Technical Field

[0001] The present disclosure relates to tufting, and more specifically to tufting needles and tufting guns including constituent components.

Background

[0002] The simplest tool for hand tufting is a narrow, thin walled, hollow cylindrical tube acting as a needle. One end of the needle is bevelled to form a needle point and yarn is fed through the other open end. This needle penetrates a backing material to create a hole. The inner edge of the needle, opposite the point, pulls yam through the hole as the needle is inserted. When the needle is withdrawn a loop tuft is formed. The needle is then rotated so the needle point is facing in the direction of to the next insertion point. It is moved to that point and inserted to create another loop tuft. The height of the loop tuft is determined by how far the needle is pushed through the backing. The weight of this tufting tool is around 50 grams.

[0003] Around 1957 Tai Ping Carpets introduced an electro-mechanical hand tufting gun which was a needle and blade tufting mechanism powered by an electric hand drill. Crank/connecting rod/slider mechanisms, powered by the drill motor, were used to separately reciprocate the needle and the blade. The gun contained a yarn brake which, when combined with a scissor mechanism attached to the blade, enabled tufting of cut pile. An improvement of the tufting gun used a blade containing a sharp V to replace the scissors. Another later improvement was the addition of a hand lever driven rotating presser foot. Yet another improvement was powering a feed roller by the motor to feed yarn into the tufting gun. Electro -mechanical hand tufting guns increase hand tufting productivity by a factor 4 to 5. A disadvantage is the weight of the tufting gun, between 2 to 3 kilograms, which makes their use physically demanding. Another disadvantage is that changing pile type and pile heights is time consuming and quite complex mechanical adjustments. [0004] Electro-pneumatic hand tufting guns were mentioned in Patent Application DE2815801 A1 (Hartleb), published 18 Oct 1979, US patent 4,388,881 A (Price), published 21 Jun 1983 and German patent DE 2621360 C2 (Verzicht), published 6 December 1984. Hofmann Handtuft-Technik GmbH in Germany was producing electro-pneumatic tufting guns prior to 1983. Pneumatic tufting guns, powered by an electric motor, use a jet of compressed air, instead of a yarn blade, to insert yarn, through the needle, into the backing. The needle is reciprocated by a crank/connecting rod/slider mechanism. Cut pile is produced by a rotating a blade, powered by the electric motor, laterally across the face of the tufting needle to cut the yarn. Electro pneumatic hand tufting guns increase hand tufting productivity by a factor of 6 to 7 times. A disadvantage is the weight of the tufting gun, between 4 to 6 kilograms, which makes their use even more physically demanding than electro -mechanical tufting guns. Manufacturers recommend use of a counter balance to support the gun during tufting. Another disadvantage is that changing pile type and pile heights requires spare parts and is time consuming and mechanically quite complex.

[0005] Whereas tufting guns mechanised hand tufting, automation of hand tufting was disclosed by US patent 5,503,092 (Aubourg, Pongrass, Wilson) in 1996. The method and system of automated tufting has since become known as “robot tufting”. A tufting robot consists of a computer controlled tufting gun mounted on a computer controlled co-ordinate movement system operating under the control of a CAM tufting system.

The computer controlled tufting gun mounted on a carriage of the movement system has become known as a “tufting head”. Further improvements to tufting guns employed as tufting heads were in disclosed in a number of subsequent patents. US patent 5,829,372 (Aubourg, Pongrass, Wilson) disclosed a rotating tufting head where the reciprocating mechanism remained stationary. US patent 7,218,987 B2 (Mile, Wilson) disclosed a method of controlling a tufting head to selectively tuft cut pile or loop pile, known “cut/loop tufting”. US patent 8,225,727 B2 (Wilson, Mile, Van Woerkom) discloses a method of controlling a tufting head to selectively vary the tuft pile height, known as “3D tufting”. The combination of this feature with US patent 7,218,987 B2 is known as “3D cut/loop tufting”. Tufting robots have increased the overall productivity of hand tufting by a factor greater than 40 times. Summary

[0006] There is provided a multi-needle tufting gun for use in robotic tufting, the tufting gun comprising: a support; a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support, and wherein each module comprises a tufting needle.

[0007] The tufting gun may further comprise a spacing actuator mounted to the support to move the at least one tufting module relative to another tufting module.

[0008] The spacing actuator may comprise a motor and a lead screw configured to engage a corresponding drive nut on the at least one module.

[0009] The lead screw may comprise a first portion threaded in a first direction on a first side of neutral point and a second portion threaded in a second direction on a second side of the neutral point.

[0010] A pitch of the first threaded portion may be greater at a greater distance from the neutral point.

[0011] A pitch of the second threaded portion may be greater at a greater distance from the neutral point.

[0012] A pitch of the lead screw may vary along the length of the lead screw.

[0013] The tufting gun may further comprise a reciprocation actuator mounted to the support to reciprocate the tufting needle of each module. [0014] The reciprocation actuator may comprise a linear actuator and a needle plate.

[0015] The reciprocation actuator may comprise a motor and a crank shaft.

[0016] The tufting gun may further comprise a rotation actuator mounted to the support to rotate the tufting needle of each module.

[0017] The rotation actuator may comprise a motor and one or more worm drives to operatively rotate each needle.

[0018] The rotation actuator may comprise a linear actuator and linkages to operatively rotate each needle.

[0019] The support may further comprise a pivot to allow rotation of the tufting gun relative to a backing material.

[0020] Each module may comprise a filament feed system and the tufting gun further comprises a rotatable feed shaft having formations for engaging corresponding formations in each filament feed system.

[0021] The tufting gun may further comprise a controller and wherein each tufting module may further comprise: a reciprocation actuator controllable by the controller to selectively reciprocate the tufting needle; and a filament feed system controllable by the controller to selectively feed a filament to the tufting needle.

[0022] The tufting gun may further comprise an electric motor to translate the tufting gun through space in a tufting direction, wherein the electric motor is torque limited when a tufting needle engages a backing material to reduce radial distorting forces by the needle engaged in the backing material. [0023] At least one tufting module may be selectively movable relative to the support in an opposite direction to a tufting direction such that the needle is stationary relative to the backing material to reduce radial distorting forces by the needle engaged in the backing material.

