Circular knitting machine capable of immediately prompting state of knitting machine

Abstract

The invention relates to a circular knitting machine capable of immediately prompting the state of the knitting machine. The circular knitting machine is provided with a base, a cloth rolling machine, a main camera shooting module and an auxiliary camera shooting module, wherein the cloth rolling machine rotates relative to the base when knitting operation is carried out; the main camera shooting module is fixed on the base, and the auxiliary camera shooting module is fixed on the base and is arranged close to the main camera shooting module. The main camera shooting module is provided with a first middle shaft, and the main camera shooting module shoots a cylindrical fabric woven by the circular knitting machine. The auxiliary camera shooting module is provided with a second center shaft staggered with the first center shaft, the auxiliary camera shooting module and the main camera shooting module face the same side of the cylindrical fabric, and the auxiliary camera shooting module is started only when one of the connecting rods passes through the space between the main camera shooting module and the cylindrical fabric. Data generated by the main camera module and the auxiliary camera module are used for knowing the state of the circular knitting machine.

Description

Technical Field

[0001] This invention provides a circular knitting machine, and more particularly a circular knitting machine that can determine the state of the knitting needles by the knitting result of the tubular fabric during knitting operations. Background Technology

[0002] The knitting quality of a circular knitting machine is equivalent to the presence of defects in the fabric surface. The occurrence of defects is closely related to the condition of the needles on the machine. When the lower edge of a needle's foot is excessively worn, the upward push height of that needle will not reach the expected height, leading to the following: the latch cannot fully open; old loops are not cleared (the needle knits incorrectly with double yarn); and the hook cannot catch new yarn (holes appear in the fabric). Conversely, when the upper edge of a needle's foot is excessively worn, the following will occur: old loops cannot be properly disengaged (holes appear in the fabric, and abnormal lines and textures are visually apparent after knitting); the knitted loops are smaller than the previously knitted loops (abnormal lines and textures are visually apparent in the fabric).

[0003] While there are existing technical solutions for inspecting fabric quality, such as those disclosed in patents CN102778414A, CN102967606A, CN103451846A, CN103604809A, CN108364291A, CN108921819A, CN109696442A, and CN110389130A, these technologies only inspect the quality of the knitted fabric after the circular knitting machine has finished knitting. Even if defects are found in the fabric, it is impossible to determine which part of the circular knitting machine's needles needs to be replaced. As a result, when manufacturers discover that the fabric has defects, the common practice is to replace all the needles on the circular knitting machine. Circular knitting machines typically have 1500 to 2640 needles, and replacing too many needles at once makes it time-consuming and costly to evaluate the condition of all needles. This results in a waste of resources and indirectly increases the production costs for producers.

[0004] Furthermore, US04748334A, CN114808260A, and CN104178907A disclose a circular knitting machine with a fabric winding mechanism. During the knitting operation, the fabric winding mechanism rotates and simultaneously winds up the completed fabric. However, the multiple linkages of the fabric winding mechanism can affect the image recognition of the outer side of the tubular fabric, which needs to be improved. Summary of the Invention

[0005] The main objective of this invention is to solve the problem that existing circular knitting machines equipped with fabric winding mechanisms need to perform image recognition on the outer side of tubular fabrics.

[0006] To achieve the above objectives, the present invention provides a circular knitting machine with real-time status indication. The circular knitting machine has a base, a cylinder that rotates relative to the base during knitting operations, and a fabric winding machine that rotates relative to the base along with the cylinder during knitting operations. The fabric winding machine includes a winding rod and multiple connecting rods connected to the winding rod, the connecting rods being displaced relative to the base when the fabric winding machine rotates. Further, the circular knitting machine includes a main camera module fixed to the base and a secondary camera module fixed to the base and disposed near the main camera module. The main camera module has a first central axis and captures images of a tubular fabric rotating with the cylinder. The secondary camera module has a second central axis intersecting the first central axis, and the secondary camera module is activated only when one of the connecting rods passes between the main camera module and the tubular fabric. The information generated by the main camera module and the secondary camera module is used to understand the status of the circular knitting machine.

[0007] In one embodiment, the circular knitting machine includes an encoder that generates multiple pulse signals when the needle cylinder rotates, and the multiple capture signals of the main camera module and the auxiliary camera module are generated based on counting these pulse signals.

[0008] In one embodiment, the capturing signals of the main camera module are generated by factoring the total number of pulse signals when the syringe rotates once.

[0009] In one embodiment, the number of shots taken by the main camera module can be divided equally by the central angle and also by the total number of knitting needles belonging to the cylinder.

