Patent ID: 12254248

DETAILED DESCRIPTION OF THE INVENTION

Turning then toFIG.1A, a general depiction of the tufting machine10with take up rolls19for the tufted fabric and two-story creel14to hold cones of yarn is illustrated. It will be understood that the invention can be practiced on a wide variety of tufting machines, not simply the broadloom machine10represented inFIG.1A. For instance, ColorTec ICN machines and Colortron/iTron hollow needle tufting machines also have the capability to place yarns in individual pixel locations according to a pattern and thus are suitably adapted for use with the invention. In addition, the yarn creel set up is exemplary and yarns could be supplied to the tufting machine from a single-story creel or from beams that are wound for use in supplying yarns. In the typical case there will be hundreds of separate yarns fed from the creel, most frequently between about 600 and 1800 yarns and most commonly between about 1100 and 1700 yarns, although some machine and pattern combinations, such as relatively narrow hollow needle machines tufting patterns with a limited number of colors, could operate with a much smaller number and perhaps only about 200 yarns.

The tufting machine10disclosed inFIG.1Bincludes a rotary needle shaft or main drive shaft11driven by stitch drive mechanism12from a drive motor or other conventional means. Rotary eccentric mechanism15mounted upon rotary needle shaft11is adapted to reciprocally move the vertical push rod16for vertically and reciprocally moving the needle bar slide holder17and needle bar18. The needle bar18supports a plurality of uniformly spaced tufting needles20in a longitudinal row, or staggered longitudinal rows, extending transversally of the feeding direction of the backing fabric or material22. The backing fabric22is moved longitudinally in direction21through the tufting machine10by the backing fabric feed mechanism23and across a backing fabric support with needle plate and needle plate fingers.

Yarns25are fed from the creel14to the pattern control yarn feed26to the respective needles20. As each needle20carries a yarn25through the backing fabric22, a hook is reciprocally driven by the looper drive29to cross each corresponding needle20and hold the corresponding yarn end25to form loops. Cut pile tufts are formed by cutting the loops with knives.

The needle bar shifting apparatus32is designed to laterally or transversely shift the needle bar18relative to the needle bar holder17a predetermined transverse distance equal to the needle gauge or multiple of the needle gauge, and in either transverse direction from its normal central position, relative to the backing fabric22, and for each stroke of the needles20. It will be understood that the lateral displacement of needles relative to the backing fabric22may also be achieved by the use of a backing fabric shifter, or by the combination of a backing fabric shifter with needle bar positioners for one or more needle bars. When using a backing fabric shifter, the shifting is not constrained to shifting in needle gauge increments.

In order to generate input encoder signals for the needle bar shifting apparatus32corresponding to each stroke of the needles20, an encoder34may be mounted upon a stub shaft35, or in another suitable location, and communicate positional information from which the tufting machine controller can determine the position of the needles in the tufting cycle. Alternatively, drive motors may use commutators to indicate the motor positions from which the positions of the associated driven components may be extrapolated by the controller. Operator controls24also interface with the tufting machine controller to provide appropriate instructions and pattern information.

On a broadloom tufting machine, these components can be operated in a fashion to provide pixel-addressed yarn placement as described in various prior patents such as U.S. Pat. Nos. 6,439,141; 7,426,895; and 8,359,989 and continuations thereof. Pixel controlled yarn placement in connection with ICN machines is described in U.S. Pat. Nos. 5,382,723 and 5,143,003; while pixel controlled placement of yarns utilizing hollow needle tufting machines is described in U.S. Pat. Nos. 4,549,496 and 5,738,030. Similar yarn placement may be achieved utilizing backing shifting as is disclosed in PCT/US17/54683 filed Sep. 30, 2017. All these patents and applications are incorporated herein by reference.

Turning then to the process of designing and manufacturing tufted fabric as reflected inFIG.2, the first step28is the creation of a graphic design to be tufted. The design can be created by an artist or adapted from a photograph or preexisting image. In either case, the image should be created or processed to limit the color palette to a manageable number of yarn colors, preferably between two and twelve, and most commonly three to six colors.