[0024] At least one tufting module may be movable relative to the support and resiliently biased to move in a tufting direction by a spring member such that a radial distorting force on the needle by engagement with a backing material causes the module to move in an opposite direction to the tufting direction relative to the support.

[0025] At least one tufting module may be movable relative to the support and further comprising a linear actuator configured to bias the module in a tufting direction when the needle is not engaging a backing material and further configured to allow the module to move in an opposite direction to the tufting direction when the needle is engaging the backing material thereby to reduce radial distorting forces by the needle engaged in the backing material.

[0026] According to a second aspect, there is provided a frame for tufting of a backing material, the frame comprising: a tensioning system to tension the backing material at a tufting area; a feed system to convey the backing material through the tufting area.

[0027] The tufting area may comprise a substantially planar tufting plane, and wherein the feed system may convey the backing material across the tufting plane along a first axis.

[0028] The tensioning system may tension the backing material in the tufting plane substantially along the first axis. [0029] The tensioning system may tension the backing material in a second axis, wherein the second axis is across the tufting plane and substantially perpendicular to the first axis.

[0030] The feed system may comprises at least one movable belt or track to support, at least in part, the backing material in the tufting area.

[0031] The feed system may comprise at least one pair of continuous tracks to engage with, and convey, the backing material along first axis, wherein the at least one pair of continuous tracks comprises: a first continuous track to engage a first periphery of the backing material passing through the tufting area; and a second continuous track to engage a second periphery, opposite to the first periphery, of the backing material passing through the tufting area.

[0032] The at least one pair of continuous tracks, may, at least in part, have a divergent section to form at least part of the tensioning system, wherein as the continuous tracks convey the backing material along the first axis, the divergent section may tension the backing material along the second axis.

[0033] The feed system may comprise at least one tenter needle track having a plurality of tenter needles for engaging the backing material.

[0034] The tensioning system may comprise a spreader to bi-directionally tension the backing material.

[0035] The backing material may be drawn from a spool of backing material.

[0036] The feed system may be configured to convey the backing material between the tufting area and a non-tufting area. [0037] The non-tufting area may comprise at least one substantially planar non tufting plane.

[0038] The feed system may extend through the tufting area and the non-tufting area and securely engage the backing material.

[0039] The feed system may comprise at least one track extending through the tufting area and the non-tufting area, the track engageable with the backing material for indexed movement of the backing material through the tufting area.

[0040] The present disclosure also provides a tufting cartridge for use in a tufting system, the tufting cartridge comprising: a support housing; a reciprocation actuator mounted in the support housing to reciprocate a tufting needle relative to the support housing); a rotation actuator mounted in the support housing to rotate the tufting needle relative to the support housing; a filament feed system to selectively feed a filament to the tufting needle and to control tension of the filament passing through the tufting needle; a cartridge controller to enable selective operation of the reciprocation actuator, rotation actuator, and filament feed system; a communication interface to enable communication between an external computer system and the cartridge controller, wherein the cartridge controller is configured to enable selective operation of the reciprocation actuator, rotation actuator, and filament feed system in response to instruction from the external computer system.

[0041] In some examples of the tufting cartridge, the communication interface may comprise a wireless communication module to enable wireless communication with the external computer system.

[0042] The tufting cartridge may further comprise: a control output interface to enable communication between the cartridge controller and at least one external actuator, wherein the cartridge controller is configured to send external actuator control signals to enable selective operation of the external actuator in response to instruction from the external computer system, and wherein the external actuator is configured to translate and/or rotate the tufting cartridge.

[0043] In some examples of the tufting cartridge, the external actuator control signal is associated with a specified tufting angle for the tufting needle relative to a backing material to be tufted. In some examples of the tufting cartridge, the external actuator control signal is associated with specifying one or more distances between the tufting cartridge and the backing material to be tufted.

[0044] In some examples, the tufting cartridge further comprises: at least one mount at the support housing, wherein operation of the at least one external actuator is operative to translate and/or rotate the tufting cartridge by the at least one mount.

[0045] In some examples of the tufting cartridge, the at least one mount includes a pivot, or forms part of a pivot mechanism.

[0046] In some examples of the tufting cartridge, the filament feed system includes a pneumatic feed system comprising: an air jet nozzle to generate a stream of compressed gas to entrain the filament to the tufting needle.

[0047] There is also provided a multi-needle tufting head for use in robotic tufting, the tufting head comprising: a support; and a plurality of independently operable tufting cartridges mounted to the support, wherein at least one of the tufting cartridges is movably mounted to the support such that at least one tufting cartridge is selectively spaced relative to at least another tufting cartridge mounted to the support, wherein each tufting cartridge is configured to perform tufting operations with a reciprocating needle and filament.

[0048] In some examples of the multi-needle tufting head, the plurality of independently operable tufting cartridges comprise a tufting cartridge described in the examples above. [0049] There is also provided a multi-needle tufting gun according to examples described above, wherein the tufting module comprise a tufting cartridge as described in the examples above.

[0050] There is also provided a robot tufting machine system comprising: a frame for tufting of a backing material, the frame comprising: a tensioning system to tension the backing material at a tufting area; a feed system to convey the backing material through the tufting area along an x-axis; a tufting carriage movable relative to the tufting area in the x-axis; a support supported by the tufting carriage and movable relative to the tufting area in a y-axis that is perpendicular to the x-axis; one or more tufting cartridges mounted to the support, wherein the at least one or more tufting cartridges are selectively movable relative to the support in at least a z-axis that is perpendicular to both the x-axis and the y-axis, the tufting, wherein each tufting cartridge is configured to perform tufting operations with a reciprocating needle and filament. Tufting can include at least one of: operating one or more of the tufting cartridges whilst maintaining the backing material stationary in the x-axis relative to the frame with the feed system, and moving the tufting carriage in the x-axis relative to the frame; or operating one or more of the tufting cartridges whilst moving the backing material in the x-axis through the tufting area with the feed system, and maintaining the tufting carriage stationary relative to the frame.

[0051] In some examples of the robotic tufting machine system, moving the tufting carriage during tufting includes moving the tufting carriage in a forward direction along the x-axis, and moving the backing material during tufting includes moving the backing material in an opposite backward direction along the x-axis.

