Needle cylinder wear-preventing structure of circular knitting machine and installation method thereof

Abstract

The application discloses a kind of knitting large circular knitting machine needle cylinder anti-abrasion structure and its installation method, it is related to installation test field, and its technical solution main point is that including needle cylinder body, annular first installation slot is equipped on the sinker movement path of needle cylinder body, annular second installation slot is equipped on the needle movement path of needle cylinder body;First installation slot and second installation slot are all arranged with a plurality of ceramic guide arc pieces along the circumference, each ceramic guide arc piece has a seamless working end and a jointed expansion end opposite to the seamless working end.The application is through "seamless working end close abutment, jointed expansion end reserved micro gap", both form annular guide surface on working surface to completely eliminate the jamming of moving parts, and wear-resistant ring is independently set for sinker and needle double path in non-working surface through expansion joint network Effective release thermal stress, wear-resistant ring is independently set for sinker and needle double path, realize comprehensive protection, preassembly mold method moves irreversible installation risk to observable, adjustable simulation link.

Description

Technical Field

[0001] This invention relates to the field of installation and testing, and more specifically, to an anti-wear structure for the cylinder of a circular knitting machine and its installation method. Background Technology

[0002] Circular knitting machines are core equipment in the knitting industry. During high-speed operation, the sinker groove (also known as the settling plate groove) on the top of the cylinder and the needle groove on the outer wall must withstand continuous high-speed reciprocating friction from the sinker and the needles, which easily leads to wear on the cylinder's base material. Once the cylinder base material is worn, it directly causes serious quality problems such as yarn snagging, fabric holes, or stripes. Therefore, the industry commonly adopts a technical solution of adding wear-resistant rings or plates along the wear path. This involves bonding high-hardness wear-resistant parts (such as ceramic plates) as vulnerable components, sacrificing some protection for the expensive cylinder body.

[0003] However, conventional segmented wear-resistant structures reveal two interrelated deep contradictions in practical applications: On the one hand, from a structural design perspective, to prevent moving parts (sinking plates, knitting needles) from getting stuck in the seams of the wear-resistant parts, the seams are required to be as tight as possible or even seamless; however, the physical property of material thermal expansion requires that sufficient expansion gaps be reserved at the seams to release stress, otherwise it will lead to warping of the wear-resistant plates, cracking of the adhesive layer, or deformation of the needle cylinder. This contradiction between "tightness to prevent jamming" and "leaving gaps to resist expansion" is particularly prominent under the operating conditions of circular knitting machines that operate at high speed and high temperature.

[0004] On the other hand, from the perspective of installation process, since the bonding of wear-resistant parts (especially highly brittle ceramic parts) to the syringe base is an irreversible operation, if the cumulative error is found to be due to the second half of the installation process, resulting in the last section being unable to be installed or the joint being severely misaligned, the solidified part is extremely difficult to remove without damage. Forced disassembly often damages the syringe base groove, causing the entire syringe to be scrapped and resulting in significant economic losses.

[0005] This invention provides a technical solution to this technical problem. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide an anti-wear structure for the cylinder of a circular knitting machine and its installation method.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a wear-resistant structure for a circular knitting machine cylinder, comprising a cylinder body, an annular first mounting groove provided on the movement path of the sinker plate of the cylinder body, and an annular second mounting groove provided on the movement path of the knitting needle of the cylinder body. Several ceramic guide arc plates are arranged circumferentially in both the first and second mounting slots. Each ceramic guide arc plate has a seamless working end and a slotted telescopic end opposite to the seamless working end. The slotted telescopic end fits against the bottom surface of the first or second mounting slot. Adjacent ceramic guide arc plates are tightly abutted against each other circumferentially at the seamless working end. An expansion joint for thermal expansion compensation is reserved between adjacent ceramic guide arc plates at the slotted telescopic end. The seamless working end is used to limit the contact between the sinker or knitting needle and the needle cylinder body.

[0008] The present invention is further configured such that the number of ceramic guide arc plates is at least 30, and the width of the expansion joint is 0.02mm-0.2mm.

[0009] The present invention is further configured such that: along the circumference of the syringe body, the seamless working end and the slotted telescopic end are flush with one end of the ceramic guide arc plate and form an expansion joint at the other end of the ceramic guide arc plate.

[0010] The present invention is further configured such that: a casting section is provided in both the first mounting groove and the second mounting groove, and the casting section fills the space between two adjacent ceramic guide arc plates.

