Tufting machine with self-aligning gauging modules

Abstract

Symmetrical, modular blocks each having a plurality of fixed, equally spaced, gauging elements, namely loopers, needles, and reeds protruding therefrom, the blocks are positioned on the sides of the guide bars of a tufting machine, each guide bar having transverse channels at equally spaced intervals. These channels respectively receive guide bars of the blocks when the blocks are removably positioned on the sides of the guide bar. Bolts or screws secure the blocks in place on their guide bars so that their needles, loopers, and reeds are appropriately gauged and positioned for tufting action, protruding toward the tufting zone.

I claim:  
     
       1. A gauging module assembly for being selectively received over at least one recess of a plurality of equally  spaced sidewise opening channel shaped  recesses along  defined in a side surface of a gauge bar of a tufting machine, said gauge bar also defining detent receiving holes within said side surface, said gauging module assembly comprising: 
       (a) a modular block having a front surface, a pair of side surfaces opposed to each other, and a rear surface opposite to said front surface, said modular block defining a hole therein;  
       (b) a plurality of equally  spaced, parallel, tufting machine gauging elements protruding from said modular block, each of said tufting machine gauging elements having a proximal end and a distal end, the proximal end of each of said gauging elements being embedded in a fixed, retained, condition in said modular block, said elements protruding in transverse parallel alignment with each other, from said block;  
       (c) an  at least one elongated tab fixed  on the rear surface of said modular block for being received sidewise in any one of said spaced recesses in said  in at least one of the recesses of the spaced recesses defined in the side surface of the gauge bar on said tufting machine,  when said modular block is positioned with its rear surface against said side surface of said gauge bar, said at least one tab centering said modular block on said gauge bar when said at least one tab is received in at least one of the recesses said spaced recesses; and  
       (d) a detent for securing said modular block to said gauge bar, said modular block when attached to said gauge bar,  being adapted to hold said spaced gauging elements in a fixed position protruding toward a tufting zone of said tufting machine with said distal ends of said spaced elements being in said tufting zone, said detent also urging said modular block toward said said gauging block  gauge bar and said at least one tab into at least one of said recesses as said detent is passed into said hole in said modular block and received into one of said detent receiving holes, said modular block being held in a vertically nonadjustable position with respect to said gauge bar when said elongated tab is received in at least one of the recesses of said spaced recesses and said detent is received in said one of said detent receiving holes.  
     
     
       2. The gauging module assembly defined in claim  1  wherein said tufting machine gauging elements include  comprise a plurality of tufting needless said needles having eyes at their distal end portions. 
     
     
       3. The gauging module assembly defined in claim  2  wherein said modular block is rectangular and has opposed parallel side surfaces, and wherein said tufting machine gauging elements are straight members,  the outermost members  tufting machine gauging elements being spaced inwardly from said side surfaces of said modular block by a distance of about one-half the spacing of said gauging elements from each other. 
     
     
       4. The gauging module assembly defined in claim  1  wherein said tufting machine gauging elements are  comprise loopers. 
     
     
       5. The gauging module assembly defined in claim  1  wherein said modular block is rectangular and has parallel side surfaces, and wherein said tufting machine gauging elements are disposed in a common plane which is  with respect to one another, said plane being approximately parallel to the side  front and rear surfaces of said modular block. 
     
     
       6. The gauging module assembly defined in claim  1  including a stop for forming with said  positioned adjacent to said at least one tab, said stop and said at least one tab forming a T-shaped member on said rear surface of said modular block, said stop protruding on both sides of said tab  along at least a portion of the length of said modular block with respect to said at least one tab. 
     