Brief Description of Drawings

[0052] Fig. 1 A is an illustration of a multi-needle tufting gun;

[0053] Fig. IB is an illustration of a multi-needle tufting gun; [0054] Fig. 1C is an illustration of a multi-needle tufting gun; [0055] Fig. ID is an illustration of a multi-needle tufting gun; [0056] Fig. IE is an illustration of a multi-needle tufting gun; [0057] Fig. 2A is a cross-section of an exemplary tufting module; [0058] Fig. 2B is an illustration of an exemplary tufting module; [0059] Fig. 2C is a cross-section of an exemplary tufting module; [0060] Fig. 2D is an illustration of an exemplary tufting module; [0061] Fig. 3A is a cross-section of an exemplary tufting module; [0062] Fig. 3B is an illustration of an exemplary tufting module; [0063] Fig. 3C is a cross-section of an exemplary tufting module; [0064] Fig. 3D is an illustration of an exemplary tufting module; [0065] Fig. 3E is a cross-section of an exemplary tufting module; [0066] Fig. 4A is a cross-section of an exemplary tufting module; [0067] Fig. 4B is an illustration of an exemplary tufting module; [0068] Fig. 4C is a cross-section of an exemplary tufting module; [0069] Fig. 4D is an illustration of an exemplary tufting module; [0070] Fig. 5A is a cross-section of an exemplary tufting module; [0071] Fig. 5B is an illustration of an exemplary tufting module;

[0072] Fig. 5C is a cross-section of an exemplary tufting module;

[0073] Fig. 5D is an illustration of an exemplary tufting module;

[0074] Figs. 6A to 6F illustrate the movement of a tufting module during tufting; [0075] Fig. 7 A is an end elevation view of a tufting frame;

[0076] Fig. 7B is a side elevation view of a tufting frame;

[0077] Fig. 7C is a perspective view of a tufting frame;

[0078] Fig. 8 shows a robot tufting system;

[0079] Fig. 9 is a side view of a tufting frame;

[0080] Fig. 10 illustrates a tufting frame engaged by multiple tufting guns;

[0081] Fig. 11 illustrates a lead screw;

[0082] Fig. 12 illustrates an example of a tufting cartridge;

[0083] Figs. 13a and 13b illustrate a tufting system utilising a plurality of tufting cartridges;

[0084] Fig. 14 illustrates tufting at a specified tufting angle; and

[0085] Fig. 15 illustrates an example of a robot tufting machine system using tufting cartridges. Description of Embodiments

[0086] Tufting is a type of weaving in which a filament is inserted through a backing material by a tufting gun to form a tuft. For example, in the process of producing chenille fabric or carpet making, yarn is inserted through a backing material to form tufts. The process is however, applicable to filamentary materials other than yarn depending on the intended purpose.

MULTI-NEEDLE GUN

[0087] Typically, tufting gun output is limited to tufting rate of a single tufting needle. Areas filled with identical tufts require a tufting gun to traverse the backing material many times. The rate of tufting is limited to the speed of a single tufting needle. In the following disclosure, a multi-needle is a tufting gun will be described. This tufting gun increases the rate of tufting proportionally to the number of tufting needles. Accordingly, the productivity of a tufting robot using a tufting head employing a multi-needle tufting gun is significantly increased.

MULTI-NEEDLE GUN

[0088] Figs. 1A to IE illustrate a multi-needle tufting gun 100 for use in robotic tufting. Tufting gun 100 comprises a support 27, a plurality of tufting modules 36, 37 and 38 mounted to support 27. At least one tufting module of modules 36, 37 and 38 is movably mounted to the support 27 such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module 36, 37 and 38 comprises a tufting needle 102 as illustrated in Fig. 2A.

[0089] The needle 102 may be a standard tufting needle, or a needle-blade as described in Australian provisional patent application 2019904414, which is hereby incorporated. Needle-blades may be rotating needles or non-rotating needles.

[0090] Tufting gun 100 may further comprise a pivot 28 to allow rotation of the tufting gun relative to a backing material 29. [0091] Each tufting module may tuft with a different yarn. This provides the ability to change tufting yarn by simply selecting another tufting head with the new yarn, as required for colour changes in a design. Currently tufting robots stop at a yam or colour change in a design and an operator is required to change the yarn or colour. Usually one operator can only operate tufting 1-3 robots. Using a multi-gun tufting gun enables designs to run unattended and would enable an operator to run many more machines.

MODULES

[0092] Figs. 2 to 5 show side and end elevation sections of a tufting module 36,

37, 38.

[0093] Figs. 2A, 2B show the needle-blade in the topmost position and Figures 2C,

2D with needle-blade in bottommost position. The housing of the tufting module 39 is supported on the module guide rods 33 passing through guide holes in the housing. The feed roller drive shaft 34 passes through the driven feed roller and the lead screw 35 passes through the drive nut 40 which is fixed to the housing. The horizontal position of the tufting module relative to the tufting gun housing 27 is varied by rotation of the lead screw. The needle support rods 32, held in the needle plate assembly 31 pass horizontally through the needle rod guide holes in the needle-blade 8. The needle-blade itself is guided in the vertical plane by the bearing 41 with the bottom surface of the bearing 10 acting as a presser foot. On a signal from the controller the linear actuators move the needle plate assembly 31 the needle support rods 32 and the attached needle- blades of the tufting modules towards the backing material. The needle -blades 8, attached to the needle support rods penetrate the backing material and travel until the desired pile height is achieved.

[0094] Fig. 3 shows sections of side and end elevation of a pneumatic tufting module with nonrotating needle. Figs. 3 A, 3B show the needle-blade in the topmost position and Figs. 3C, 3D with needle-blade in bottommost position. A presser foot 10, is formed by the bottom surface of the tufting module housing 39, which holds the air jet nozzle 20. The cutting blade pinion drive shaft 42 is mounted on and moves with the needle bar. It is hexagonal in shape, passing through and driving the pinion gear 43 of each tufting module (although it is to be appreciated other keying means are suitable). The pinion gear is connected to a rack cutting blade 44 which has a rack gear profile and a sharpened edge that acts as a cutting blade. When the shaft 42 is rotated, the pinion 43 rotates and moves the rack cutting blade 44 in a linear horizontal motion across the hole at the top of the needle 102 to cut the yam. The position of the cutting blade relative to the needle surface is always maintained because they are mounted and travel together on the needle plate assembly.