[0011] A method for installing an anti-wear structure for the cylinder of a circular knitting machine, used for installing the aforementioned anti-wear structure for the cylinder of a circular knitting machine, includes the following steps: S1. Provide two sets of pre-assembly molds, corresponding to the first mounting groove and the second mounting groove respectively, including mutually interlocking concave molds and convex molds. Insert the corresponding convex molds into the first mounting groove and the second mounting groove respectively. Perform trial assembly of ceramic guide arc pieces in the corresponding concave molds. During the trial assembly, a pre-cast cavity is left between the first ceramic guide arc piece and the last ceramic guide arc piece. After the trial assembly, check the surface flatness of the ring formed by the ceramic guide arc piece. If it is qualified, proceed to S2. Otherwise, troubleshoot the problem and replace the unqualified ceramic guide arc piece. S2. Remove the punch from the first mounting groove and the second mounting groove, and apply adhesive to the inner walls of the first mounting groove and the second mounting groove. S3. The ceramic guide arc pieces are transferred sequentially into the corresponding first or second mounting slot according to their arrangement in the cavity mold, forming a casting cavity in the first or second mounting slot. S4. After the adhesive has cured, confirm that the seamless working ends of the adjacent ceramic guide arc plates are pressed together, and pour the casting into the casting cavity to form the casting section.

[0012] The present invention is further configured such that, in step S1, when the ceramic guide arc sheet is trial-assembled in the corresponding concave mold, a pad for simulating adhesive is detachably connected to the inner wall of the concave mold.

[0013] The present invention is further configured such that both the concave mold and the pad film are made of transparent materials.

[0014] The present invention is further configured such that: in step S3, during the installation of the ceramic guide arc plate, a water-soluble anti-overflow plate is inserted at the corresponding expansion joint between adjacent ceramic guide arc plates; and in step S4, after the casting is completed, the water-soluble anti-overflow plate is removed by rinsing.

[0015] In summary, this invention offers the following advantages: Through an integrated design of "seamless working end with tight contact and seamed expansion joint with micro-gaps," a continuous, smooth annular guide surface is formed on the working surface to completely eliminate jamming of moving parts. Simultaneously, a uniformly distributed network of expansion joints effectively releases thermal stress on the non-working surface, preventing warping of wear-resistant parts or failure of the adhesive layer. This achieves a balance between protective function and long-term reliability. Independent wear-resistant rings are set for both the settling plate and the knitting needle path, providing comprehensive protection. The multi-arc plate distributed design and the closed structure of the end cast-in-place section significantly improve the structure's tolerance to manufacturing and assembly errors while ensuring thermal compensation.

[0016] The pre-assembly mold method moves the irreversible installation risks forward to the observable and adjustable simulation stage. Through simulation pre-running, state calibration, and precise transfer, combined with process safeguards such as water-soluble anti-overflow sheets, a high degree of consistency between the simulation and the finished product state is ensured. This achieves successful one-time installation of high-precision structures and completely avoids substrate damage and scrap losses caused by installation accidents. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 for Figure 1 Enlarged view of point A in the middle; Figure 3 This is a partial cross-sectional view of the present invention; Figure 4 This is a schematic diagram of the ceramic guide arc sheet in this invention; Figure 5 for Figure 4 Enlarged view of point B in the middle; Figure 6 This is a schematic diagram of the structure of the concave mold and the convex mold corresponding to the first mounting groove in this invention; Figure 7 This is a schematic diagram of the structure of the concave mold and convex mold corresponding to the second mounting groove in this invention.

[0018] In the figure: 1. Syringe body; 2. First mounting groove; 3. Second mounting groove; 4. Ceramic guide arc plate; 5. Seamless working end; 6. Jointed expansion end; 7. Expansion joint; 8. Casting section; 9. Cavity mold; 10. Punch mold. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] Example 1: A wear-resistant structure for the cylinder of a circular knitting machine, such as... Figure 1 , Figure 2 , Figure 3 As shown, the cylinder body 1, as the core load-bearing structure of the circular knitting machine, is typically made of high-grade alloy steel that has undergone precision heat treatment. Its structural strength and dimensional stability are the foundation for the long-term reliable operation of the equipment. In this invention, two key structural features need to be machined on the cylinder body 1: firstly, an annular first mounting groove 2 located at the top of the cylinder and surrounding the outside of the sinker groove (Sinker groove); secondly, an annular second mounting groove 3 located on the outer wall of the cylinder and adjacent to the needle groove. The machining of these two mounting grooves requires high-precision CNC turning or grinding processes to ensure that the roundness of the groove bottom, depth, and verticality of the sidewalls meet the requirements of precision assembly. The setting of the first mounting groove 2 and the second mounting groove 3 provides an independent and precise positioning basis for the subsequent installation of wear-resistant components, fundamentally realizing targeted and integrated protection for the two different movement paths of the sinker and the needle, avoiding blind spots in protection.

