Dial adjusting device and method of circular knitting machine

Abstract

The invention discloses a dial adjusting device and method of a circular knitting machine, and relates to the technical field of knitting machinery. The device comprises a high-precision displacement sensor module, a triangular seat type intelligent identification module and an intelligent control and visualization terminal. The displacement of the knitting needle is measured in real time through the sensor, the waveform is intelligently analyzed by the recognition module to judge the type and the road number of the triangular seat and calculate the displacement peak value, and the terminal compares the standard value and graphically displays the adjustment deviation and the guide information. According to the invention, the problems of low precision, poor efficiency and poor consistency existing in the existing adjustment depending on artificial experience are solved, the rapid, high-precision and visual calibration of the triangular seat is realized, and the cloth cover quality and the production efficiency are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of knitting machinery technology, and in particular to a needle plate adjustment device and adjustment method for a circular knitting machine. Background Technology

[0002] The circular knitting machine is the core equipment for producing knitted fabrics. Its working principle is as follows: the main shaft drives the needle plate, needle cylinder, and cam set to rotate synchronously. While the needles revolve with the needle plate, their needle heels are constrained by the track on the cam set, making regular up-and-down reciprocating movements. This, in conjunction with the yarn feeding and tensioning mechanisms, completes the loop-forming process. The cam set, as the core component controlling the movement trajectory of the needles, is typically divided into different types depending on the fabric structure requirements, such as loop-out cam sets, loop-in cam sets, and flat loop cam sets. Various weaving processes can be achieved through the arrangement and combination of different types of cam sets.

[0003] The consistency of the track height on the cam set is crucial, as it directly determines the uniformity of needle displacement at the highest and lowest points, thus affecting yarn tension uniformity and fabric quality. Inconsistent cam set positions can easily create "needle path" defects on the fabric, leading to yarn breakage and other problems. Therefore, when changing fabric types or adjusting processes, all cam sets of the same type on the needle plate must be precisely adjusted to ensure their tracks are aligned.

[0004] Currently, the industry primarily relies on manual adjustments based on experience. A slightly improved method is to use mechanical or electronic displacement gauges for "dial" measurements to assist in adjustments (using, for example...). Figure 1 The measurement auxiliary device shown can be used in accordance with the method of using a triangular seat correction device for the lower plate of a single or double-sided large circular machine disclosed in patent publication number CN211136150U.

[0005] However, when adjusting using the above method, the high speed of the knitting needles, especially the fleeting highest point of the exit cam, makes it extremely difficult for operators to accurately capture. Once missed, the operator must wait for the next knitting cycle, making the adjustment process cumbersome and inefficient. Therefore, this method heavily relies on the skill and experience of the knitting operator, and generally suffers from low adjustment accuracy (typically with an error exceeding ±0.01mm), long processing time (a single production changeover often requires several hours to several days), and poor consistency, severely hindering the improvement of production efficiency and product quality. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the purpose of this invention is to provide a needle plate adjustment device and adjustment method for a circular knitting machine, so as to solve the problems of high-precision, fast and intelligent adjustment of the needle position of the cam seat, reduce the operation threshold and ensure the quality of the fabric.

[0007] A needle plate adjustment device for a circular knitting machine includes: The high-precision displacement sensor module has a first contact part at one end of its measuring rod for contacting the top of the knitting needle, which is used to collect the displacement data of the knitting needle in real time when the needle plate rotates; The intelligent identification module for the type of triangular seat is connected to the high-precision displacement sensor module to receive and process displacement data in order to automatically identify the type, track number, and high and low point coordinates of the corresponding needle running trajectory of the triangular seat on the needle plate. A multi-degree-of-freedom magnetic support has a strong magnetic adsorption base and a multi-directional adjustable linkage mechanism, used to adsorb and fix the high-precision displacement sensor module and / or the triangular seat type intelligent recognition module near the needle plate of a circular knitting machine. The intelligent control and visualization terminal communicates with the triangular seat type intelligent recognition module to receive recognition results and coordinate data, has a built-in standard parameter library and calculates the adjustment deviation between the current position of the knitting needle and the standard position, and generates a visual operation guide that includes the adjustment direction and value.