[0095] Fig. 4 shows sections of side and end elevation of a mechanical tufting module with rotating needle. Figs. 4A, 4B show the needle -blade in the topmost position and Figs. 4C, 4D with needle -blade in bottommost position. The rotating presser foot bearing 47 is located at the bottom of the housing and its bevel gear surface 48 engages with the worm gear 45. The worm gear is rotated by the hexagonal worm gear drive shaft 46 which is common to all tufting modules in the tufting gun. Rotation of the worm gear causes the rotating presser foot to rotate which in turn rotates the tufting needle 102. The tufting needle 102 is held by the needle guide 49 and is free to rotate. The needle guide sits on the needle support rods 32 of the needle plate assembly 31 and transfers the needle plate vertical movement to the tufting needle-blade.

[0096] Fig. 5 shows sections of side and end elevation of a pneumatic tufting module with rotating needle. Figs. 5 A, 5B show the needle -blade in the topmost position and Figs. 5C, 5D with needle -blade in bottommost position. The rotating tufting needle- blade 52 incorporates a bevel gear profile on its external surface 48 which engages with the worm gear 45 located on the worm gear drive shaft. The needle-blade 52 is held in the needle bearing guide 51 and is free to rotate. The needle guide sits on the needle support rods of the needle plate and transfers the needle plate vertical movement to the tufting needle-blade. SPACING ACTUATOR

[0097] In some embodiments, a means of adjusting the spacing of tufting modules in multi-needle tufting guns, as disclosed in previous embodiments, is included. The distance between each tufting module 36, 37 and 38 is adjusted by a single rotary actuating system while maintaining equal spacing between tufting modules. This can change the stitch spacing for a design, or between designs.

[0098] Referring to Figs. 1A to IE, spacing between tufting needles is achievable using a spacing actuator 14. In some embodiments, spacing actuator 14 is a lead screw actuator comprising a motor 16 and a lead screw 35 configured to engage a corresponding drive nut 40 (shown in Fig. 2A) on the at least one module 36, 37, 38.

[0099] Motor 16 rotates lead screw 35 to adjust the spacing between the multiple tufting modules. Another servo motor, attached to a common rotary actuator, rotates the actuator to rotate all the needles simultaneously. Thus all needles are oriented correctly for the coming tufts.

[0100] The lead screw 35, shown in more detail in Fig. 11, may comprise a first portion 19 threaded in a first direction on a first side of neutral point 21, and a second portion 22 threaded in a second direction on a second side of the neutral point 21. The neutral point is not threaded. This configuration allows a tufting module located at the neutral point to remain stationary relative to support 27 and will mainly be used with an odd number of modules.

[0101] For example, in Fig. ID, centre tufting module 36, located at the neutral point 21, remains stationary while the module on either side moves due to rotation of the lead screw 35. The drive nuts on either side of neutral rotate in opposite directions causing modules 37 and 38 to move away from centre module 36 as indicated by arrows 101.

[0102] For configuration having more than three tufting modules, the pitch of the first threaded portion and/or second threaded portion is greater at a greater distance from the neutral point. This ensures that modules which are a greater distance from the neutral point move faster as a result of lead screw rotation ensuring that module spacings remain even.

[0103] The nut for each module has a specific lead angle so as to move the module the specific amount lead to maintain equal spacing. For example a five needle multi needle tufting gun, shown in Fig. IE, fixes the position of the centre module and adjusts the position of needles to the left and to the right. The first needle to the right, Rl, may have a clockwise lead of lmm/rotation with the second needle, R2 a clockwise lead of 2mm/rotation. Needles LI and L2 have anticlockwise leads of 1mm and 2mm respectively. When the lead screw actuator is rotated clockwise Rl and R2 away from the centre needle, maintaining equal spacing between each needle. Similarly LI and L2 move away from the centre needle, in the opposite, maintaining equal spacing between each needle. The lead screw actuator may be operated manually or by an electronically controlled motor.

NEEDLE RECIPROCATOR

[0104] Tufting gun 100 may further comprise a reciprocation actuator mounted to support 27. Reciprocation actuator comprises linear actuators 30 are attached to the support 27 (also referred to as housing) connecting it to the needle plate assembly 31 to reciprocate the needle plate with its attached needles. The actuator stator is rigidly connected to the housing with the actuator moving core attached at the other end to the needle plate assembly. A pair of needle support rods 32 which pass through each module to support their tufting needles are rigidly attached to the needle plate 31. Downward movement of the linear actuators causes the needle bar to move towards the surface of the backing material 29, simultaneously forcing synchronised penetration of the backing material by all the needles in the tufting modules. Reversing the motion of the linear actuators withdraws the needle plate with its connected needles to form tufts of yam at each tufting module. [0105] In some embodiments, the reciprocation actuator comprises a motor and a crank shaft. Each needle is connected to the crank shaft which is rotated by the motor causing the needles to reciprocate. In some embodiment, the crank shaft is configured such that the needles are synchronised, while in other embodiments the needles are out of phase.

NEEDLE ROTATOR

[0106] In some embodiments, tufting gun 100 comprises a rotation actuator mounted to the support 27 to rotate the tufting needle 102 of each module. This allows the tufting gun to change the direction of tufting without having to rotate the whole tufting gun.

[0107] Turning to Fig. 4, a means of simultaneous needle rotation is the use of a worm gear 45 in each module driven by a common rotary shaft 46. The direct needle rotator in each module contains a bevel gear profile which matches with the worm gear. When the worm gear is rotated in the XY plane the needle rotator and its connected needle is rotated about the Z axis. The rotary actuator may be operated manually or by an electronically controlled motor.

[0108] In some embodiments, the rotation actuator comprises a linear actuator and linkages to each needle 102 to operatively rotate each needle. The linear actuator drives the linkages on an axis perpendicular to the needle axis causing each needle to rotate on its axis. For example, the linkages may comprise a shaft having gear teeth which engage corresponding gear teeth in the rotating presser foot.

