Pattern method for multicolor designs

A machine for producing a pattern on a backing web comprising:

• (1) a plurality of thread placement tools, each capable of placing a selected thread end from a plurality of thread end supply sources into the backing web;
• (2) a control means responsive to an instruction set for carrying out sequential operations to produce a desired pattern;
• (3) means for accurately positioning the thread placement tools relative to the backing;
• and (4) means for changing the relative positions of the thread placement tools in relationship to the backing web to place threads at multiple relative locations on the backing web;
• (5) means for supplying an instruction set to produce a multicolor pattern requiring at least three different colors, to be produced;
• (6) a threading sequence which includes the plurality of thread end supply sources for a first thread placement tool including at least two thread end colors and the plurality of thread end supply sources for a second thread placement tool including at least one thread end color different than the colors supplied to the first thread placement tool;
• (7) the thread placement tool spacing being established by the instruction set, and means for implementing transverse position shifts to produce the desired pattern by placing the selected thread color ends to be supplied to each thread placement tool such that each thread placement tool is supplied fewer than the total number of colors to be used in the pattern and the pattern is completed by shifting thread placement tool locations to supply additional colors to complete the selected pattern when a selected color is not available at a particular location in a first thread tool placement position and the unavailable desired thread color is available at a second thread placement tool position which is shifted to supply the desired thread at the particular location and the second thread placement tool selectively supplies the desired color.

An instruction set to be supplied to a tufting machine control system in a tufting machine for placing a plurality of colors of threads into a backing web to form a desired pattern having (a) a plurality of thread placement tools for placing a selected thread color from a plurality of thread color supply sources into the backing web;

• (b) a control means responsive to an instruction set for carrying out sequential operations to produce a desired pattern;
• (c) means for accurately relatively positioning the thread placement tools relative to the backing web in response to commands from said control means and (d) means for selective placement of said thread colors into said backing web in response to commands from said control means, that comprises codes for establishing a desired gauge;
• computing a number of shifts required to bring each pattern color to a desired location;
• codes for initializing the tufting machine;
• codes for resetting servo motors, relays and position encoders;
• codes for loading data to calculate a row pattern into a system;
• codes to order thread selections for all locations having a color selection and codes to select the thread colors matching the pattern and codes to place only selected threads when the machine is operated for one complete cycle;
• codes for advancing the machine one increment in a first direction and placing selected colors to the pattern;
• codes for supplying instructions for positioning a second thread placement tool at a position wherein a thread has already been placed on a previous cycle at some locations and supplying a color not available to the first thread placement tool at a location by a thread placed by the second thread placement tool.