastener that extends across the second slit of the first body. The at least one threaded fastener that extends across the second slit of the first body can threadedly couple to the first body so that a tightening of the at least one threaded fastener that extends across the second slit of the first body causes the second longitudinally extending through-bore to tighten against the third shaft segment.

The second body can define a first longitudinally extending through-bore for receiving the second shaft segment. The second body can define a second longitudinally extending through-bore for receiving the fourth shaft segment.

The second body can define a first slit that extends between a first side of the second body and the first longitudinally extending through-bore. The second body can define a second slit that extends between a first edge of the second body and the second longitudinally extending through-bore. The shifter adjustment assembly can comprise at least one threaded fastener that extends across the first slit of the second body. The at least one threaded fastener that extends across the first slit of the second body can threadedly couple to the first body so that a tightening of the at least one threaded fastener that extends across the first slit of the second body causes the first longitudinally extending through-bore to tighten against the second shaft segment. The shifter adjustment assembly can comprise at least one threaded fastener that extends across the second slit of the second body. The at least one threaded fastener that extends across the second slit of the second body can threadedly couple to the first body so that a tightening of the at least one threaded fastener that extends across the second slit of the second body causes the second longitudinally extending through-bore to tighten against the fourth shaft segment.

The first body can define one of a tongue or a groove, and the second body can define the other of the tongue and the groove. The tongue can be receivable into the groove with a clearance in the transverse dimension between the groove and the tongue that inhibits transverse movement between the tongue and the groove.

The tongue can define first and second longitudinally extending outer edges. The groove can define corresponding first and second longitudinally extending inner edges that are outward of the respective outer edge of the first and second outer edges of the tongue relative to the transverse dimension. The first and second outer edges of the groove can respectively slidingly engage the first and second inner edges of the tongue to thereby restrict movement between the first body and the second body in the transverse dimension.

The shifter adjustment assembly can further comprise a linear position sensor that is configured to detect at least one of a distance or a change in distance between the first body and the second body relative to the longitudinal dimension.

Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

As used herein the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. For example, use of the term "a screw" can refer to one or more of such screws, and so forth.

All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

Optionally, in some aspects, when values are approximated by use of the antecedent "about," it is contemplated that values within up to <NUM>%, up to <NUM>%, up to <NUM>%, or up to <NUM>% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, in some optional aspects, when values are approximated by use of the terms "substantially" or "generally," it is contemplated that values within up to <NUM>%, up to <NUM>%, up to <NUM>%, or up to <NUM>% (above or below) of the particular value can be included within the scope of those aspects. When used with respect to an identified property or circumstance, "substantially" or "generally" can refer to a degree of deviation that is sufficiently small so as to not measurably detract from the identified property or circumstance, and the exact degree of deviation allowable may in some cases depend on the specific context.

As used herein, the term "at least one of" is intended to be synonymous with "one or more of. " For example, "at least one of A, B and C" explicitly includes only A, only B, only C, and combinations of each.

The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list.

It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without employing these specific details.

Disclosed herein, in various aspects and with reference to <FIG> is a shifter adjustment assembly <NUM> in combination with with a needle bar shifter assembly <NUM> (referred to herein as a "shifter"). The shifter <NUM> comprises a first shaft segment <NUM> having a first end <NUM> and an opposing second end <NUM>, a second shaft segment <NUM> having a first end <NUM> and an opposing second end <NUM>, a third shaft segment <NUM> having a first end <NUM> and an opposing second end <NUM>, and a fourth shaft segment <NUM> having a first end <NUM> and an opposing second end <NUM>. The first and second shaft segments are aligned and spaced apart in a longitudinal dimension <NUM>, and the first end <NUM> of the first segment <NUM> faces the first end <NUM> of the second shaft segment <NUM>. The third and fourth shaft segments is aligned and spaced apart in the longitudinal dimension <NUM>, and the first end <NUM> of the third segment <NUM> faces the first end <NUM> of the fourth shaft segment <NUM>. The first and second shaft segments are offset from the third and fourth shaft segments in a transverse dimension <NUM> that is perpendicular to the longitudinal dimension <NUM>. Optionally, the transverse dimension <NUM> can be horizontal.