FORCE LIMITING

[0109] During tufting, relative movement between tufting gun 100 and backing material 29 is required. XY movement systems are programmed to traverse the tufting head over tufting frame at a constant speed while the tufting needle moves in and out of the backing material. At some time during the tufting cycle, the tufting needle is engaged in the backing material while the head is moving, applying a force to the filaments of the backing surrounding needle 102. The force exerted by the needle is generated by the torque of the servo motors driving the XY movement system. This force causes an elliptical elongation of the hole in the backing material, in the direction of tufting. This results in distortion of the backing material. Minimising distortion and stopping breakage of filaments necessitates the use of high tensile strength backing materials. Low tensile strength backing materials like cotton, as used in hand tufting, cannot withstand the rigours of current robot tufting and are subject to breakage.

Below are described methods for reducing this force.

[0110] In an embodiment, the electric motor electric motor used to translate the tufting gun through space in a tufting direction, is torque limited when the tufting needle engages a backing material. The limited torque reduces forces, exerted radially from the needle onto the backing material.

[0111] Turning to Fig. 6 a mechanism for reducing distorting forces on the backing material is described. The tufting module 600, represented by needle 60, is movable relative to support 27 in an opposite direction 62 to a tufting direction 64 of tufting gun 100. The movement of tufting module 600 is electronically controlled such that when needle 60 engages backing material 29, tufting module 600 moves in an opposite direction relative to support 27 such that the needle is stationary relative to the backing material. With no movement between needle and backing there is no force exerted by the needle on the backing.

[0112] This can be achieved by a force control system 66 attached between module 600 and the support 27 in Fig. 6A yarn 602 is fed through the tufting gun 32 into the tufting needle 60. The tufting needle 60 is positioned at backing grid space xl, yl in preparation for a needle penetration. It has moved from the previous tuft 68 which was inserted in the backing material 29. In Fig. 6B the tufting needle 60 is penetrating the backing material as the remainder of the tufting head, such as support 27, is moving in a tufting direction 64 towards the next penetration point x2, y2. Simultaneously the force control system 66 is moving module 600, and therefore needle 60, in the opposite direction to the tufting head at the same speed, thereby maintaining the tufting needle at position xl, yl. The tufting needle reaches its end of stroke in Fig. 6C while the tufting head 27 and tufting module 600 continue to move in opposite directions. In Fig. 6D, the tufting needle 60 withdraws 70 from the backing forming a tuft 72 while tufting head 27 and force control system 66 continuing to move in opposite directions at equal speed. When the tufting needle has been fully withdrawn from the backing material as shown in Fig. 6E the stabiliser reverses direction 74 and moves at maximum speed towards x2, y2 to meet up with a starting position 604 on tufting head 27. When tufting head and module 600 have both reached x2, y2 as shown in Fig. 6F the tufting gun and tufting needle are position to produce the next tuft.

[0113] In some embodiments, a linear actuator is configured to bias the module 60 in a tufting direction 64 when the needle 60 is not engaging a backing material 29. This is shown in Fig. 6E, where needle 60 is withdrawn (i.e. not engaged) from backing material 29 and the linear actuator causes the module to move 74 relative to the support 27. When needle 60 is engaged with backing 29 (Figs. 6B to 6D) the linear actuator allows the module 600 to move in an opposite direction 62 to the tufting direction. This can be achieved by de-energising the linear actuator when needle 60 is engaging backing material 29.

[0114] In an embodiment, the tufting module 60 is mounted such that it is movable, in a direction opposite 62 the tufting direction 64, relative to the support 27. The module is resiliently biased to move in the tufting direction 64 by a spring member. When the needle engages the backing material 29 (Fig. 6B), radial forces on the needle (from the backing material) cause the module 60 to move in the direction opposite to the tufting direction (Figs.6B to 6D) and against the resilient bias of the spring member. When the needle is withdrawn (Fig. 6E) from the backing material, the spring member moves the module in the tufting direction 64. Allowing module 60 to move relative to support 27 in a direction 62 opposite to the tufting direction 64 reduces the distorting forces exerted on the backing material by the needle. TUFTING FRAME

[0115] Tufting frames are used in robot tufting applications to hold backing material in a tensioned state defining a plane. The tensioned backing material is presented to a tufting head which traverses over the surface of the plane, tufting it in a desired pattern. The size of a tufted rug is determined by the XY dimensions of the coplanar tufting frame. Accordingly the tufting field of the tufting robot matches the dimensions of the tufting frame. For example a 24 square metre rug requires a tufting frame of 4 metres high and 6 metres wide with a tufting robot having a matching field. The XY movement system of the tufting robot is over 5 metres in height.

[0116] Furthermore, the size and inertia of the tufting robot’s XY movement system is the main determinant of the cost and performance of the tufting robot. The physical dimensions of the tufting frame also determine the manufacturing space required for operation of the tufting robot. Generally tufting frames and tufting robots are vertically oriented, necessitating factory space with high ceilings. A further consequence is that attaching and detaching backing material to the tufting frame requires the use of elevating platforms or scaffolding.

[0117] A frame 700 for tufting of a backing material 29 is shown with in Figs. 7A, 7B and 7C. Frame 700 reduces the travel requirements for a tufting head to tuft backing material of given dimensions. This results in reduced size and inertia of the tufting robots XY movement system and reduced vertical clearance requirements.

[0118] Frame 700 comprises a tensioning system to tension the backing material 29 at a tufting area 80 and a feed system to convey the backing material through the tufting area.

[0119] In this example, frame 700 holds stretched backing material 29 on pins of needle tracks 17 on either side of the frame. The left and right needle tracks 17, which form part of the tensioning system, are guided by a number of tenter rollers 11 which form part of the feed system. The tenter rollers are located on drive shafts 12 powered by a drive motor 13. The backing material is positioned by drive motor at any point along its length, as determined by a computer control system. The backing material is presented by the tenter frame 700 to a tufting robot in a tufting plane. The tufting plane 82 could be the vertical section shown in the end elevation of Fig. 7A or the top horizontal section shown in side elevation of Fig. 7B or 7C. The indexing of the backing material along its length by the tenter frame, is synchronised with the operation of a tufting robot by the computer control system.

