Multi-head tufting system

Abstract

A multi-needle tufting gun for use in robotic tufting includes a support and 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. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

1 . A multi-needle tufting gun for use in robotic tufting, the tufting gun comprising:
 a movable tufting head 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 tufting module comprises a tufting needle;   a spacing actuator mounted to the support to selectively move the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted.   
     
     
         2 . The tufting gun of  claim 1  wherein the at least one axis includes a first axis and a second axis perpendicular to the first axis, wherein both the first axis and the second axis are across the tufting plane. 
     
     
         3 . The tufting gun of  claim 1  wherein the spacing actuator comprises a motor and a lead screw configured to engage a corresponding drive nut on the at least one tufting module. 
     
     
         4 . The tufting gun of  claim 3  wherein the lead screw comprises a first threaded portion threaded in a first direction on a first side of a neutral point and a second threaded portion threaded in a second direction on a second side of the neutral point. 
     
     
         5 . The tufting gun of  claim 4  wherein a pitch of the first threaded portion is greater at a greater distance from the neutral point. 
     
     
         6 . The tufting gun of  claim 4  wherein a pitch of the second threaded portion is greater at a greater distance from the neutral point. 
     
     
         7 . The tufting gun of  claim 3  wherein a pitch of the lead screw varies along the length of the lead screw. 
     
     
         8 . The tufting gun of  claim 1  further comprising a reciprocation actuator mounted to the support to reciprocate the tufting needle of each tufting module. 
     
     
         9 - 10 . (canceled) 
     
     
         11 . The tufting gun of  claim 1  further comprising a rotation actuator mounted to the support to rotate the tufting needle of each tufting module. 
     
     
         12 - 13 . (canceled) 
     
     
         14 . The tufting gun of  claim 1  wherein the support further comprises a pivot to allow rotation of the tufting gun relative to a backing material. 
     
     
         15 - 16 . (canceled) 
     
     
         17 . The tufting gun of  claim 1  further comprising 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 tufting needle engaged in the backing material. 
     
     
         18 . The tufting gun of  claim 1  wherein at least one tufting module is selectively movable relative to the support in an opposite direction to a tufting direction such that the tufting needle is stationary relative to the backing material to reduce radial distorting forces by the tufting needle engaged in the backing material. 
     
     
         19 . The tufting gun of  claim 1  wherein at least one tufting module is 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 tufting needle by engagement with a backing material causes the at least one tufting module to move in an opposite direction to the tufting direction relative to the support. 
     
     
         20 . The tufting gun of  claim 1  wherein at least one tufting module is movable relative to the support and further comprising a linear actuator configured to bias the tufting module in a tufting direction when the tufting needle is not engaging a backing material and further configured to allow the tufting module to move in an opposite direction to the tufting direction when the tufting needle is engaging the backing material thereby to reduce radial distorting forces by the tufting needle engaged in the backing material. 
     
     
         21 - 34 . (canceled) 
     
     
         35 . A tufting cartridge for use in a tufting system having multiple tufting cartridges, the tufting cartridge comprising:
 a support housing movable by at least one external actuator of the tufting system, wherein the at least one external actuator is separate from the tufting cartridge;   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, the rotation actuator, and the filament feed system;   a communication interface to enable communication between an external computer system and the cartridge controller; and   a control output interface to enable communication between the cartridge controller and the at least one external actuator,   wherein the cartridge controller is configured to enable selective operation of the reciprocation actuator, the rotation actuator, and the filament feed system, in response to instruction from the external computer system,   wherein the cartridge controller is configured to send an external actuator control signal to enable selective operation of the at least one external actuator in response to instruction from the external computer system, and   wherein the at least one external actuator is configured to independently translate the tufting cartridge in an x axis and/or y axis across a tufting plane of a sheet of backing material to be tufted.   
     
     
         36 . The tufting cartridge according to  claim 35  wherein the communication interface comprises a wireless communication module to enable wireless communication with the external computer system. 
     
     
         37 . (canceled) 
     
     
         38 . The tufting cartridge according to  claim 35  wherein the external actuator control signal is associated with a specified tufting angle for the tufting needle relative to the backing material to be tufted. 
     
     
         39 . The tufting cartridge according to  claim 35  wherein the external actuator control signal is associated with specifying one or more distances between the tufting cartridge and the backing material to be tufted. 
     
     
         40 - 41 . (canceled) 
     
     
         42 . The tufting cartridge according to  claim 35  wherein 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. 
 
     
     
         43 . A multi-needle tufting head for use in robotic tufting, the tufting head comprising:
 a support that is movable relative to an x axis and/or y axis across a tufting plane of a sheet of backing material to be tufted;   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; and one or more external actuators configured to translate at least one of the tufting cartridges, relative to another tufting cartridge, in the x axis and/or y axis across the tufting plane of the sheet of backing material to be tufted.   
     
     
         44 - 47 . (canceled)