     
       7. A  In a tufting machine of the type in which a reciprocating looper gauge bar moves toward and away from a tufting zone as needles of the tufting machine are reciprocated toward and away from the tufting zone for inserting yarns through a backing material, the improvement comprising: 
       (a) said looper gauge bar having a prescribed length and a flat side and being provided with  defined on the looper gauge bar, said flat side defining a plurality of equally  spaced, parallel, sidewise opening,  recesses along said flat side and also defining a plurality of spaced detent receiving holes therein;  
       (b) a plurality of symmetrical, substantially identical, modular mounting blocks mounted side by side on said flat side of said looper gauge bar, each of said modular mounting blocks defining a hole therein;  
       (c) a plurality of equally spaced loopers carried by each of said modular mounting blocks, said loopers being imbedded  embedded in each of said modular mounting blocks so that each said modular mounting block retains the loopers in a spaced, parallel relationship with respect to one another according to the  a predetermined gauge of the tufting machine, each of  said modular blocks  mounting block being provided with a tab which is received sidewise within one of said  recesses that block is  for being received sidewise within one of said spaced recesses when that block is  defined in said flat side of the looper gauge bar when said modular mounting blocks are moved toward said looper gauge bar; and  
       (d) a detent means individual to  for each of said modular mounting blocks for removably securing that modular mounting block against the flat side of said looper gauge bar in a fixed position with respect to the other modular mounting blocks carried by said looper gauge bar as each said detent is passed into said hole in said modular mounting block and into said detent receiving hole, said detent means  urging said tab into one of said spaced recesses and also urging said modular mounting block against said flat side of said looper gauge bar to hold said modular mounting block in a vertically nonadjustable position with respect to said looper gauge bar.  
     
     
       8. The tufting machine defined in claim  7 , wherein each tab  respective one of said tabs is T-shaped and includes a  an elongate shoulder extending at least partially along one  an edge portion of said modular mounting block for limiting sidewise movement of that tab  the respective ones of said tabs within sidewise  the respective ones of said one of said  recesses and for preventing appreciable rotation of said modular mounting block with respect to said looper gauge bar. 
     
     
       9. The tufting machine defined in claim  7  wherein said detent means  includes a bolt for passing through said hole in said modular mounting block and through said tab for removably securing that  each said modular mounting block onto said looper gauge bar. 
     
     
       10. Process  A process of producing a tufting machine, the tufting machine having a tufting zone therein, said process comprising the steps of: 
       (a) producing  forming a plurality of equally spaced, parallel, transverse, sidewise opening, straight recesses across one side portion of an elongated gauge bar of the tufting machine, each of said recesses having equally spaced parallel centerlines, and forming a plurality of detent receiving holes within said side of said gauge bar;  
       (b) installing said gauge bar transversely of the tufting machine so that said centerlines of said recesses extend toward the tufting zone of the tufting machine;  
       (c) producing a plurality of substantially identical modular block assemblies  blocks, wherein each said modular block assembly  has opposed parallel side surfaces, a bottom portion  surface, and a rear surface, and so that the width between said side surfaces is approximately equal to the width between the centerline of adjacent recesses in said gauge bar  and defines a hole therein;  
       (d) permanently embedding spaced gauging elements by their proximal end portions in each of said modular blocks has the same number of equally spaced, parallel gauging elements  , in parallel relationship to said side surfaces and  so that the gauging elements protrude from the respective bottom portions  surfaces of said modular blocks and so that the outermost gauging elements of each of said modular blocks are respectively spaced inwardly of said parallel side surfaces of each modular blocks by a distance equal to approximately one-half the distance between centerlines of said gauging elements;  
       (e) producing,  forming on the rear surface of each of said modular blocks, an elongated straight non-circular tabs, each of  tab, which is equally spaced from said side surfaces and is approximately the width of one of said recesses; and  
       (f) securing said modular blocks side-by-side on said side portion of said gauge bar and with  by passing a detent associated with each said modular block into each said respective hole in each said respective modular block and into one of said detent receiving holes so that the respective tabs of said modular blocks are received respectively in said recesses and  to secure each said respective modular block to said gauge bar in a vertically nonadjustable position so that all of said gauging elements extend toward the tufting zone of said tufting machine for , thereby spacing all of  said gauging elements from their adjacent gauging elements by substantially the same amount.  
     
     
       11. The process defined in claim  10  wherein the modular blocks are removably secured to said guide  gauge bar, and including the step of replacing selected modular blocks with new modular blocks whenever a gauging element is damaged . 
     
     
       12. The process defined in claim  11  including the steps  step of producing on said block  an alignment  abutment bar which is  on each said modular block, said abutment bar being perpendicular to the guide bar  elongated tab and abuts  abutting a surface of said guide  gauge bar member  when each respective one of said modular blocks is installed on said guide  gauge bar member . 
     