[0120] The tufting area 80 comprises a substantially planar tufting plane 82, and wherein feed system conveys the backing material 29 across the tufting plane along a first axis.

[0121] This embodiment holds a length of tensioned backing material in a tenter frame in multiple planes 82, 84 etc. The motion of the frame, under electronic control, is bi-directional and intermittent (or in some embodiments continuous). The tensioned backing material is attached to the frame along its width. The backing material may be indexed and held stationary to present a section for tufting by a tufting robot. The section of backing material to be tufted may be in the vertical or horizontal planes.

After tufting the selected section of backing material, the tufting frame advances the backing to the next section to be tufted. A design may be indexed to start in the middle and tuft outwards or simply indexed to tuft from one end to the other. A design can be tufted by colour in sections of the design or across the full length of the backing to more evenly distribute the weight of the tufting. The number and direction of indexes is not limited.

[0122] This embodiment of tufting frame overcomes the problems of existing tufting frames. The short dimension of a tufted rug is defined by the width of the frame with the long dimension defined by the length of the tenter track. For example, a tenter frame which is 5 metres wide with a rectangular tenter track 2 metres high and 2 metres long can be used to tuft a rug measuring 5 metres by 8 metres. Using an XY movement system whose height is 2, a tufting robot can tuft the design by indexing the tufting frame 4 times. [0123] The motor 13 powering the tufting frame may be fixed onto the frame or detachable from the frame when the tenter is not positioning the backing material. The tenter frame may be mobile or fixed in position. A design may be tufted uni- directionally where the tenter frame progresses the backing material in sections of the design that are completely tufted before indexing. Where a design is completed in this manner the backing material may be fed continuously from its source and completed sections of the design removed. This can provide tufted fabric whose length is limited only by the length of the source of backing material. The tenter tufting frame also enables robot tufting of mgs much larger than those currently available. It also enables the use of lower height tufting robots which are less expensive and have better tufting performance than existing tufting robots.

[0124] Fig. 8 shows frame 700 in operation with a robot tufting machine 800. Robot tufting machine 800 may comprise multi-needle tufting gun 100 or a conventional tufting head. Primary backing material 29 supplied from the source 802 and fed into the spreader 804 which attaches the backing material to the tenter needle track 17. The spreader 23 is set to bi-directionally tension the backing material as it is fed onto the tenter needle track. A computer control system controls the speed of the tenter drive motor 13 and synchronises the action of the spreader as the tensioned backing material is progressively attached to the needle track. The tenter rollers 11, driven by the drive shafts 12 progress the attachment of the backing material to the tenter frame, loading the backing material until the desired length of material has been fully attached. The primary backing material is then cut and the spreader disconnected from the tenter frame.

[0125] When the full length of primary backing material has been attached to the tenter tufting frame the first section of backing material to be tufted is presented to the robot tufting machine 800. When the tufting of the design on the presented section has been completed the tufting frame, under the control of the computer control system indexes the backing material to the next section of the design to be tufted. The sequence of tufting and indexing of the backing material is repeated until the design has been completely tufted. [0126] Secondary backing material from the source 806 is introduced to the spreader 804 and attached to the tenter needle track 17, on top of the previously attached tufted primary backing. The tenter tufting frame is driven forward in one direction until the full length of secondary backing material has been attached and held in the tenter frame on top of and joined to the previously tufted primary backing material. The secondary backing material is then cut to length and disconnected from the spreader.

[0127] The tenter tufting frame now grips on its needle track a fabric structure comprising a tufted primary backing material and a secondary backing material. The computer control system indexes the fabric structure to position it, section by section, under the adhesive application system 808. The adhesive application system, under the control of the computer control system lowers the applicator head to press against the fabric structure and to start the application of the adhesive. The computer control system traverses the adhesive applicator over the surface of the fabric structure as it regulates the flow of adhesive onto it.

[0128] When the section of the fabric structure presented to the applicator system has been fully covered with adhesive the applicator head is withdrawn from contact with the fabric structure. The tenter frame is indexed to position the next section of fabric structure under the adhesive application system for application of adhesive. This process is repeated until the length of the complete fabric structure has been covered in adhesive. The fabric structure covered in adhesive is left in position in the tenter frame until the adhesive dries and sets at which time the fabric structure becomes a fully bonded tufted fabric.

[0129] One embodiment of the system uses a moveable tenter frame module which can be disconnected from the integrated system. The tenter frame containing the wet adhesive fabric structure is removed to a separate location to allow the adhesive to dry and set. An empty tenter frame replaces the removed loaded frame and is connected to the other system modules to provide a complete system. This new system starts producing the next design without having to wait for the adhesive to dry on the previous design. This enables the system to be continuously engaged in tufting fabric structures.

[0130] Another embodiment of the system produces bonded tufted fabric without incorporating a secondary backing material in the structure.

[0131] In some embodiments, the feed system conveys the backing material across the tufting plane along a first axis, applying tension to the backing material in the tufting plane substantially along the first axis. This can be achieved, for example by source 802, also referred to a spool, applying a resistance to backing material 29 being drawn onto frame 700 by rollers 11. The resistance allows tension to be created in the direction of feed. In this case, source 802 and rollers 11 form part of the tensioning system. It will be appreciated that rollers 11 can engage backing material 29 in many different ways. For example, the feed system may comprise at least one pair of continuous tracks, driven by rollers 11, to engage with, and convey, the backing material along the first axis. The pair of continuous tracks comprise a first continuous track to engage a first periphery of the backing material passing through the tufting area; and a second continuous track to engage a second periphery, opposite to the first periphery, of the backing material passing through the tufting area. The tracks may comprise a plurality of tenter needles for engaging the backing material and or have a clamp to engage the backing material.

[0132] In some embodiments, as shown in side perspective view in Fig. 9, the tensioning system tensions the backing material in a second axis 902, wherein the second axis is across the tufting plane 82 and substantially perpendicular to the first axis 904. For example, the at least one pair of continuous tracks 906, at least in part, has a divergent section 908 to form at least part of the tensioning system. In this embodiment, the tracks 906 engage backing material 29 and convey it along a first axis 904. As the backing material is conveyed along the diverging section 908 of tracks, the backing material is tensioned along the second axis 902 perpendicular to the first. Tensioning in the first axis can be achieved as described above, i.e. by a resisting force from spool 802 as backing material 29 is drawn onto frame 700. [0133] Alternatively, in embodiments where the at least one pair of continuous tracks comprises tenter needles for engaging the backing material, tensioning in the first axis can be achieved by increasing the spacing between tenter needles. This results in the backing material being tensioned in the first axis and the second axis at the tufting area 80.

