# US 8,770,122 B2 · Methods and devices for controlling a tufting machine for forming tufted carpet > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,770,122 B2 - Document ID: US8770122B2 - Status: Granted - Kind: B2 - Application number: 13/873,810 - Filed: 2013-04-30 - Published: 2013-12-26 - Granted: 2014-07-08 - Earliest claimed: 2010-10-28 - Assignees: Columbia Insurance Company - Applicants: Shaw Industries Group, Inc. - Inventors: Neil Vaughan; Mark Honeycutt - Web page: https://patentgrep.com/patent/US8770122B2 ## CPC - D05C 5/04: by input of recorded information, e.g. on perforated tape - D05B 19/08: Arrangements for inputting stitch or pattern data to memory {; Editing stitch or pattern data} - D05C 15/18: Thread feeding or tensioning arrangements - D05C 15/26: with provision for producing patterns - D05C: EMBROIDERING; TUFTING (making non-woven fabrics D04H; sewing D05B) - D05B: SEWING (appliances for the tailoring trade A41H; sewing tables A47B29/00; sewing in bookbinding B42B2/00; sewing machines modified for knitting D04B39/08) ## Abstract The invention relates to a control system for a tufting machine configured for forming tufted carpet. The tufting machine can have a system controller in communication with the tufting machine and with a plurality of yarn feed controllers for controlling operation of yarn feed motors that are configured to supply yarn from a source of yarn to the tufting machine. The system controller is programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted such that, although at least two of the predetermined yarn feed profiles can be different, substantially the same feed length of yarn is used from each of the plurality of yarns. ## Claims ### Claim 1 A control system for a tufting machine for forming patterned tufted articles of the type having a plurality of needles carrying a plurality of yarns into a backing material that passes through the tufting machine at a desired rate, the control system comprising: a source of yarns having a plurality of yarns; a plurality of yarn feed controllers, each yarn feed controller being configured to control the amount of yarn being supplied to a respective needle; and a system controller in communication with the tufting machine for controlling operation of the tufting machine and the yarn feed controllers; wherein the system controller is programmable to: enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted; and control the operation of the respective yarn feed controllers to feed yarns to the plurality of needles for each selected stitch to be tufted according to the predetermined yarn feed profile, wherein at least two predetermined yarn feed profiles of the plurality of predetermined yarn feed profiles are different, wherein, for each repeat of the programmed pattern, each yarn of the plurality of yarns has a respective feed length of yarn that is used, and wherein the feed length of each yarn of the plurality of yarns is substantially equal to the feed length of every other yarn of the plurality of yarns. ### Claim 2 (depends on 1) The control system of claim 1, wherein each predetermined yarn feed profile is programmed by the steps of: determining a base yarn feed value for each stitch of the yarn for each pattern repeat of the programmed pattern; and varying the yarn feed profile from the base yarn feed value for at least one stitch of the yarn for each pattern repeat. ### Claim 3 (depends on 2) The control system of claim 2, wherein the steps of claim 2 are repeated for each predetermined yarn feed profile until the feed length of yarn per pattern repeat is substantially the same for the plurality of predetermined yarn feed profiles. ### Claim 4 (depends on 2) The control system of claim 2, wherein the amount of variation from the base yarn feed value is less than 0.3 inches. ### Claim 5 (depends on 2) The control system of claim 2, wherein the amount of variation from the base yarn feed value is less than 0.2 inches. ### Claim 6 (depends on 2) The control system of claim 2, wherein the amount of variation from the base yarn feed value is less than 0.1 inches. ### Claim 7 (depends on 2) The control system of claim 2, wherein the amount of variation from the base yarn feed value is less than 0.05 inches. ### Claim 8 (depends on 2) The control system of claim 2, wherein the amount of variation can be a positive or negative variation in yarn feed length from the base yarn feed value. ### Claim 9 (depends on 1) The control system of claim 1, further comprising a series of loopers adapted to engage the needles for forming loop pile tufts. ### Claim 10 (depends on 1) The control system of claim 1, further comprising a drive roll in communication with the source of yarns, the drive roll configured to draw the plurality of yarns from the source of yarns at a substantially constant yarn feed rate. ### Claim 11 (depends on 10) The control system of claim 10, wherein the yarn feed rate can selectively be less than, equal to, or greater than the average feed control rate of the plurality of predetermined yarn feed profiles. ### Claim 12 (depends on 11) The control system of claim 11, wherein the drive roll is positioned between the source of yarns and the plurality of yarn feed motors. ### Claim 13 (depends on 1) The control system of claim 1, wherein the source of yarns comprises at least one beam. ### Claim 14 (depends on 1) The control system of claim 1, wherein the source of yarns comprises at least one creel. ### Claim 15 (depends on 1) The control system of claim 1, further comprising a yarn accumulator system that is in communication