     
       13. The process defined in claim  12  wherein the step of securing said modular blocks to said guide  gauge bar includes the step of inserting the guide bar  tab of each said modular block in a channel  recess of said guide  gauge bar so that the abutment bar is spaced from said guide  gauge bar, and progressively moving each of said modular blocks transversely of  toward said guide  gauge bar for causing said abutment bar to abut said guide  gauge bar, and the step of securing the modular blocks on said guide  gauge bar include passing detents through said modular blocks and  includes threading said detent into a detent receiving hole of said guide  gauge bar. 
     
     
       14. The gauging modular  module assembly defined in claim  1  wherein said gauging elements are disposed in a plane parallel to the plane of said rear surface. 
     
     
       15. The gauging modular  module assembly defined in claim  1  wherein said detent includes a bolt individual to each of said respective modular blocks, and passing said detent through said respective modular block and through said tab for threadedly engaging said gauging  the gauge bar when said at least one tab is received within one  a respective one of the recesses of said spaced recesses and is at a prescribed position along said recess  on the gauge bar. 
     
     
       16. A  In a tufting machine of the type having a tufting zone and a gauging assembly, the improvement comprising: 
       (a) a gauge bar having a fast side surface and a second side surface, said gauge bar being provided with a plurality of equally spaced, straight, transverse, channel shaped, outwardly opening parallel, recesses, and said gauge bar defining detent receiving holes across at least a portion of said first side surface of said gauge bar, said recesses each opening sidewise along said second  first side surface, said recesses each being defined by a pair of opposed parallel sides;  
       (b) a plurality of generally rectangular modular blocks each having a flat rear surface for being received against said first side surface of said gauge bar, each of said modular blocks defining a hole therein;  
       (c) an alignment member secured to each of said modular blocks, said alignment member including:  
       (i) a  at least one tab conforming to the shape of said opposed sides and protruding from each of said modular blocks, said tab sized and shaped for being received therebetween  within at least one of the spaced recesses when that  the respective ones of said modular block  blocks containing said alignment member is  are received against said first side surface; and  
       (ii) a stop protruding from each of said modular blocks for engaging said second side surface and arresting movement of that modular block;  
       (d) a plurality of equally spaced parallel gauging elements protruding from said modular block toward said tufting zone; and  
       (e) a detent passing into the respective hole in each said modular block and into a detent receiving hole defined in the side surface of the gauge bar for removably securing each respective one of said modular blocks against said gauge bar and simultaneously urging the at least one tab of each of said modular blocks into at least one of said recesses when said at least one tab is received in a respective one of said recess  recesses and said stop engages the second side surface wherein each said modular block is secured in a vertically nonadjustable position with respect to said gauge bar.  
     
     
       17. The tufting machine defined in claim  16  wherein said first surface and said second surface interact essentially perpendicular to each other and wherein said tab extends to said stop. 
     
     
       18. The tufting machine defined in claim  16  wherein said stop forms a straight shoulder perpendicular to said tab and said recesses are perpendicular to said second surface. 
     
     
       19. The tufting machine defined in claim  16  wherein said gauging elements are  comprise loopers and said gauge bar is a looper bar. 
     
     
       20. The tufting machine defined in claim  14   16 wherein said gauging elements arecomprise reeds and said gauge bar is a bed railreed gauge bar and said modular block also is secured in a horizontally nonadjustable position with respect to said gauge bar. 
     
     
       21. The tufting machine defined in claim  16 , wherein said gauging elements comprise needles and said gauge bar comprises a needle bar.  
     
     
       22. The process defined in claim  10 , wherein said gauging elements comprise loopers.  
     
     
       23. The process defined in claim  10 , wherein said gauging elements comprise needles.  
     
     
       24. The process defined in claim  10 , wherein said gauging elements comprise reeds and wherein each said modular block also is secured to said gauge bar in a horizontally nonadjustable position.  
     
     
       25. The gauging module assembly defined in claim  1 , wherein said gauging elements comprise reeds and wherein said modular block also is held in a horizontally nonadjustable position with respect to said gauge bar.  
     
