Tufting machine yarn feed system

A system, comprising:

• at least one yarn feed unit having a plurality of yarn feed devices received therein, the yarn feed devices configured for feeding yarns to a plurality of needles of a tufting machine;
• wherein the yarn feed devices each comprise:
• at least one motor package comprising two or more motors and a shared motor controller coupled directly to each of the motors so as to be substantially aligned with the motors as part of a substantially integrated component or unit that is configured to be mounted within and removeable from the yarn feed unit as a substantially unitary structure;
• and
• at least one yarn feed roll assembly comprising a plurality of yarn feed rolls;
• wherein the yarn feed rolls are arranged in sets of at least two yarn feed rolls, and each comprise a body having a forward portion about which one or more yarns are passed and a rear portion;
• wherein the shared motor controller of the at least one motor package is configured to receive instructions from a control system of the tufting machine to independently control operation of each motor of the motor package to drive rotation of the yarn feed rolls so as to feed selected amounts of yarns to the needles;
• wherein each motor drives at least one yarn feed roll of a set of yarn feed rolls of a yarn feed roll assembly associated therewith;
• wherein rotation of the at least one yarn feed roll drives rotation of other yarn feed rolls of the set of yarn feed rolls such that the one more yarns extended about the forward portions of each of the yarn feed rolls are drawn thereabout and fed to the needles of the tufting machine.

A tufting machine, comprising:

• backing feed rolls configured to feed a backing material;
• at least one needle bar having a plurality of needles positioned therealong;
• a yarn feed system including:
• a plurality of yarn feed devices, each of the yarn feed devices configured to feed at least one yarn to a needle of the plurality of needles;
• wherein each yarn feed device comprises:
• at least one motor package comprising:
• at least two motors coupled together in a side-by-side or stacked configuration, and
• a shared motor controller in communication with each motor;
• wherein the shared motor controller is directly attached to each motor so as to define a substantially integrated component that is configured to be removeable from the yarn feed system as a substantially unitary structure;
• and
• wherein the shared motor controller of the at least one motor package is configured to independently control each motor;
• at least one yarn feed roll assembly positioned in front of the at least one motor package and including at least two sets of yarn feed rolls about which a selected number of yarns are fed, each set of yarn feed rolls comprising a plurality of yarn feed rolls including at least one driven yarn feed roll operatively connected to one of the motors of the at least one motor package so as to be rotated thereby, and at least one additional yarn feed roll driven by the rotation of the at least one driven yarn feed roll;
• and
• a system controller for the tufting machine in communication with the shared motor controller of each motor package and configured to provide instructions to the shared motor controller to selectively operate each motor in communication therewith to control of rotation of the yarn feed rolls of the set of yarn feed rolls associated with each motor for feeding varying amounts of yarns for form high or low pile tufts or to pull back certain yarns as needed to form a tufted pattern.

A yarn feed system for a tufting machine, comprising:

• at least one yarn feed unit having a housing or frame;
• and
• a series of yarn feed devices received within the housing or frame and each comprising:
• a motor package received within the housing or frame and comprising two or more motors and a shared motor controller substantially aligned with the two or more motors and connected to a rear end of each of the two or more motors to form a substantially unitary component;
• and
• one or more yarn feed roll assemblies positioned in front of the integrated motor package and comprising at least one set of yarn feed rolls associated with each motor, each of the yarn feed rolls comprising a body about which one or more yarns are passed;
• wherein each of the motors drives at least one yarn feed roll of the set of yarn feed rolls associated therewith, in response to which at least one other yarn feed roll of the set of yarn feed rolls is correspondingly driven such that the one more yarns extended about the yarn feed rolls are fed to the needles of the tufting machine;
• and
• wherein each shared motor controller of each motor package is configured to receive instructions from a system controller for the tufting machine and in response, independently operate each motor of its motor package to drive the sets of yarn feed rolls associated therewith for selectively feeding the one or more yarns to each of a plurality of needles.