[0010] In one embodiment, the circular knitting machine includes a data processor that receives multiple image data provided by the main camera module and the secondary camera module, and the data processor causes each of the image data to be image compared only with another of the image data located on the same vertical line of the tubular fabric.

[0011] In one embodiment, each of the image data generated by the main camera module includes multiple horizontal loop images, each of the horizontal loop images corresponding to one of the multiple needles on the circular knitting machine. The number of horizontal loop images included in the image data generated by the main camera module is similar or equal, and the number of horizontal loop images included in the image data generated by the secondary camera module is similar or equal.

[0012] In one embodiment, each of the image data contains a plurality of longitudinal loop images, and the sum of the lengths of the longitudinal loop images in each of the image data is proportional to the amount of fabric dropped in one revolution of the syringe.

[0013] In one embodiment, the circular knitting machine has two main camera modules, which face an outer side and an inner side of the tubular fabric, respectively. One of the main camera modules facing the outer side is adjacent to a secondary camera module, which faces the outer side of the tubular fabric.

[0014] In one embodiment, the two main camera modules are at different horizontal heights.

[0015] In one embodiment, the base has a suspension arm that provides one of the two main camera modules facing the inner side of the tubular fabric.

[0016] In one embodiment, the data processor receives multiple image data provided by the two main camera modules and the secondary camera module, and the data processor causes each of the image data to be compared with only one of the image data located on the same vertical line of the tubular fabric.

[0017] Compared to existing technologies, the circular knitting machine of this invention, through the aforementioned technical implementation, has the following advantages: By using a main camera module and a secondary camera module, the circular knitting machine of this invention solves the problem of poor quality inspection caused by fabric rolling machines. The information generated by the main camera module and the secondary camera module can be used to understand the status of the circular knitting machine, clearly identifying which needles on the machine may be faulty, thus solving the waste caused by the previous method of replacing the entire batch. Furthermore, this invention allows operators of the circular knitting machine to react quickly to repairs, avoiding the discovery of defects in the finished product only after the entire knitting operation is completed. Attached Figure Description

[0018] Figure 1 This is a partial structural schematic diagram of the circular knitting machine of the present invention.

[0019] Figure 2 This is a bottom view of a partial structure of the circular knitting machine of the present invention.

[0020] Figure 3 This is a partial structural cross-sectional schematic diagram of the circular knitting machine of the present invention.

[0021] Figure 4 This is a bottom view schematic diagram of a partial structure of the circular knitting machine of the present invention.

[0022] Figure 5 This is a schematic diagram of a partial structural cross-section of the circular knitting machine of the present invention.

[0023] Figure 6 This is a schematic diagram of a unit in the first embodiment of the circular knitting machine of the present invention.

[0024] Figure 7 This is a schematic diagram of the image data provided by the main photography module of the present invention.

[0025] Figure 8 This is a schematic diagram of a unit in the second embodiment of the circular knitting machine of the present invention.

[0026] Figure 9 This is a schematic diagram of a unit in the third embodiment of the circular knitting machine of the present invention. Detailed Implementation

[0027] Please see Figures 1 to 3 This invention provides a circular knitting machine 20, which can provide real-time indication of the knitting machine status during knitting operations by observing the looping state of a tubular fabric. First, the basic structure of the circular knitting machine 20 is described. The machine includes a base 21, a cylinder 22, and a fabric winding machine 23. During knitting operations, the cylinder 22 rotates relative to the base 21 to engage with a knitting needle structure (not shown, but this knitting structure is common knowledge in the art) on the base 21 to knit a tubular fabric 30. The tubular fabric 30 rotates with the cylinder 22. The fabric winding machine 23 is mainly used to wind up the tubular fabric 30. During knitting operations, the fabric winding machine 23 rotates relative to the base 21 along with the cylinder 22. The structure of the fabric winding machine 23 is as disclosed in CN114808260A, but is not limited to the foregoing example. The fabric winding machine 23 includes a winding rod 231 and a plurality of connecting rods 232 connected to the winding rod 231. The connecting rods 232 are displaced relative to the base 21 when the fabric winding machine 23 rotates.