     
       26. A gauging module assembly for a tufting machine having an elongated gauge bar defining a substantially flat side extending along at least a portion of the length of the gauge bar, spaced recesses defined within the side of the gauge bar and extending at least partially along the length thereof and detent receiving holes defined within the side of the gauge bar, said gauging module assembly comprising: 
       
         a plurality of modular mounting blocks for being received on the side of the gauge bar, each said modular mounting block defining a hole therein and having:  
       
       ( i )  a rear surface;    
       ( ii )  spaced tufting machine gauging elements protruding from said modular mounting block, each said gauging element having a proximal end and a spaced distal end, the proximal ends of said gauging elements being embedded in said modular mounting block so that the distal ends of said gauging elements extend away from the modular mounting block; and    
       ( iii )  at least one tab on said rear surface, said at least one tab being sized and shape to be received within at least one of the recesses of said spaced recesses;    
       
         wherein each of said modular mounting blocks is constructed ad arranged to be mounted on the gauge bar, respectively, so that the respective rear surfaces of each of said modular mounting blocks are received flatly against the side of the gauge bar as said at least one tab of each said modular mounting block, respectively, is moved sidewise into one of the recesses of said spaced recesses defined within the side of the gauge bar; and  
       
       
         a detent associated with each said modular mounting block and passing into said respective hole in each said modular mounting block and into a detent receiving hole of sad gauge bar for urging each said associated modular muting block toward said gauge bar and said tab into at least one of said recesses and for removably securing each said associated modular mounting block to said gauge bar in a vertically nonadjustable position with respect to said gauge bar.  
       
     
     
       27. The gauging module assembly defined in claim  26 , wherein each said detent is constructed and arranged to be threadedly received in said detent receiving hole to urge the at least one tab of the modular mounting block into at least one of the recesses of said spaced recesses while also urging the rear surface of the modular mounting block against the side of the gauge bar.  
     
     
       28. The gauging module assembly defined in claim  26 , each said modular mounting block including a stop positioned on the rear surface of said modular mounting block for positioning said modular mounting block on the gauge bar as said at least one tab of the modular mounting block is moved into one of the recesses of said spaced recesses.  
     
     
       29. The gauging module assembly defined in claim  26 , wherein said gauging elements comprise loopers.  
     
     
       30. The gauging module assembly defined in claim  26 , wherein said gauging elements comprise needles.  
     
     
       31. A gauging module assembly for a tufting machine having an elongated gauge bar defining a substantially flat side extending along at least a portion of the length of the gauge bar, spaced recesses defined within the side of the gauge bar and extending at least partially along the length thereof and detent receiving holes defined within the side of the gauge bar, said gauging module assembly comprising: 
       
         a plurality of modular mounting blocks for being received on the side of the gauge bar, each said modular mounting block defining a hole therein and having:  
       
       ( i )  a rear surface;    
       ( ii )  spaced parallel tufting machine gauging elements protruding from said modular mounting block, each said gauging element having a proximal end and a spaced distal end, the proximal ends of said gauging elements being embedded in said modular mounting block so that the distal ends of said gauging elements extend away from the modular mounting block;    
       ( iii )  at least one tab on said rear surface; and    
       
         a detent individual to each of said modular mounting blocks for removably securing said modular mounting blocks, respectively, to said gauge bar, each said detent being constructed and arranged to urge the at least one tab of the respective modular mounting blocks sidewise into respective ones of the recesses of said spaced recesses while also urging the rear surface of the modular mounting block against the side of the gauge bar, said detent being received within said hole in an associated one of said modular mounting blocks and within a detent receiving hole of said gauge bar for removably securing said respective modular mounting block to said gauge bar in a vertically nonadjustable position with respect to said gauge bar.  
       
     
     
       32. The gauging module assembly defined in claim  31 , said at least one tab being sized and shaped to be received within at least one of the recesses of said spaced recesses.  
     
     
       33. The gauging module assembly defined in claim  31 , each said modular mounting block including a stop, said stop being positioned on the rear surface of said modular mounting block for positioning said modular mounting block on the gauge bar as said at least one tab of the modular mounting block is moved into one of the recesses of said spaced recesses.  
     
     
       34. The gauging module assembly defined in claim  33 , said modular mounting block including a bottom surface perpendicular to said rear surface, said stop being positioned on said rear surface adjacent said bottom surface and extending at least partially along the length of said bottom surface.  
     