As further explained below, it is contemplated that the disclosed shifter adjuster assemblies can permit faster, safer, and more precise tensioning adjustments in comparison to conventional methods. More particularly, the disclosed shifter adjuster assemblies can be located under the head of the tufting machine, making the location of adjustment easily and safely accessible without the need for entering a guarded area or using tools that cause damage to the shifter shaft. Optionally, the disclosed shifter adjuster assemblies can make use of fine threads that permit more precise tensioning adjustment.

Referring also to <FIG> and <FIG>, the shifter adjustment assembly <NUM> comprises a first body <NUM> coupled to the first end <NUM> of the first shaft segment <NUM> and the first end <NUM> of the third shaft segment <NUM>. The shifter adjustment assembly <NUM> further comprises a second body <NUM> coupled to the first end <NUM> of the second shaft segment <NUM> and the first end <NUM> of the fourth shaft segment <NUM>. For example, each of the first body <NUM> and second body <NUM> can define first and second through-bores <NUM> on opposing sides. Each of the first body and the second body <NUM> can have opposing first and second sides 113a, 113b. A slit <NUM> can extend inwardly from a respective side (e.g., the first or second side 113a,b) of the respective body to a respective through-bore <NUM>. One or more fasteners <NUM> (e.g., screws) can extend through a clearance hole <NUM> on a first (e.g., upper) side of the slit <NUM> and engage a threaded hole <NUM> on an opposing second (e.g., lower) side of the slit <NUM>. In this way, tightening the fasteners <NUM> in the threaded hole can compress the body to close the slit, thereby decreasing the inner diameter of the through bore <NUM> and frictionally engaging the respective shaft segment.

Referring to <FIG> and <FIG>, the first body <NUM> and second body <NUM> are slidingly coupled so that movement between the first body <NUM> and the second body <NUM> in the transverse dimension <NUM> is restricted, but movement between the first body <NUM> and the second body <NUM> in the longitudinal dimension <NUM> is permitted. For example, the first body <NUM> can define a tongue <NUM> that can have a first longitudinally extending outer edge <NUM> and a second longitudinally extending outer edge <NUM> that is spaced from the first longitudinally extending outer edge <NUM> in the transverse dimension <NUM>. The second body <NUM> can define a groove <NUM> having a first longitudinally extending inner edge <NUM> and a second longitudinally extending inner edge <NUM>. The tongue <NUM> can be receivable into the groove with a small clearance in the transverse dimension between the groove <NUM> and the tongue <NUM> to inhibit transverse movement greater than the small clearance between the tongue and the groove. The first outer edge <NUM> of the tongue <NUM> can slidingly engage the first inner edge <NUM> of the groove <NUM>, and the second outer edge <NUM> of the tongue <NUM> can slidingly engage the second inner edge <NUM> of the groove. Thus, the first inner edge <NUM> of the groove <NUM> can restrict the movement of the tongue in a first direction relative to the transverse dimension, and the second inner edge <NUM> of the groove <NUM> can restrict the movement of the tongue in an opposing second direction relative to the transverse dimension, yet the first and second inner edges can guide the longitudinal movement of the tongue <NUM>, and thus, the first body <NUM>.

It is further contemplated that many alternative structures known to those skilled in the art can slidingly couple the first body to the second body, such as, for example, a dowel rod that is fixedly coupled to the first body and slidably receivable within a bore of the second body.

Referring to <FIG>, a coupling <NUM> between the first body <NUM> and the second body <NUM> can secure the position of the first body with respect to the second body. For example, in some aspects, the coupling <NUM> can comprise one or more fasteners <NUM> (e.g., screws or bolts) and, optionally, washers <NUM>. In some optional aspects, the tongue <NUM> of the first body <NUM> can define one or more slots <NUM> that are elongate in the longitudinal dimension <NUM>. The second body <NUM> can define respective holes <NUM> (optionally, threaded holes) that are aligned in the transverse dimension with respective slots <NUM> along a portion of a longitudinal travel of the first body <NUM> relative to the second body <NUM>. In some aspects, the fasteners <NUM> can threadedly engage the holes <NUM>. In further aspects (not shown), the fasteners <NUM> can be bolts that are bolted through the holes <NUM> into correspond nuts. When the fasteners <NUM> are loosened, the first body <NUM> can slide relative to the second body <NUM> along the longitudinal dimension, optionally limited by the length of the slots in the longitudinal dimension. When the fasteners <NUM> are tightened down, the first body <NUM> can be held in a fixed position with respect to the second body.