with the source of yarns, wherein the yarn accumulator system is disposed between the source of yarns and the plurality of yarn feed motors and comprises a plurality of weight elements, wherein each weight element is configured to allow for the free passage of one yarn therethrough the weight element. ### Claim 16 (depends on 1) The control system of claim 1, further comprising a plurality of yarn feed motors, each yarn feed motor in communication with one yarn from the source of yarns and one needle of the plurality of needles, wherein each yarn feed controller is coupled to a respective yarn feed motor for controlling the amount of yarn being supplied by the respective yarn feed motor, and wherein the system controller is in communication with the yarn feed controllers for controlling operation of said yarn feed motors. ### Claim 17 A control system for a tufting machine for forming patterned tufted articles of the type having a plurality of needles carrying a plurality of yarns into a backing material that passes through the tufting machine at a desired rate, the control system comprising: a source of yarns having a plurality of yarns; a plurality of yarn feed controllers, each yarn feed controller being configured to control the amount of yarn being supplied to a respective needle; and a system controller in communication with the tufting machine for controlling operation of the tufting machine and the yarn feed controllers; wherein the system controller is programmable to: enable input of a plurality of N predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted; index each of the plurality of N predetermined yarn feed profiles to operatively control a different yarn feed controller after every X pattern repeat; and control the operation of the respective yarn feed controllers to feed yarns to the plurality of needles for each selected stitch to be tufted according to the selected predetermined yarn feed profile, wherein, after (N·X) repeats of the pattern repeat, each yarn of the plurality of yarns has a respective feed length of yarn that is used, and wherein the feed length of each yarn of the plurality of yarns is substantially equal to the feed length of every other yarn of the plurality of yarns. ### Claim 18 (depends on 17) The control system of claim 17, further comprising a plurality of yarn feed motors, each yarn feed motor in communication with one yarn from the source of yarns and one needle of the plurality of needles, wherein each yarn feed controller is coupled to a respective yarn feed motor for controlling the amount of yarn being supplied by the respective yarn feed motor, and wherein the system controller is in communication with the yarn feed controllers for controlling operation of said yarn feed motors. ### Claim 19 (depends on 17) The control system of claim 17, wherein at least two predetermined yarn feed profiles of the plurality of N predetermined yarn feed profiles are different. ### Claim 20 (depends on 17) The control system of claim 17, wherein X=1, and wherein the pattern repeat is repeated N times for N predetermined yarn feed profiles. ### Claim 21 (depends on 17) The control system of claim 17, wherein each yarn feed controller is controlled by a different one of the N predetermined yarn feed profiles for each of the respective pattern repeats. ### Claim 22 (depends on 21) The control system of claim 21, wherein, over the course of the N repeats of the pattern repeat, each yarn feed controller uses each one of the N predetermined yarn feed profiles. ### Claim 23 (depends on 17) The control system of claim 17, wherein the pattern repeat is repeated N·X times for N predetermined yarn feed profiles. ### Claim 24 (depends on 17) The control system of claim 17, wherein each yarn feed controller is controlled by a different one of the N predetermined yarn feed profiles after every X pattern repeats of the pattern repeat. ### Claim 25 (depends on 24) The control system of claim 24, wherein, over the course of the N·X repeats of the pattern repeat, each yarn feed controller uses each one of the N predetermined yarn feed profiles. ### Claim 26 (depends on 17) The control system of claim 17, further comprising a series of loopers adapted to engage the needles for forming loop pile tufts. ### Claim 27 (depends on 17) The control system of claim 17, further comprising a drive roll in communication with the source of yarns, the drive roll configured to draw the plurality of yarns from the source of yarns at a substantially constant yarn feed rate. ### Claim 28 (depends on 27) The control system of claim 27, wherein the yarn feed rate can selectively be less than, equal to, or greater than the average feed control rate of the plurality of predetermined yarn feed profiles. ### Claim 29 (depends on 27) The control system of claim 27, wherein the drive roll is positioned between the source of yarns and the plurality of yarn feed motors. ### Claim 30 (depends on 17) The control system of claim 17, wherein the source of yarns comprises at least one beam. ### Claim 31 (depends on 17) The control system of claim 17, wherein the source of yarns comprises a plurality of creels. ### Claim 32 (depends on 17) The control system of claim 17, further comprising a yarn accumulator system that is in communication with the source of yarns, wherein the yarn accumulator system is disposed between the source of yarns and the plurality of yarn feed motors and comprises a plurality of weight elements, wherein each weight element is configured to allow for the free passage of one yarn therethrough the weight element.