[0008] In this invention, the high-precision displacement sensor module adopts grating measurement technology, with a measurement accuracy of ≤0.001mm, a response speed of ≥2kHz, and a measurement range of 0-20mm; the measuring rod has a bidirectional measurement function, with a first contact part at one end being a disc structure for detecting the highest point of the knitting needle, and a second contact part at the other end being a hook structure for detecting the lowest point of the knitting needle, and the measuring rod has a built-in automatic springback mechanism.

[0009] In this invention, the intelligent identification module for the type of knitting needle is integrated with an MCU. It processes displacement data through built-in peak capture, filtering algorithms and knitting needle type identification algorithms, identifies the type of knitting needle including out-of-loop knitting needle, loop-containing knitting needle and flat loop knitting needle, and can calculate the displacement values ​​of the highest and lowest points of the track of the knitting needle on various types of knitting needles.

[0010] In this invention, the strong magnetic adsorption base of the multi-degree-of-freedom magnetic bracket has an adsorption force of ≥50kg, and the linkage mechanism supports 360° rotation and multi-dimensional angle and position adjustment to adapt to the installation requirements of single-sided or double-sided circular knitting machines at different positions.

[0011] In this invention, the intelligent control and visualization terminal is a portable tablet computer with a built-in dedicated APP. The APP has functions such as parameter setting, data acquisition and control, adjustment calculation, dynamic deviation display, and adjustment completion judgment. It can also store and manage the standard needle height and low point parameters of different fabrics.

[0012] In this invention, the triangular seat type intelligent identification module is connected to the intelligent control and visualization terminal via a TYPE-C interface to achieve power supply and data communication; the high-precision displacement sensor module is connected to the triangular seat type intelligent identification module via a dedicated interface.

[0013] The present invention also provides a method for adjusting the needle plate of a circular knitting machine based on the above-mentioned device, characterized by comprising the following steps: S1: Device Deployment and Data Acquisition: Fix the device to the side of the needle plate using a multi-degree-of-freedom magnetic bracket, so that the first contact part of the measuring rod of the displacement sensor abuts against the top of the knitting needle; start the device and set the circular knitting machine to run at low speed. The displacement sensor collects the knitting needle displacement data in real time, and the data is received by the intelligent recognition module. S2: Intelligent Recognition and Deviation Calculation: The intelligent recognition module processes the collected displacement data and automatically identifies the type and number of the triangular seat on the current scanning path, as well as the actual high and low point coordinates of the needle when passing through each triangular seat; the intelligent control terminal retrieves the preset standard high and low point coordinates and calculates the deviation value between the actual coordinates of each needle and the standard coordinates. S3: Visualized Guided Adjustment: The operator adjusts according to the adjustment instructions displayed on the intelligent control terminal. The adjustment instructions include the path number to be adjusted, the adjustment direction, and the specific adjustment amount. The operator moves the triangular seat to be adjusted to an operable position by jogging the dial. The operator then rotates the corresponding dial according to the instructions to make the adjustment. During the adjustment process, the displacement sensor provides real-time feedback on the displacement change, and the terminal dynamically updates the current deviation display. S4: Adjustment Completion Judgment and Batch Calibration: When the terminal displays that the adjustment deviation value of the current path has entered the preset qualified threshold range, it indicates that the adjustment of the path is complete; repeat step S3 until all needle paths that need to be adjusted have been adjusted; the data acquisition process can be restarted to verify the overall adjustment effect.

[0014] Furthermore, in step S2, the intelligent recognition module adopts a peak capture algorithm with a response time ≤0.5ms to accurately capture the instantaneous displacement value of the highest point of the triangular base.

[0015] Furthermore, the acceptable threshold range mentioned in step S3 is that the deviation between the actual high and low point coordinates and the standard coordinates is ≤ ±0.002mm.