[0028] Please refer to the following: Figures 1 to 3 The circular knitting machine 20 of the present invention further includes a main camera module 24 and a secondary camera module 25. The main camera module 24 is fixed to the base 21. The main camera module 24 faces the side of the tubular fabric 30, more specifically, the tubular fabric 30 has an outer side 301 and an inner side 302. In this embodiment, the main camera module 24 faces the outer side 301 of the tubular fabric 30. The main camera module 24 captures images of the tubular fabric 30 as it rotates with the needle cylinder 22 based on control. On the other hand, the secondary camera module 25 is fixed to the base 21 and is positioned close to the main camera module 24. Viewed from a low angle of the base 21 (e.g.) Figure 2The secondary camera module 25 is not parallel to the main camera module 24, and its imaging range overlaps with that of the main camera module 24. Furthermore, the main camera module 24 has a first central axis 241, and the secondary camera module 25 has a second central axis 251, which intersects with the first central axis 241. Moreover, the secondary camera module 25 and the main camera module 24 face the same side of the tubular fabric 30, i.e., the secondary camera module 25 faces the outer side 301 of the tubular fabric 30. The activation timing of the secondary camera module 25 differs from that of the main camera module 24; it is activated only when one of the connecting rods 232 passes between the main camera module 24 and the tubular fabric 30. The secondary camera module 25 is designed to address the problem that the main camera module 24 is blocked by one of the connecting rods 232 and cannot photograph the tubular fabric 30.

[0029] As described above, when the circular knitting machine 20 performs knitting operations, the tubular fabric 30 rotates with the needle cylinder 22, and the main camera module 24 continuously captures images of the tubular fabric 30 based on control. Figure 4 and Figure 5 As shown. Because the main camera module 24 is fixed, the fabric rolling machine 23 rotates with the syringe 22. When the fabric rolling machine 23 rotates to a point where it affects the main camera module 24's ability to photograph the tubular fabric 30, the secondary camera module 25 will be triggered to take at least one photograph of the tubular fabric 30. Figure 2 and Figure 3 As shown. The data generated by the main camera module 24 and the auxiliary camera module 25 will be used to understand the status of multiple needles on the circular knitting machine 20. The data generated by the auxiliary camera module 25 compensates for the portion that the main camera module 24 cannot capture due to being blocked by one of the connecting rods 232. The data generated by the main camera module 24 and the auxiliary camera module 25 can understand the status of multiple needles (not shown) on the circular knitting machine 20 through the rings on the tubular fabric 30, thereby enabling rapid response and maintenance, and avoiding the discovery of defects in the finished product only after the entire knitting operation is completed. Furthermore, the present invention solves the problem of resource waste caused by the prior art, which cannot check the status of each needle on the circular knitting machine individually and can only replace the entire batch of needles.

[0030] It should be understood that the main camera module 24 of the present invention does not continuously photograph the tubular fabric 30 and does not generate video data. The main camera module 24 only photographs the tubular fabric 30 during doffing when it is under control.

[0031] Please refer to the accompanying text. Figure 6In one embodiment, the circular knitting machine 20 has an encoder 26 that generates multiple pulse signals 261 when the cylinder 22 rotates. Multiple capture signals from the main camera module 24 and the auxiliary camera module 25 are generated based on counting these pulse signals 261. The main camera module 24 starts capturing images at continuous intervals, and these capture signals can be activated when the number of pulse signals 261 generated reaches a certain value. In one embodiment, to simplify subsequent data comparison, the capture signals from the main camera module 24 are generated by counting the total number of pulse signals 261 generated when the cylinder 22 rotates once. For example, if the encoder 26 generates a total of 2640 pulse signals 261 in one rotation of the cylinder 22, the count value can be selected to be divisible by 2640, such as 88, and the portion used to control the main camera module 24, or the main camera module 24 itself, will capture an image every time 88 pulse signals 261 are received. Continuing from the above, the number of shots taken by the main camera module 24 is the quotient obtained by dividing the count value by the total number of pulse signals 261. For example, when the syringe 22 rotates once, the main camera module 24 takes 30 shots. Furthermore, the number of shots taken by the main camera module 24 can be evenly divided by the central angle, reducing overlapping shots from affecting subsequent interpretation, and distinguishing the specific location of each shot, which is beneficial for subsequent rapid repair.

[0032] Please refer to the following: Figure 6 In one embodiment, the main camera module 24 includes a controller 242 and a camera head 243 controlled by the controller 242. The main camera module 24 is connected to the encoder 26 to obtain the pulse signals 261, and the controller 242 controls the camera head 243 to start shooting based on the pulse signals 261. On the other hand, the secondary camera module 25 includes a controller 252 and a camera head 253 controlled by the controller 252. The secondary camera module 25 is connected to the encoder 26 to obtain the pulse signals 261, and the controller 252 controls the camera head 253 to start shooting based on the pulse signals 261. In addition, the main camera module 24 and the secondary camera module 25 can also be controlled by an external control device. The external control device is connected to the encoder 26 to obtain the pulse signals 261 and controls the main camera module 24 and the secondary camera module 25 to perform shooting based on the pulse signals 261.