The next step30is to load the image into a tufting machine having a controller running a control software system such as the iTuft or Tuftworks system sold by Tuftco Corp. and to process the pattern graphics to create machine instructions. When using the iTuft system, there are two principal steps prior to creating machine instructions. One step33(inFIG.2), carried out as reflected inFIG.4, is to assign a shift pattern or step pattern41to the needle bar37(shown inFIG.2) and a stitch rate to the pattern. In the case of a two-color pattern, it is quite practical to use a very simple stepping pattern of over and back so that the needle bar merely moves from dead center42to a position offset by one gauge unit43and then repeats. In this case, the repeat length44is only two steps. In the event that a four-color pattern were being tufted, typical stepping pattern would involve two steps to the right, four steps to the left, and two steps to the right. Variations of the shift profile for other numbers of colors utilized on a broadloom tufting machine are well known and easily computed. It can also be seen that the stitch rate45may be specified which can affect the density of yarn bights and the weight of the resulting tufted fabrics.

In addition to entering the stepping pattern inFIG.4, in the iTuft system the yarns and yarn feed increments are assigned to the colors in the graphic pattern37(inFIG.2). In the prior art, at this point the pixel-mapped design can be translated into tufting machine instructions39and the tufting machine10operated with the tufting machine instructions39to produce a tufted fabric of the design40.

Using the yarn planning techniques of the invention requires some modifications to the prior art process. The pixel-mapped design is created as before28but then the design file is loaded into a tufting machine, or possibly a desk top simulator30where the physical characteristics of the tufting machine have been stored, or may be specified. The shift pattern and stitch rate may be set33and yarn feed increments assigned to colors in the design37. After the pattern has been associated with yarns, yarn feed increments, and a stepping pattern for a particular tufting machine, it is then possible to compute the yarn consumption for each needle71as shown inFIG.3. In fact the tufting machine instructions39may be utilized to provide calculations involving combining the lengths of yarn that are utilized in shifting yarns from one position to another in addition to the lengths of yarn that are actually fed and tufted into the backing fabric. This calculation varies depending upon the type of tufting machine, the needle bar gauge and configuration (single, staggered, graphics), lateral shifting mechanism(s) and stitch rates. The earlier versions of yarn planning, even by the applicant lacked the ability to utilize the tufting machine instructions39to calculate yarn length.

Calculating yarn consumption involves the specification of the characteristics of the tufting machine51. This tufting machine configuration may be uniform for some types of machines or may require specific machine information or preloaded configuration to be input. If the yarn planning software is being run on a particular tufting machine rather than at a remote workstation, the characteristics of that machine may be entered by default to provide the tufting machine instructions39. In addition, the production target52will be specified and the stitch rate53, thread-up54, and yarn types55based on the tufting machine instructions39. The yarn type will preferably include denier information so that yarn lengths can be converted to weights. Based upon the pattern information, machine information, and this production and yarn information, the yarn consumption for each needle can be computed61and graphically displayed60using the tufting machine instructions39. Then yarn consumption by thread for a particular amount of carpet can be sent to a winder102,104to wind yarn cones106,108for specific locations in a creel. A set off which would be zero or more to allow for threading up as a creel/tufting machine may be provided with the yarns.

Yarn consumption may be aggregated by yarn group62and the relative weight and percentage of each yarn group can be visualized, and then compared to existing inventory and orders if necessary. By utilizing the tufting machine instructions39extending precise yarn lengths may be calculated in an effort to minimize waste. A variety of operations may be executed upon the yarn consumption data63. For instance, after data is changed, yarn consumption by needle can be calculated64. A report of this data may be printed, or that data can be saved, a set of saved date can be loaded, or the data can be cleared for the entry of new yarn plan data.

Selecting the Order Calculator feature65generates the Yarn Plan Weight Analysis view80ofFIG.6. This view shows the needle or end count for each yarn group A, B, C, and D in the illustrated example. It is possible that patterns may have more or less yarn groups. The Calculate Weight functionality81generates the Cone Weight Analysis view90. This view shows the various cone weights of yarn for the selected yarn group required for the production target—the largest, smallest, median, and average cone weights. The operator can then select the number of yarn cones that may be specially rewound to add yarn (or alternatively replaced during production) with a view to the total weight of wasted yarn. Weight is provided because the yarn denier is known, but in the absence of that information, the total length of yarn that would be “waste” for salvage purposes would be shown. The yarn cone weight analysis90provides an analysis of the number of yarn cone rewinds (replacements) in comparison to the amount of waste yarn that must be salvaged after the production run.