[0016] Furthermore, the method also includes step S5: data recording and tracing, wherein the intelligent control terminal automatically saves the final data of each adjustment, including the delta seat number, the displacement value before and after adjustment, and the adjustment time, forming a traceable adjustment record file.

[0017] The beneficial effects of this invention are: This invention uses a high-precision displacement sensor to capture the displacement of rapidly moving knitting needles in real time. An intelligent recognition algorithm automatically and accurately identifies the type and path number of the cam seat and calculates the peak displacement. The deviation is then visually displayed on a terminal, providing precise real-time adjustment guidance. This solution effectively overcomes the drawbacks of manual dial-up adjustments, which struggle to capture instantaneous high points and rely on experience. It improves adjustment accuracy to the ±0.002mm level, significantly shortening changeover and debugging time, ensuring the consistency of the cam seat height, and fundamentally solving the problems of fabric "needle path" defects and yarn breaks caused by inconsistent cam seat positions. This greatly improves production efficiency and product quality. Attached Figure Description

[0018] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the measurement auxiliary device in the background art; Figure 2 This is a schematic diagram of the needle plate adjustment device in this embodiment; Figure 3 This is a schematic diagram showing the usage state of the needle plate adjustment device in this embodiment; Figure 4 This is a flowchart of the adjustment method in this embodiment; The attached figures are labeled as follows: 1. High-precision displacement sensor module; 11. Measuring rod; 12. Disc; 13. Hook; 2. Triangular seat type intelligent recognition module; 3. Multi-degree-of-freedom magnetic bracket; 31. Strong magnetic adsorption base; 32. Linkage mechanism; 4. Intelligent control and visualization terminal; 5. Needle plate. Detailed Implementation

[0019] This invention provides a needle plate adjustment device and method for a circular knitting machine. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention.

[0020] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0021] like Figure 2As shown in the figure, this embodiment discloses a needle plate adjustment device for a circular knitting machine, which mainly consists of a high-precision displacement sensor module 1, a triangular seat type intelligent recognition module 2, a multi-degree-of-freedom magnetic support 3, and an intelligent control and visualization terminal 4.

[0022] The high-precision displacement sensor module 1 is based on the grating principle, has a compact shape, and a total length of less than 100mm. One end of its measuring rod 11 is equipped with a 6mm diameter disc 12, used to press down on the top of the knitting needle to measure the displacement of the highest point; the other end can be switched to a hook 13, used to hook the knitting needle to measure the displacement of the lowest point. The sensor has a measurement accuracy of 0.001mm, a response frequency of 2kHz, and a built-in spring to ensure gentle contact force (≤1N) to avoid bending the knitting needle.

[0023] The intelligent identification module 2 for the type of knitting needle seat is connected to the sensor module 1 via a cable, and its size is matched to facilitate integration. Its core is a high-performance MCU, which runs peak capture, filtering algorithms and knitting needle seat type identification algorithms. It can analyze the displacement waveform in real time, intelligently determine the type of knitting needle seat (out-of-loop, in-loop, flat loop) and its corresponding track number, and accurately calculate the displacement peak value (high and low points) when the knitting needle passes through the knitting needle seat.

[0024] The base 31 of the multi-degree-of-freedom magnetic support 3 uses neodymium iron boron strong magnets, which have strong adsorption force and can be firmly adsorbed onto the needle plate 5. The multi-section linkage mechanism 32 can realize flexible adjustment of multiple angles such as forward and backward, left and right, up and down, pitch, and rotation, to ensure that the sensor's detection head can be accurately and stably aligned with the top of the knitting needle.

[0025] The intelligent control and visualization terminal 4 is an industrial tablet PC that powers and communicates with the identification module 2 and sensor 1 via a TYPE-C data cable. A dedicated app is installed within the terminal, allowing users to set the total number of channels, select fabric type (calling corresponding standard parameters), start / stop data acquisition, display identification results, and calculate and graphically display the adjustment deviation of each needle channel (e.g., "The fifth channel's out-of-circle triangle seat needs to be adjusted clockwise by 0.15mm").