Referring to <FIG>, in some aspects, the shifter adjustment assembly <NUM> can comprise an adjustment device <NUM>. In some aspects, the first body can define a first through-hole <NUM> that extends through the first body in the longitudinal dimension. The first through-hole <NUM> can define one at least one right-handed thread. The second body <NUM> can comprise a second through-hole <NUM>. The second through-hole <NUM> can define at least one left-handed thread. An elongate rod <NUM> can have a length, a first end <NUM>, and an opposing second end <NUM>. The elongate rod <NUM> can define right-handed thread(s) <NUM> on the first end and extending along a portion of the length of the elongate rod <NUM>. The elongate rod <NUM> can define left-handed thread(s) <NUM> on the second end <NUM> and extending along a portion of the length of the elongate rod <NUM>. The elongate rod can be threadedly coupled to, and extend between, the first body <NUM> and the second body <NUM>. The right-handed thread(s) <NUM> of the elongate rod <NUM> can be threaded into the first through hole <NUM> of the first body, and the left-handed thread(s) <NUM> of the elongate rod can be threaded into the second hole <NUM> of the second body.

Rotation of the elongate rod in a first direction can cause the first body to move away from the second body in the longitudinal dimension, and rotation of the elongate rod in a second direction that is opposite the first direction can cause the first body to move toward the second body. Optionally, the elongate rod can define one or more gripping features, such as, for example, a hexagonal head <NUM>, to facilitate rotation of the elongate rod. For example, a nut can be threaded onto one of the ends of the elongate rod <NUM> and then attached thereto via weldment. Optionally, a jam nut <NUM> can be threaded onto one of the ends of the elongate rod. The jam nut can be tightened down against a face of the respective body of the first and second body that shares the same thread(s) as the jam nut <NUM> to inhibit further rotation of the elongate rod with respect to either of the first or second bodies.

It is contemplated that the spacing between the first body <NUM> and the second body <NUM> can, in some circumstances, be critical. Accordingly, the clearance between the threads of the first through-hole <NUM> and the right-handed thread(s) <NUM>, and the clearance between the thread(s) of the second through-hole <NUM> and the left-handed thread(s) <NUM> can be minimized so that no (or substantially no) longitudinal movement is allowed between the elongate rod and the first and second bodies. For example, the first through-hole <NUM> and the second through-hole <NUM> can define Unified Thread Class 3A threads, and the right- and left-handed thread(s) <NUM>, <NUM> can define Unified Thread Class 2B threads. In further aspects, all of the threads can be Class 3A. In this way, the exact spacing between the first and second bodies can be selected.

In some optional aspects, the first body <NUM> can comprise a first portion <NUM> and a second portion <NUM> that can be coupled to the first portion (e.g., via screws <NUM>). The first portion can define the through-hole <NUM>. The first portion <NUM> of the first body <NUM> can extend perpendicularly or generally perpendicularly from the second portion <NUM>, such as, for example, vertically upward from an upper face of the second portion <NUM>. Likewise, the second body <NUM> can comprise a first portion <NUM> and a second portion <NUM> that is coupled to the first portion (e.g., via screws <NUM>). The first portion <NUM> of the first body <NUM> can extend perpendicularly or generally perpendicularly from the second portion <NUM>, such as, for example, vertically upward from an upper face of the second portion <NUM>.

Referring to <FIG>, optionally, a linear position sensor <NUM> (e.g., a linear potentiometer) can be coupled between the first body <NUM> and the second body <NUM> so that their positions relative to each other in the longitudinal dimension can be known. For example, a first end of the linear position sensor <NUM> can couple to the first body <NUM>, and a second end of the linear position sensor can couple to the second body <NUM>. Optionally, the linear position sensor can be a capacitive scale having a resolution of, for example, <NUM> inches. The linear position sensor can be in communication with a computing device (e.g., desktop computer, laptop, smartphone, tablet, etc.), a small LED display, or other output device to convey its sensed position to an operator.

Although the specification and figures describe certain features on the first body <NUM> and complementary features on the second body <NUM>, it should be understood that the features can be reversed unless specifically stated in the claims. For example, it should be understood that, in some alternative aspects, the first body can define the groove <NUM>, and the second body can comprise the tongue <NUM>. In further alternative aspects, the first body <NUM> can define the left-handed thread(s) <NUM>, and the second body <NUM> can define the right-handed thread(s) <NUM>. Thus any feature stated in the claims should not be limited to its association with the first body or the second body unless the claims specifically state so.