[0134] In some embodiments, the feed system is configured to convey the backing material between the tufting area 80 and at least one non-tufting area. The non-tufting area may comprise at least one substantially planar non-tufting plane 84. The feed system, which could comprise tenter needle tracks, extends through the tufting area and the non-tufting area and is configured to provide indexed movement of the backing material through the tufting area. This allows backing material 29 to be conveyed between the tufting 80 and non-tufting 84 areas in an indexed fashion. Accordingly, the tufting robot is able to tuft sections of backing material, which can be moved between the tufting and non-tufting areas, with a specific yarn and return to the same indexed location at a later time to tuft with a different yarn. In some embodiments, as shown in Fig. 10, multiple tufting areas 80 are used, each with respective tufting guns 100.

[0135] Additional variations of the present disclosure are described below.

TUFTING CARTRIDGE

[0136] In some examples, the tufting modules are in the form of tufting cartridges 1038 as illustrated in Fig. 12. In some examples, the tufting cartridge 1038 is a self- contained, physically and electrically removable, plug in tufting module that can be used in the robot or used in other applications where only control signals and power are needed for operation.

[0137] Each of the tufting cartridges can be used to tuft specific yam (e.g. yam type, colour, etc.). In some examples, the robotic tufting system may include multiple tufting cartridges (as illustrated in Fig. 13) to enable quick and efficient colour change. In some examples, this includes using a robotic tufting system with a flatbed plotter type arrangement, where the plotting head moves the tufting cartridge 1038 to the desired location at the backing material for tufting. Such a system can include moving the tufting cartridges in an X and Y axis to the desired location across a sheet of the backing material. An additional Z axis can be used to selectively displace the tufting cartridge 1038 and, respective tufting needle 102, towards or away from the surface of the backing material 29.

[0138] The plurality of tufting cartridges 1038 mounted on a support 27 of the tufting system 1100 (as illustrated in Figs. 13a and 13b) may be independently operable. Thus at least one of the tufting cartridges is movable mounted to the support such that at least one tufting cartridge can be selectively spaced relative to at least another tufting cartridge mounted to the support.

[0139] Turning to Fig. 12, the tufting cartridge 1038 includes a support housing 1040 to enable the tufting cartridge 1038 to self-contain and support various components. This includes a reciprocating actuator 1050 mounted to the supporting housing to reciprocate a tufting needle 102 relative to the support housing 1040. The reciprocating actuator 1050 can include a linear actuator, or in other examples a motor and crank shaft to create reciprocating motion. A rotation actuator 1052 is mounted to the support housing to rotate the tufting needle relative to the support housing 1040. The rotation actuator 1052 can include a worm drive system 1053 to selectively rotate the tufting needle 102.

[0140] A filament feed system 1054 selectively feeds a filament 1066 (e.g. yam) to the tufting needle 102 and controls tension of the filament 1066 passing through the tufting needle. This can include a motor driven feed wheel 1055 to control feeding of the filament 1066. The filament 1066 can be contained in a spool 1067 inside the support housing 1040.

[0141] In some other examples, the filament feed system 1054 can include an air jet nozzle to generate a stream of compressed gas to entrain the filament to the tufting needle 102. This can be used to drive the filament through the hole in the backing material opened by the tufting needle 102. In some examples, the filament feed system include a filament port to introduce filament to the filament feed system 1054; and a convergent and divergent jet nozzle formed symmetrically about the filament port and configured to generate a supersonic stream of compressed gas to entrain the filament to a tufting needle. An example of a filament feed system using an air jet is described in PCT application no. PCT/AU2020/051262 filed 20 November 2020 which is hereby incorporated by reference.

[0142] The operation of the reciprocation actuator 1050, rotation actuator 1052, and filament feed system 1054 to effect tufting may be similar, or the same, as the earlier described examples.

[0143] The tufting cartridge 1038 also includes a cartridge controller 1056 to enable and control selective operation of the reciprocating actuator 1050, rotation actuator 1052, and filament feed system 1054. The cartridge controller 1056 can include microcontroller including a processor and memory to execute program instructions. These program instructions, when executed, cause the cartridge controller 1056 to send control signals to operate the reciprocation actuator 1050, rotation actuator 1052, and filament feed system 1054.

[0144] The tufting cartridge 1038 also includes a communication interface 1058 to enable communication between an external computer system 1060 and the cartridge controller 1056. This communication can include the cartridge controller 1056 receiving instructions from the external computer system 1060 for tufting operations.

In turn, the cartridge controller 1056 processes the instructions and outputs the control signals to the reciprocation actuator 1050 (for needle penetration), rotation actuator 1052 (for needle rotation), and the filament feed system (for feeding the filament).

[0145] In some examples, the communication interface 1058 includes a wired connection to the external computer system 1060. In other examples, the communication interface 1058 includes a wireless communication module 1062 to enable the cartridge to wirelessly communicate with the external computer system 1060. This may include communication via Bluetooth and/or Wi-Fi protocols. In some examples, using wireless communication can reduce complexities in inserting, removing and swapping the tufting cartridges. In some preferred examples, this enables the tufting cartridge 1038 to require electrical connection for power. In yet further examples, the tufting cartridges receive power through inductive coils for power and/or charging. This can further reduce electrical connectors and wired connections.

[0146] Further features of a tufting cartridge, according to some examples, will now be described.

[0147] In one example, the cartridge controller 1056 is configured to selectively control one or more external actuators 1066 outside of the tufting cartridge 1038. The tufting cartridge 1038 may include a control output interface 1064 to enable communication between the cartridge controller 1056 and the external actuator 1066. This enables actuator control signals to be send from the cartridge controller 1056 to operate the external actuators 1066 in response to instructions that the cartridge controller 1056 receives from the external computer system 1060.

[0148] The external actuators can include actuators to translate the tufting cartridge in the X axis and/or the Y axis (such as a flatbed plotter type of movement).