[0033] Following on above, please pair with... Figure 6 and Figure 7The data generated by the main camera module 24 and the auxiliary camera module 25 can be analyzed by an external computing device or a computing unit on the circular knitting machine 20. In one embodiment, the circular knitting machine 20 includes a data processor 27, which stores multiple computing programs. The data processor 27 is connected to the main camera module 24 and the auxiliary camera module 25. The data processor 27 receives multiple image data 244, 254 generated by the main camera module 24 and the auxiliary camera module 25, and performs calculations and comparisons using its own computing programs. Further, the data processor 27 causes each of the image data 244, 254 to be compared only with another of the image data 244, 254 located on the same vertical line 303 of the tubular fabric 30. Specifically, such as one of the image data 244 (e.g. Figure 7 A) shown is the 24th image data captured by the main camera module 24 during one rotation of the syringe 22. The image data compared to this is the 24th image data captured by the main camera module 24 during the previous rotation of the syringe 22 (e.g., A). Figure 7 As shown in B). Two of the aforementioned image data 244 are continuous on the vertical line 303. After comparing the two, the data processor 27 detects a difference and indicates the status of the knitting machine. This is because the difference is caused by a problem with at least one of the needles on the circular knitting machine 20, resulting in different knitting results. The comparison by the data processor 27 can be based on the comparison of color pixels or other image recognition calculation programs. Furthermore, in one embodiment, the image data 254 generated by the sub-camera module 25 are determined independently. That is, the image data 254 generated by the sub-camera module 25 will not be integrated with the image data 244 generated by the main camera module 24 to form an image representing the complete loop of the tubular fabric 30, thereby simplifying the calculation program of the data processor 27 and avoiding erroneous judgments caused by splicing images. Please refer to Figure 8 In one embodiment, the data processor 27 may also be connected to the encoder 26 to receive the pulse signals 261, thereby controlling the main camera module 24 and the auxiliary camera module 25 to take pictures.

[0034] Furthermore, each of the image data 244 generated by the main camera module 24 contains multiple horizontal loop images, each of which corresponds to one of the knitting needles on the circular knitting machine 20. The number of horizontal loop images contained in the image data 244 generated by the main camera module 24 is similar or equal. Therefore, by observing at least one of the differing horizontal loop images, it can be determined which of the knitting needles is malfunctioning and needs replacement. Similarly, each of the image data 254 generated by the secondary camera module 25 also contains multiple horizontal loop images, each of which also corresponds to one of the knitting needles on the circular knitting machine 20. The number of horizontal loop images contained in the image data 254 generated by the secondary camera module 25 is similar or equal. Furthermore, each of the image data 244 and 254 generated by the main camera module 24 and the auxiliary camera module 25 contains multiple longitudinal ring images, and the sum of the lengths of the longitudinal ring images in each of the image data 244 (254) is proportional to the amount of fabric dropped by the syringe 22 in one rotation.

[0035] Please refer to the following: Figures 1 to 3 and Figure 9 In one embodiment, the circular knitting machine 20 has two main camera modules 24, which face the outer side 301 and the inner side 302 of the tubular fabric 30, respectively. A secondary camera module 25 is adjacent to one of the main camera modules 24 facing the outer side 301, and the secondary camera module 25 faces the outer side 301 of the tubular fabric 30. In one embodiment, the two main camera modules 24 are at different horizontal heights. One of the main camera modules 24 facing the inner side 302 is suspended within the area enclosed by the needle cylinder 22, or more precisely, suspended within the tubular fabric 30. In one embodiment, the base 21 has a suspension arm 211 for one of the two main camera modules 24 facing the inner side 302 of the tubular fabric 30. The shooting control of the two main camera modules 24 is as described above and will not be repeated here. In this embodiment, the circular knitting machine 20, which can be used to knit double-sided fabrics with the aforementioned structure, can quickly determine whether the knitting needles or related knitting pieces used for double-sided knitting on the circular knitting machine 20 are damaged or erroneously operated based on the knitting results of the tubular fabric 30.

[0036] Furthermore, the image data 244 generated by the two main camera modules 24 are not limited to parallel comparison; that is, the image data 244 can be divided into the outer portion 301 and the inner portion 302 for separate processing. Of course, when the image data 244 generated by the two main camera modules 24 are compared in parallel, the data processor 27 needs to use a calculation program to correlate and compare two of the image data 244 representing the same part of the tubular fabric 30.