Conventionally, both of the original shafts of the shifter of the tufting machine extend along the longitudinal length of the tufting machine. Thus, to attach the shifter adjustment assembly <NUM>, it is contemplated that the shafts can be cut to provide the first, second, third, and fourth shafts segments. It is further contemplated that the original shafts can be removed and replaced with shorter segments (i.e., the first, second, third, and fourth shaft segments) that, when coupled to the shifter adjustment assembly <NUM>, provide the same length, or substantially the same length, as the original shafts of the shifter assembly. The first and third shaft segments can be inserted into the respective through-bores <NUM> of the first body, and the fasteners <NUM> can be tightened down. Likewise, the second and fourth shaft segments can be inserted into the respective through-bores <NUM> of the second body, and the fasteners <NUM> can be tightened down.

To adjust the needle tension with the shifter adjustment assembly, an operator can first verify that the needles are in an up position and not crossing over any hooks of the tufting machine. It can be desirable for the bracket not to be under tension or compression during adjustment. The tufting machine can be locked out for safety.

The jam nut <NUM> can be loosened from against the first or second body, and the slide fasteners <NUM> can be loosened to enable movement between the first and second body. Using a wrench, an operator can rotate the tension adjustment nut to adjust the position of the first body relative to the second body in the longitudinal dimension. For example, to increase tension on the needles, the first and second bodies can be moved toward each other. To decrease tension, the first and second bodies can be moved away from each other. Adjustment between the first and second bodies can shift the needle bar relative to the hook bar, thereby adjusting the positions of the needles with relative to their respective hooks. Optionally, the linear position sensor can output a readout, and the operator can select the relative position between the first and second body based on a desired readout from the linear position sensor.

Once the select position is achieved, the jam nut can be tightened against a respective body. The fasteners <NUM> can be tightened down (e.g., to about <NUM> ft-lbs) to hold the first and second bodies in their relative positions. The tufting machine can be locked out to put the machine back in production.

Claim 1:
An apparatus comprising:
a needle bar shifter (<NUM>) of a tufting apparatus, the needle bar shifter having first (<NUM>), second (<NUM>), third (<NUM>), and fourth (<NUM>) shaft segments, each of the first (<NUM>), second (<NUM>), third (<NUM>), and fourth (<NUM>) shaft segments having respective first (<NUM>,<NUM>,<NUM>,<NUM>) and second (<NUM>,<NUM>,<NUM>,<NUM>) ends, the first (<NUM>) and second (<NUM>) shaft segments being aligned and spaced apart in a longitudinal dimension (<NUM>), the third (<NUM>) and fourth (<NUM>) shaft segments being aligned and spaced apart in the longitudinal dimension (<NUM>), the first ends (<NUM>,<NUM>) of the first (<NUM>) and second (<NUM>) shaft segments facing one another, the first ends (<NUM>,<NUM>) of the third (<NUM>) and fourth (<NUM>) shaft segments facing one another, the third (<NUM>) and fourth (<NUM>) shaft segments being offset from the first (<NUM>) and second (<NUM>) shaft segments in a transverse dimension (<NUM>) that is perpendicular to the longitudinal dimension; and
a shifter adjustment assembly (<NUM>) configured to couple to the needle bar shifter (<NUM>), the shifter adjustment assembly (<NUM>) configured to cause adjustment of a position of a needle bar of the tufting apparatus relative to a hook bar of the tufting apparatus in order to maintain a select positioning of needles of the needle bar relative to respective hooks of the hook bar, the shifter adjustment assembly (<NUM>) comprising:
a first body (<NUM>) that is configured to couple to the first ends (<NUM>,<NUM>) of the first (<NUM>) and third (<NUM>) shaft segments;
a second body (<NUM>) that is configured to couple to the first ends (<NUM>,<NUM>) of the second (<NUM>) and fourth (<NUM>) shaft segments; and
a coupling between the first body (<NUM>) and the second body (<NUM>), wherein the coupling is configured to releasably secure an axial position of the first body (<NUM>) with respect to the second body (<NUM>) along the longitudinal dimension (<NUM>),
wherein the first body (<NUM>) and second body (<NUM>) define respective complementary surfaces that are configured for sliding engagement so that:
movement between the first body (<NUM>) and the second body (<NUM>) in the transverse dimension (<NUM>) is restricted; and
movement between the first body (<NUM>) and the second body (<NUM>) in the longitudinal dimension (<NUM>) is permitted.