Based upon this information, the operator of the yarn planner software can select the most desirable yarn cone weight for each position in a creel to result in minimization of the cost of salvaged yarn and labor attendant with rewinds during the production run. The analysis also generates a ratio of the yarn cone weight selected to the average weight of all cones in the group. In the illustrated example, the highlighted weight for the yarn cones, requiring 5 rewinds, is 3.994 pounds. When this weight is divided by the average yarn weight required (2.777 pounds), it provides a factor or ratio of 1.438. This ratio may be used in future production planning for different target production lengths, to provide similarly useful results without repeating all of the calculations and decision process.

It is anticipated that additional visual presentations of the yarn consumption data may be created. For instance, there may be some clusters of yarn cone weights that are particularly common in a pattern and that would justify dividing a single yarn group, such as the A yarns, in to two or more subgroups. While this would complicate the loading of the creel, it could nonetheless provide valuable savings in waste yarn and rewinds.

Accordingly, as reflected inFIG.3, an optimized yarn planning process may involve creating a pattern28, loading the pattern into a tufting machine or desktop simulator30, designating the machine configuration31, designating the shift pattern for the machine configuration (if not already included in the pattern file)32, setting a stitch rate reflective of the number of yarn bights intended to be visible over a specified longitudinal distance of backing33, designating a production objective34, assigning yarns and yarn information to pattern colors (and specifying yarn feed increments if not already included in the pattern file)37, computing yarn consumption by needle71based on tufting machine instructions39, optionally displaying visual representations of yarn consumption by needle or by yarn type72, grouping yarn consumption by needle according to yarn type/color for analysis73, selecting individual yarn types/colors to display analysis of yarn consumption across needles carrying the selected yarn74, displaying an analysis of yarn waste and labor/rewinds attendant to different yarn cone weights/winding lengths75, selecting a desired yarn cone weight/winding length for each individual yarn type/color76.

The applicant has continued to develop yarn planning sophistication so as to be able to utilize the exact same pet file provided to a tufting machine to run the carpet and simulation so as to know relatively exactly how much yarn will be used during the tufting process. The accuracy of the calculations have improved over time. Utilizing the same pct files that run the tufting machines the linear lengths of yarn provided on each yarn cone can be calculated which could also be converted to weight for ease of winding cones. This information can be transferred to a winder or warper preferably in an automated fashion so as to wind unique cones for a particular run of the tufting machine with possibly a small amount of extra yarn included for the set up so as to precisely provide yarn cones for a desired amount of a carpet run of a set pattern using the tufting machine instructions39rather than stitching simulations.

FIG.7shows the sending of the information from the yarn planner or tufting machine to winders or warpers or other ways of making beams or cones so as to provide the specific amount of yarn for each specific location to be tufted by the tufting machine.

FIG.8shows an alternative ending toFIG.3beginning at step71with the information from step71and proceeding to step171and175where either yarn as ordered for a specific run of carpet or a specific job or yarn data is sent to the winder at step171so as to wind the yarn cones in step172to then locate the yarn cones and creel at step173and tuft carpet at step174. Utilizing this technology extremely little waste will be experienced since the cones can be wound such as cones106,108can be wound with almost the exact amount needed for a particular run plus potentially a little extra for the setup. This technology continues to progress as it is possible that the winders102,104may have the yarn cones106,108removed by robots and installed on the creel so as to remove many of the steps currently performed by people. Also, at step175information received relative to the amount of yarn needed may be utilized to order yarn at step175to assist in planning purposes as jobs are being lined up for a particular tufting machine.

Additionally, as the software and sophistication continues to evolve, simpler systems may be provided for simpler tufting machines which provide the pattern on the pct files. More complex analysis of each particular length of yarn may be performed for other tufting machines.

The yarn planner implemented on the machine100may utilize the same files that operate the tufting machines to calculate the displacement yarn which then can be converted to weight and/or length by the winders102,104. Such factors as double density yarn and other variables may be accounted for by the software in performing the calculations of how much yarn is needed. Calculations may employ approximations which has been found satisfactory for calculating actual yarn utilized by some machines. Additionally, some machines shift yarn either by shifting needles or shifting backing and this shift can be accounted for by the machine100utilizing the yarn planning software of this invention.

Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.