     
       35. The gauging module assembly defined in claim  34 , wherein said stop comprises an elongate member extending parallel to said bottom surface.  
     
     
       36. The gauging module assembly defined in claim  31 , wherein the respective recesses of said spaced recesses each comprise a recessed channel defined within the side of the gauge bar.  
     
     
       37. The gauging module assembly defined in claim  36 , wherein the at least one tab of each said mounting block comprises a raised member defined on the rear surface of the modular mounting block, said raised member being sized and shaped to be received within one of said channels in the side of the gauge bar.  
     
     
       38. The gauging module assembly defined in claim  31 , wherein each said modular mounting block further comprises a pair of opposed and parallel side surfaces extending from said rear surfaces and wherein said modular mounting blocks are received on said gauge bar in a side- by - side relationship.    
     
     
       39. The gauging module assembly defined in claim  31 , wherein said gauging elements comprise loopers.  
     
     
       40. The au module assembly defined in claim  31 , wherein said gauging elements comprise needles.  
     
     
       41. A gauge module assembly for use on a tufting machine having an elongated gauge bar defining a substantially flat side extending along at least a portion of the length of the gauge bar, spaced recesses defined within the side of the gauge bar and extending at least partially along the length thereof and detent receiving holes defined within the side of the gauge bar, said gauging module assembly comprising: 
       
         a plurality of modular mounting blocks for being received on the side of the gauge bar, each said modular mounting block defining a hole therein and having:  
       
       ( i )  a rear surface, and a pair of opposed side surfaces extending from said rear surface;    
       ( ii )  spaced tufting machine gauging elements protruding from said modular mounting block, each said gauging element having a proximal end and a spaced distal end, the proximal ends of said gauging elements being embedded in said modular mounting block so that the distal ends of said gauging elements extend away from the modular mounting block;    
       ( iii )  at least one tab on said rear surface, said at least one tab being sized and shaped to be received within at least one of the recesses of said spaced recesses;    
       
         wherein each respective one of said modular mounting blocks is constructed and arranged to be mounted on said gauge bar by placing the rear surface of said modular mounting block on the side of the gauge bar and moving said at least one tab sidewise into at least one of the recesses of said spaced recesses;  
       
         and wherein said modular mounting blocks are received on the side of said gauge bar in a side - by - side relationship in which the side surfaces of each said modular mounting block are adjacent to the side surfaces of adjacent ones of said modular mounting blocks; and a detent individual to each of said modular mounting blocks for removably securing said modular mounting blocks, respectively, to said gauge bar by passing sad detent into said hole in said modular mounting block and into a detent receiving hole of said gauge bar, said detent for each said modular mounting block being constructed and arranged to urge the at least one tab of the modular mounting block into one of the recesses of said spaced recesses while also urging the rear surface of the modular mounting block against the side of the gauge bar wherein said modular mounting block is held in a vertically nonadjustable position with respect to said gauge bar.    
     
     
       42. The gauging module assembly defined in claim  41 , each said modular mounting block including a stop, said stop being positioned on the rear surface of said modular mounting block for positioning said modular mounting block on the gauge bar as said at least one tab of the modular mounting block is moved into one of the recesses of said spaced recesses.  
     
     
       43. The gauge module assembly defined in claim  41 , wherein said gauging elements comprise loopers.  
     
     
       44. The gauging module assembly defined in claim  41 , wherein said gauging elements comprise needles.  
     
     
       45. A gauging module assembly for use on a tufting machine having an elongated gauge bar, said gauge bar defining a substantially flat side extending along at least a portion of the length of said gauge bar and defining detent receiving holes within the side of the gauge bar, said gauging module assembly comprising: 
       ( a )  a plurality of modular mounting blocks for being received on the side of the gauge bar, each said modular mounting block defining a hole therein and having a rear surface and a plurality of spaced tufting machine gauging elements protruding from said modular mounting block, each said gauging element having a proximal end and a space distal end, the proximal ends of said gauging elements being embedded in said modular mounting block so that the distal ends of said gauging elements extend away from the modular mounting block;    
       ( b )  a plurality of spaced first mounts extending at least partially along the side of said gauge bar;    
       ( c )  a second mount on the rear surface of each said modular mounting block, each said second mount being constructed and arranged to be operably engaged with at least one of said first mounts for positioning said modular mounting blocks on said gauge bar; and    
       ( d )  a detent individual to each of said modular mounting blocks, the detent of each respective one of said modular mounting blocks being constructed and arranged to urge the rear surface of the modular mounting block sidewise against the side of the gauge bar and to simultaneously urge the respective ones of the first mounts and the second mounts into engagement with one another as said respective detent is passed into sad respective hole of each respective said modular mounting block and into a detent receiving hole in said gauge bar, wherein said modular mounting block is held in a vertically nonadjustable position with respect to said gauge bar.    
     
