Web-fed chain-stitch single-needle mattress cover quilter with needle deflection compensation

Abstract

A quilting machine is provided having at least one set of single needle stitch forming elements for forming chain stitched patterns on a thick multilayered material such as a mattress cover. The machine is preferably web-fed, with a panel of the continuous web being clamped and held stationary on a frame. The stitch forming elements include a needle and a looper mounted on separate heads that are independently moveable on a bridge transversely relative to the panel, which is moveable longitudinally relative to the frame. The bridge is longitudinally moved by a servo and the heads are transversely moved on the bridge by separate servos. The stitching elements on each head are driven by separate servos. A controller drives the servos to chain stitch patterns and differentially move the heads transversely to account for transverse needle deflection. The drives of the needle and looper are phased to compensate for longitudinal needle deflection. The controller determines or predicts needle deflection. It may store empirically determined data and respond to control signals and/or sensors to determine or predict deflection and to calculate the needle deflection compensation, in response to which it generates deflection compensation signals to drive the servos. Infrared, LED or magnetic deflection sensors are preferred, but many other types are or will become available that will be suitable.