[0026] like Figure 3 and Figure 4 As shown, the method for adjustment using the above-mentioned device includes the following steps: S1. Device Deployment and Initialization: Attach the magnetic bracket 3 to a suitable position on the side of the needle plate 5. Adjust the connecting rod 32 so that the disc 12 on the sensor measuring rod 11 gently presses against the top of a knitting needle. Connect all cables and select the corresponding machine model and fabric parameters on the terminal 4.

[0027] S2. Data Acquisition and Intelligent Recognition: Set the circular knitting machine to run at a low speed (e.g., 2-5 rpm). The terminal APP enters acquisition mode, and sensor 1 begins to continuously collect displacement data and transmit it to recognition module 2. The algorithm of recognition module 2 quickly analyzes the data stream, identifies the type and path number of the knitting cam corresponding to each displacement cycle, and records the coordinates of the highest and lowest points of the needles on the tracks of each cam. The recognition results and coordinate data of all paths are uploaded to terminal 4.

[0028] S3. Visualized Guided Adjustment: The terminal APP switches to adjustment mode, and the interface list displays all identified triangulation point numbers and their deviations from the standard coordinates. The operator selects the point to be adjusted and jogs the machine to rotate the triangulation point to a convenient angle. The terminal will highlight the adjustment information for that point, for example: "Point 3, out-of-circle triangulation point, highest point is 0.12mm low, please adjust the dial counterclockwise X turns (approximately 0.12mm)." Following the prompts, the operator uses the tool to fine-tune the dial, while the terminal interface refreshes the current displacement value in real time and dynamically displays the remaining deviation.

[0029] S4. Judgment and Cyclic Operation: When the terminal displays that the deviation value of the current path enters the green qualified zone (e.g., ±0.002mm), a prompt sound will be emitted, indicating that the adjustment of this path is complete. The operator then selects the next path for adjustment until all non-compliant delta mounts are adjusted.

[0030] S5. Verification and Data Saving: After all routes have been adjusted, the low-speed acquisition and identification steps can be executed again to verify the overall adjustment effect. The terminal APP automatically saves the final adjustment data of all routes (including route number, triangular bracket type, value before adjustment, value after adjustment, standard value, and operation timestamp) as a record file, which can be queried, printed, or uploaded to the factory management system later.

[0031] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of the present invention.

Claims

1. A needle plate adjustment device for a circular knitting machine, characterized in that, include: The high-precision displacement sensor module has a first contact part at one end of its measuring rod for contacting the top of the knitting needle, which is used to collect the displacement data of the knitting needle in real time when the needle plate rotates; The intelligent identification module for the type of triangular seat is connected to the high-precision displacement sensor module to receive and process displacement data in order to automatically identify the type, track number, and high and low point coordinates of the corresponding needle running trajectory of the triangular seat on the needle plate. A multi-degree-of-freedom magnetic support has a strong magnetic adsorption base and a multi-directional adjustable linkage mechanism, used to adsorb and fix the high-precision displacement sensor module and / or the triangular seat type intelligent recognition module near the needle plate of a circular knitting machine. The intelligent control and visualization terminal communicates with the triangular seat type intelligent recognition module to receive recognition results and coordinate data, has a built-in standard parameter library and calculates the adjustment deviation between the current position of the knitting needle and the standard position, and generates a visual operation guide that includes the adjustment direction and value.

2. The needle plate adjustment device for a circular knitting machine according to claim 1, characterized in that, The high-precision displacement sensor module adopts grating measurement technology, with a measurement accuracy of ≤0.001mm, a response speed of ≥2kHz, and a measurement range of 0-20mm. The measuring rod has a bidirectional measurement function. The first contact part at one end is a disc structure for detecting the highest point of the knitting needle, and the second contact part at the other end is a hook structure for detecting the lowest point of the knitting needle. The measuring rod also has a built-in automatic springback mechanism.