     
       46. The gauging module assembly defined in claim  45 , wherein each sad modular mounting block further comprises a pair of parallel and opposed side surfaces, and wherein said modular mounting blocks are received on said gauge bar in a side- by - side relationship.    
     
     
       47. The gauging module assembly defined in claim  46 , wherein said first mounts comprise sidewise opening recesses defined in said gauge bar and said second mounts comprise at least one tab.  
     
     
       48. The gauge module assembly defined in claim  45 , wherein said gauging elements comprise loopers.  
     
     
       49. The gauging module assembly defined in claim  45 , wherein said gauging elements comprise needles.  
     
     
       50. The gauging module assembly defined in claim  45 , each said modular mounting block including a stop positioned on the rear surface of said modular mounting block for positioning said modular mounting block on the gauge bar as said detent urges the respective ones of said modular mounting blocks against the side of the gauge bar.  
     
     
       51. In a tufting machine of the type in which a reciprocating needle gauge bar moves toward and away from a tufting zone as the loopers of the tufting machine are simultaneously reciprocated toward and away from the tufting zone, the improvement comprising: 
       ( a )  a flat side defined on the needle gauge bar, said flat side defining a plurality of spaced recesses therein, said flat side also defining a plurality of spaced detent receiving holes therein;    
       ( b )  a plurality of modular mounting blocks mounted side by side on said flat side of the needle gauge bar, each of said modular mounting blocks defining a hole therein;    
       ( c )  a plurality of spaced needles carried by each of said modular mounting blocks, said needles being embedded in each of said modular mounting blocks so that each said modular mounting block retains said needles in a spaced, parallel relationship with respect to one another according to a predetermined gauge of the tufting machine, each said modular mounting block including a tab for being received sidewise within one of said spaced recesses defined in said flat side of the needle gauge bar when said modular mounting blocks are moved toward said needle gauge bar; and    
       ( d )  a detent individual to each of said modular mounting blocks for removably securing that modular mounting block against the flat side of the needle gauge bar in a vertically nonadjustable position with respect to the needle gauge bar as said detent is passed into said respective hole in said modular block and into one of said detent receiving holes, said detent urging said tab into one of said spaced recesses and also urging said modular mounting block against said flat side of the needle gauge bar.    
     
     
       52. In a tufting machine of the type in which a reciprocating looper gauge bar moves toward and away from a tufting zone as the needles of the tufting machine are simultaneously reciprocated toward and away from the tufting zone for inserting yarns through a backing material, the improvement comprising: 
       ( a )  a reed gauge bar, said reed gauge bar defining a flat side, said flat side defining a plurality of spaced recesses therein, said flat side also defining a plurality of spaced detent receiving holes therein;    
       ( b )  a plurality of modular mounting blocks mounted side by side on said flat side of the reed gauge bar each of said modular mounting blocks defining a hole therein;    
       ( c )  a plurality of spaced reeds carried by each of said modular mounting blocks, said reeds being embedded in each of said modular mounting blocks so that each said modular mounting block retains the reeds in a spaced, parallel relationship with respect to one another according to a predetermined gauge of the tufting machine, each said modular mounting block including a tab for being received sidewise within one of said spaced recesses defined in said flat side of the reed gauge bar when said modular mounting blocks are moved toward said reed gauge bar; and    
       ( d )  a detent individual to each of said modular mounting blocks for removably securing that modular mounting block against the flat side of reed gauge bar in a horizontally nonadjustable position with respect to said reed gauge bar as said detent is passed into said respective hole in said modular block and into one of said detent receiving holes, said detent urging said tab into one of said spaced recesses and also urging said modular mounting block against said flat side of said reed gauge bar.