[0149] In other examples, one or more of the external actuators 1066 move the tufting cartridge 1038 in a Z axis. This can include, for example, a linear actuator to move the tufting cartridge 1038’ a specified distance from the backing material 29 to be tufted. When a particular tufting cartridge 1038’ is used, the linear actuator may move that particular tufting cartridge 1038’ in the Z-axis (as illustrated in Fig. 13a) so that the reciprocating tufting needle 102 can effectively penetrate the backing material 29.

When that particular tufting cartridge 1038’ is not required, the linear actuator may withdraw that particular tufting cartridge 1038’ at a specified distance away from the backing material in the Z-axis (as illustrated in Fig. 13b). [0150] In some examples, the cartridge controller 1056 is configured to control at least 4 axes, notably the reciprocation actuator 1050, rotation actuator 1052, filament feed system 1054, and a linear actuator on the Z-axis. An advantage is that this enables the movement system associated with the support 27 to be a simple X and Y axis movement system. In some examples, this simplification can aid simple design or adaptation of existing bed plotter type robotic systems.

[0151] In yet another example, one or more of the external actuator 1066 is configured to rotate the tufting cartridge 1038 in an axis (such as the X or Y axis). This can be used to enable tufting at a specified tufting angle 1068 as illustrated in Fig. 14.

In some examples, rotation of the tufting cartridge 1038 can be in addition to translation in the Z axis (with the cartridge controller 1056 configured to control at least 5 axes). By using the cartridge controller 1056 to control these additional degrees of freedom, this may simplify movement of other components of the tufting system so that existing systems (both hardware and software) can be used or adapted to use the tufting cartridge.

[0152] Turning back to Fig. 12, the tufting cartridge may further include one or more mounts 1070 at the support housing 1040, wherein operation of the at least one actuator 1066 is operative to translate and/or rotate the tufting cartridge by the at least one mount 1070. In some examples, the mount can include apertures to receive corresponding mounting elements to secure the tufting cartridge 1038 for movement.

In some examples, the mount 1070 includes a pivot or is part of a pivot mechanism to enable the tufting cartridge 1038 to be selectively rotated by one or more of the external actuators 1066.

[0153] The tufting cartridge 1038 and tufting system 1100 can be used during manufacture of carpets. In addition, the tufting cartridge 1038 and tufting system 1100 can be used in other industries that require passing filament through material. For example, during manufacture of certain composite material (such as fibre reinforced plastics), it is desirable to layer multiple layers of woven material together whereby the layers are then laminated to each other with a resin. For complex shapes or parts, difficulties can arise keeping such layers together before the resin is fully cured.

Tufting can be used to join layers of material together. Referring to the example of Fig.

14, the backing material 29 includes multiple layers of woven material and the filament, with the tufting loops, hold the multiple layers of woven material together. The present disclosure, in enabling the tufting cartridge 1038 to form tufts at specified angles 1068, may assist forming of layers of woven material where the application includes forming the material in complex and non-linear molds.

BI-DIRECTIONAL OPERATION

[0154] The use of tufting cartridges can reduce the complexity of a robot tufting machine system. For example, the tufting head and corresponding support 27 can hold multiple cartridges, whereby each cartridge with their respective filaments can be individually engaged for tufting operations. This can include situations where non rotating tufting needles are used.

[0155] Another example of a robot tufting machine system 1800 is illustrated in Fig.

15. This examples includes a frame 700 similar to the frame described in Fig. 8 above where the frame includes a tensioning system 804 to tension the backing material at a tufting area 80. A feed system 802 conveys the backing material 29 through the tufting area along an x-axis. In some examples, the feed system 802 can convey the backing material 29 in a forward direction along the x-axis or an opposite backward direction along the x-axis.

[0156] The robot tufting machine system 1800 also includes a tufting head that, in conjunction with other components, provide simple X-Y movement to tufting cartridges across the tufting area 80. This can include a tufting carriage 1078 that is movable to the tufting area 80 along the x-axis. The tufting carriage 1078 carries a support 27 thus movement of the tufting carriage 1078 along the x-axis also causes movement of the support 27 along the x-axis. [0157] The support 27 is movable relative to the tufting area 80 in a y-axis that is perpendicular to the x-axis. This can include having the support 27 movably mounted to the tufting carriage 1078 and with actuators moving the support 27 along the carriage 1078 in the y-axis.

[0158] One or more tufting cartridges 1038 are mounted to the support 27, where the tufting cartridges 1038 are selectively movable relative to the support 27 in the z-axis. This z-axis is perpendicular to both the x-axis and the y-axis so that movement bring the tufting cartridge 1038 closer or away from the tufting area 80.

[0159] When tufting operations are required, a tufting cartridge 1038 with the appropriate filament is selected and positioned closer to the backing material 29 by movement along the z-axis. The relative position of needle of the tufting cartridge 1038 to the backing material 29 in the y-axis can be selected by movement of the support 27 relative to the tufting carriage 1078.

[0160] The relative movement of a reciprocating needle of a tufting cartridge 1038 relative to the backing material 29 in the x-axis can be created in multiple ways.

Firstly, by operating one or more of the tufting cartridges whilst moving the tufting carriage 1078 in the x-axis relative to the frame 700. This can coincide with maintaining the backing material 29 stationary in the x-axis relative to the frame 700 with the feed system 802.

[0161] Secondly, operating one or more of the tufting cartridges 1038 whilst moving the backing material 29 in the x-axis through the tufting area 80 with the feed system 802, and maintaining the tufting carriage 1078 stationary relative to the frame 700.

[0162] It is to be appreciated relative movement in the x-axis (or movement with a vector component in the x-axis) can be created with a combination of movement of the backing material with the feed system 802 and moving the tufting carriage 1078 relative to the frame 700. [0163] In some examples, in particular where the tufting needles are non-rotating, it is desirable to maintain relative movement of the tufting needle to the backing material in the same direction along the x-axis. Thus in one example, the system is configured to move the tufting carriage 1078 in a forward direction along the x-axis during tufting. When effecting relative movement by moving the backing material 29 with the feed system 802, this includes moving the backing material in an opposite backward direction along the x-axis during tufting.

[0164] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.