3. The needle plate adjustment device for a circular knitting machine according to claim 1, characterized in that, The intelligent identification module for the type of knitting needle is integrated with an MCU. It processes displacement data through built-in peak capture, filtering algorithms and knitting needle type identification algorithms, identifies the type of knitting needle including out-of-loop knitting needle, loop-containing knitting needle and flat loop knitting needle, and can calculate the displacement values ​​of the highest and lowest points of the knitting needle on the track of each type of knitting needle.

4. The needle plate adjustment device for a circular knitting machine according to claim 1, characterized in that, The strong magnetic adsorption base of the multi-degree-of-freedom magnetic bracket has an adsorption force of ≥50kg, and the linkage mechanism supports 360° rotation and multi-dimensional angle and position adjustment to adapt to the installation requirements of single-sided or double-sided circular knitting machines at different positions.

5. The needle plate adjustment device for a circular knitting machine according to claim 1, characterized in that, The intelligent control and visualization terminal is a portable tablet computer with a built-in dedicated APP. The APP has functions such as parameter setting, data acquisition and control, adjustment calculation, dynamic deviation display, and adjustment completion judgment. It can also store and manage the standard needle height and low point parameters of different fabrics.

6. The needle plate adjusting device for a circular knitting machine according to any one of claims 1 to 5, characterized in that, The triangular mount type intelligent identification module is connected to the intelligent control and visualization terminal via a TYPE-C interface to achieve power supply and data communication; the high-precision displacement sensor module is connected to the triangular mount type intelligent identification module via a dedicated interface.

7. A method for adjusting the needle plate of a circular knitting machine based on the device according to any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Device Deployment and Data Acquisition: Fix the device to the side of the needle plate using a multi-degree-of-freedom magnetic bracket, so that the first contact part of the measuring rod of the displacement sensor abuts against the top of the knitting needle; start the device and set the circular knitting machine to run at low speed. The displacement sensor collects the knitting needle displacement data in real time, and the data is received by the intelligent recognition module. S2: Intelligent Recognition and Deviation Calculation: The intelligent recognition module processes the collected displacement data and automatically identifies the type and number of the triangular seat on the current scanning path, as well as the actual high and low point coordinates of the needle when passing through each triangular seat; the intelligent control terminal retrieves the preset standard high and low point coordinates and calculates the deviation value between the actual coordinates of each needle and the standard coordinates. S3: Visualized Guided Adjustment: The operator adjusts according to the adjustment instructions displayed on the intelligent control terminal. The adjustment instructions include the path number to be adjusted, the adjustment direction, and the specific adjustment amount. The operator moves the triangular seat to be adjusted to an operable position by jogging the dial. The operator then rotates the corresponding dial according to the instructions to make the adjustment. During the adjustment process, the displacement sensor provides real-time feedback on the displacement change, and the terminal dynamically updates the current deviation display. S4: Adjustment Completion Judgment and Batch Calibration: When the terminal displays that the adjustment deviation value of the current channel has entered the preset qualified threshold range, it indicates that the adjustment of the channel is complete; Repeat step S3 until all needle paths that need to be adjusted have been adjusted. The data collection process can be restarted to verify the overall adjustment effect.

8. The method for adjusting the needle plate of a circular knitting machine according to claim 7, characterized in that, In step S2, the intelligent recognition module uses a peak capture algorithm with a response time of ≤0.5ms to accurately capture the instantaneous displacement value of the highest point of the triangular base.

9. The needle plate adjustment method for a circular knitting machine according to claim 7, characterized in that, The acceptable threshold range mentioned in step S3 is that the deviation between the actual high and low point coordinates and the standard coordinates is ≤ ±0.002mm.

10. The method for adjusting the needle plate of a circular knitting machine according to claim 7, characterized in that, The method further includes step S5: data recording and tracing, wherein the intelligent control terminal automatically saves the final data of each adjustment, including the delta seat number, displacement values ​​before and after adjustment, and adjustment time, forming a traceable adjustment record file.

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