CARPET TUFTING MACHINE

BY : GIRISH YADAV

2014ME20727

INTRODUCTION :-
The appearances and performance of a particular carpet can be identified by
understanding its construction ,which could be loop, cut or amalgamation of
the both. In lobbies or corridors, school rooms, hotel rooms, hospitals or
health care facilities and other public areas, loop styles with low density
construction makes it to retain its look and resilience and mostly provide a
decent surface for the rolling tires of wheel chairs or food carts. Loop pile
and cut pile carpets are appropriate choices for administration peripheries,
huge libraries, offices and boardrooms.[4,5]

CONTENT :-
> BASIC TERMS AND OVERVIEW

> BRIEF PROCEDURE OF MANFACTURING CARPETS

> DETAILED MECHANISM OF TUFTING MACHINE

> MISCS

> REFRENCES
The creation of textiles like carpets takes place through a beautiful and
elegant mechanism called Tufting. It is done by multi-needle sewing
machines. A lot of rows of pile yarn are stitched by many needles
simultaneously with the help of a backing fiber known as primary backing
.The yarn is pushed by a needle through primary backing fiber, there the
yarn is held by a loop in that place which forms tuft, as the needle is
detached. The loppers will catch the yarn and kept in same place to make
any kind of loop-pile carpet or clipped by cutters to manufacture cut-pile
carpet.[7]

Fig 1.[7]

Brief description of the process in points:-

Yarn arrives from the cones over racks (creel),(or from huge spools
also known as beams) into the tufting machine .
Then backing (primary) is fed into machine backing (primary) and yarn
get together in machine on needle bar yarn is feeded through needles
of the machine.
Backing (primary) is continuously and repeatedly penetrated or tufted
by needles.
Then the carpet is inspected.
Then carped is ready to be shipped.
DETAILED MECHANISM:-
This assembly in fig 2. importantly consists of tufted fabric parts, fabric feed
parts, level loop yarn feed parts, tufting needles, jacquard parts and loopers.
[3]

Threading the pile yarn using a tufting needle is a fairly lengthy and complex
process. The pile yarn begin its journey from the cones and threads and
makes it way through the creel tube, the sub-line frame and the first yarn
guide. Respectively, level loop yarn feed system and jacquard system are
the next steps where pile yarn enters. It first enters the second yarn guide
and yarn path splitter, and after moving out of them pile yarn threads go
through the puller rollers and jacquard system. At the last step of this
complex but beautiful process, we see the pile yarn being threaded using a
tufting needed through a quite complicated path.

The provided basic working principle of carpet tufting is as it goes.

Hundreds of needles (tufting) are to be moved downwards with the help of
the prime axis system and sunk the yarn into the backing. When the tufting
needles are at lowest position while moving downwards , the yarn is hooked
by loopers underneath backing, which cooperate with the movement of
tufting needle with full precision.

After the main axis system drives the tufting needles in upward direction and
off the backing, the yarns made by loopers with the help of the loops on the
backside of the backing. When at the highest position of the tufting needles
in upwards direction, the loopers moves out from the pile loop which is
freshly formed. just Before the tufting needles starts movement in
downward direction again, the yarns spring-back procedure is finished. now
at this stage a whole pile loop in this process of tufting is finished. Generally
a pile-loop is made whenever the main axis completes one rotation,
therefore tufting needles will continue its movement in upwards and
downward direction reciprocally, repeating the same process again and
again. By controlling the speed of yarn-feeding we can obtain different pile
heights. Through a huge variety of carpet designs can be manufactured with
the help of horizontal movement of the hackle.
Fig 2. Typical carpet tufting equipment[2]

OUTCOMES AND RESULTS :-

Carpets are woven, tufted, needled and knotted from wool, man-made
fibres, hair cords, cotton and silk and . Tufted carpet is rich in colour, design
and variation, which holds and worth for 80% of the total carpet market .
Factory-finished tufted carpet, that can be used as both wall covering and
floor covering not only increases comfort level but also considerable edge in
terms of providing heat from insulation and the heat balance in huge
buildings. Now all-over sculptured-style jacquard carpet is internationally
accepted as the most advanced tufted carpet product. Figure 3 and Figure 4
shows two distinct sculptured-style jacquard carpets with different pile
heights.
Fig 3. Fig 4.

Despite of these advantages and such a huge demand there are lot of strict
testing levels for the judgment of the quality level of tufted carpet. If tufted
carpet is flawed even by a little margin then it will lower its rank, or it may
be simply discarded as treated as a waste. The stop mark[3] is a very
important factor which affects the quality of tufted carpet by great level. In
a general tufting process, presence of working procedures such as replacing
yarns and treatment of the broken ones, makes the stopping and restarting
the tufting machine almost inevitable, which makes the original pile yarn
work in a peculiar state and produce the uneven-loop process. Tufted carpet
produces stop marks or a low-loop at the stop position is pulled out, or a
whole row is pulled out , even many rows together of loops are pulled out,
which affect the quality of the carpet by a huge factor .

Fig 5 . stop marks.[3]

EPILOUGE :-
A lot of research is going on eliminating the errors[2] so as to improve the
quality of tufted carpets like one of the error is Stop mark various steps have
been made in order to remove this error most of these devices are examples
of engineering applications without proper and necessary theoretical
approach. The yarn tension and yarn creep characteristics are responsible
for stop mark : this was the finding by the Chinese researchers[by studying
the concept of yarn tension at highest and lowest position of needle while
tufting] :

Xu Y, Sun Z, Meng Z, Sun Y. Research on Mechanism Analysis and Elimination

Method for the Tufted Carpet Stop Mark.

Which is surely a great effort in this direction but this method also leaves behind some
unsolved queries which are to be solved in future with right approach.

REFRENCES:-
1. http://www.google.co.in/patents/US2600993
2. http://dynamicsystems.asmedigitalcollection.asme.org/data/Journals/JMSEFK/
28465/031002_1.pdf
3. http://www.fibtex.lodz.pl/2014/3/66.pdf
4. http://tufting.groz-beckert.com/pages/en_tufting_principles.php
5. https://en.wikipedia.org/wiki/Tufting
6. https://www.youtube.com/watch?v=F4aGwtrhFHY
7. http://www.carpet-rug.org/carpet-and-rug-construction-business.html