[0037] [Explanation of Symbols in the Attached Drawings]

[0038] 20: Circular knitting machine

[0039] 21: Base

[0040] 211: Suspension arm

[0041] 22: Syringe

[0042] 23: Fabric rolling machine

[0043] 231: Fabric Rolling Rod

[0044] 232: Linkage

[0045] 24: Main camera module

[0046] 241: First Central Axis

[0047] 242: Controller

[0048] 243: Camera Head

[0049] 244: Image Data

[0050] 25: Secondary camera module

[0051] 251: Second Central Axis

[0052] 252: Controller

[0053] 253: Camera Head

[0054] 254: Image Data

[0055] 26: Encoder

[0056] 261: Pulse signal

[0057] 27: Data Processor

[0058] 30: Tubular fabric

[0059] 301: Outer side

[0060] 302: Inner side

[0061] 303: Vertical line

[0062] A and B: Comparators.

Claims

1. A circular knitting machine with real-time status indication, the circular knitting machine having a base, a needle cylinder that rotates relative to the base during knitting operations, and a fabric winding machine that rotates relative to the base along with the needle cylinder during knitting operations, the fabric winding machine including a winding rod and a plurality of connecting rods connected to the winding rod, the connecting rods being displaced relative to the base when the fabric winding machine rotates, the circular knitting machine being characterized in that... Include: A main camera module, fixed to the base, has a first central axis and captures images of a tubular fabric rotating with the syringe. A secondary camera module is fixed on the base and positioned close to the main camera module. The secondary camera module has a second central axis that intersects with the first central axis. The secondary camera module and the main camera module face the same side of the tubular fabric. The secondary camera module is activated only when one of the connecting rods passes between the main camera module and the tubular fabric. The data generated by the main camera module and the auxiliary camera module are used to understand the status of the circular knitting machine.

2. The circular knitting machine with real-time status indication as described in claim 1, characterized in that, The circular knitting machine includes an encoder that generates multiple pulse signals when the needle cylinder rotates. The multiple capture signals of the main camera module and the auxiliary camera module are generated based on counting these pulse signals.

3. The circular knitting machine with real-time knitting machine status indication as described in claim 2, characterized in that, The capture signals of the main camera module are generated by factoring the total number of pulse signals when the syringe rotates once.

4. The circular knitting machine with real-time knitting machine status indication as described in claim 2, characterized in that, The number of shots taken by the main camera module can be evenly divided by the central angle and is also divisible by the total number of needles belonging to the cylinder.

5. The circular knitting machine with real-time knitting machine status indication as described in any one of claims 1 to 4, characterized in that, The circular knitting machine includes a data processor that receives multiple image data provided by the main camera module and the auxiliary camera module. The data processor causes each of these image data to be compared with only one of the image data located on the same vertical line of the tubular fabric.

6. The circular knitting machine with real-time knitting machine status indication as described in claim 5, characterized in that, The image data contains multiple horizontal loop images, each of which corresponds to one of the multiple needles on the circular knitting machine. The number of horizontal loop images contained in the image data generated by the main camera module is similar or equal, and the number of horizontal loop images contained in the image data generated by the secondary camera module is similar or equal.

7. The circular knitting machine with real-time knitting machine status indication as described in claim 6, characterized in that, Each of these image data contains multiple longitudinal loop images, and the sum of the lengths of the longitudinal loop images in each of these image data is proportional to the amount of fabric dropped in one revolution of the syringe.

8. The circular knitting machine with real-time knitting machine status indication as described in any one of claims 1 to 4, characterized in that, The circular knitting machine has two main camera modules, which face one outer side and one inner side of the tubular fabric, respectively. One of the main camera modules facing the outer side is adjacent to a secondary camera module, which faces the outer side of the tubular fabric.

9. The circular knitting machine with real-time knitting machine status indication as described in claim 8, characterized in that, The two main camera modules are at different horizontal heights.

10. The circular knitting machine with real-time knitting machine status indication as described in claim 9, characterized in that, The base has a suspension arm that provides one of the two main camera modules facing the inner side of the tubular fabric.

11. The circular knitting machine with real-time knitting machine status indication as described in claim 8, characterized in that, The circular knitting machine includes a data processor that accepts multiple image data provided by the two main camera modules and the auxiliary camera module. The data processor causes each of the image data to be compared with only one of the image data located on the same vertical line of the tubular fabric.

12. The circular knitting machine with real-time knitting machine status indication as described in claim 11, characterized in that, Each of these image data contains multiple transverse loop images, each of which corresponds to one of multiple needles on the circular knitting machine, and the number of transverse loop images contained in these image data is similar or equal.

13. The circular knitting machine with real-time knitting machine status indication as described in claim 12, characterized in that, Each of these image data contains multiple longitudinal loop images, the sum of which is proportional to the amount of fabric dropped in one rotation of the syringe.

Images