[0021] like Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, the core carrier of the wear-resistant function is the ceramic guide arc plate 4. Considering the harsh working conditions of the circular knitting machine, which involves high speed, high temperature, and fiber dust, the ceramic guide arc plate 4 is preferably made of alumina or silicon nitride-based high wear-resistant ceramic materials. These materials have extremely high hardness, excellent wear resistance, good thermal stability, and self-lubricating properties. The ceramic guide arc plate 4 is formed by powder metallurgy, followed by high-temperature sintering and precision grinding, and its final dimensional accuracy needs to reach the micron level. Each ceramic guide arc plate 4 is designed with two distinct ends: a seamless working end 5 and a slotted telescopic end 6 opposite to the seamless working end 5. The seamless working end 5 will serve as the working surface that directly contacts the sinker or knitting needle, and its surface is polished to ensure smoothness and minimize frictional resistance; the slotted telescopic end 6 is designed as the mounting reference surface that fits against the bottom of the mounting groove. This separate design of "one end working, one end mounting" is a key prerequisite for realizing the subsequent "tight on top, loose on bottom" structure.

[0022] When the ceramic guide arc plates 4 are installed onto the cylinder body 1, their arrangement embodies the core concept of this invention: resolving the contradiction between "dense anti-jamming" and "leaving gaps to resist expansion." All ceramic guide arc plates 4 are arranged sequentially along the circumference of the first mounting groove 2 or the second mounting groove 3. In the installed state, the seamless working ends 5 of two adjacent ceramic guide arc plates 4 are tightly abutted in the circumferential direction of the cylinder, without any gaps for the sinker or knitting needle to insert. This tight abutment forms a continuous, complete, and smooth annular working surface. When the sinker or knitting needle slides on it, it will not encounter any seam steps or gaps, thus completely eliminating the risk of moving parts getting stuck. This is the primary structural foundation for ensuring smooth machine operation and excellent fabric quality, and its beneficial effects are directly reflected in the reduction of operating noise and a significant decrease in the fabric defect rate.

[0023] In stark contrast to the "dense" state of the seamless working end 5, a deliberately reserved expansion joint 7 for thermal expansion compensation is provided between the slotted expansion joints 6 of adjacent ceramic guide arc plates 4. This joint is the result of precise design. During continuous operation of the circular knitting machine, heat is generated, causing the temperature of the cylinder body 1 and the ceramic guide arc plates 4 to rise and expand thermally. Although the coefficients of linear expansion of ceramics and metals differ, both will experience dimensional changes. Without reserved space, the enormous stress generated by expansion would cause the tightly joined ceramic arc plates to press against each other, ultimately leading to warping, breakage, or failure of the adhesive layer of the ceramic guide arc plates 4. The expansion joint 7 provided in this invention provides a controllable release channel for this thermal expansion. When the temperature rises, each ceramic guide arc plate 4 gains a tiny space to expand towards the expansion joints 7 on both sides, thereby converting the destructive compressive stress into a harmless micro-displacement. This structural design cleverly achieves a unity of functional requirements through the separation of physical space: the working surface remains dense to perform its function, while the non-working surface is reserved with gaps to cope with physical changes.

[0024] To achieve better stress relief and reduce the stringent requirements on the width of individual gaps, this invention preferably employs a strategy of increasing the number of ceramic guide arc plates 4. In a preferred embodiment, the number of ceramic guide arc plates 4 installed in each mounting groove is no less than 30. Dividing the entire circumference into more segments means that the total expansion is distributed across more expansion joints 7 to absorb it. For example, the expansion that would originally need to be accommodated by 4 wide gaps can now be distributed evenly by 30 narrow gaps. This allows the width of each expansion joint 7 to be designed to be very small, for example, controlled between 0.02 mm and 0.2 mm. Such tiny gaps are almost imperceptible visually, functionally sufficient to cope with thermal expansion, while maximizing the overall structural strength and fit stability of the seamed expansion end 6 area. This distributed design concept of "trading quantity for width" further optimizes the compactness and reliability of the structure while ensuring thermal compensation functionality.

[0025] like Figure 4 , Figure 5 As shown, from the microscopic shape of a single ceramic guide arc plate 4, its seamless working end 5 and slotted telescopic end 6 are flush at one end along the circumference of the syringe barrel, while forming a step difference at the other end. This step difference area is part of the expansion joint 7. This asymmetrical end design allows the flush end of one ceramic guide arc plate 4 to engage with the stepped end of the adjacent ceramic guide arc plate 4 during circumferential splicing. This engagement not only facilitates quick positioning during installation but also effectively prevents the ceramic guide arc plates 4 from shifting radially, enhancing the torsional stiffness of the overall ring structure. After all the ceramic guide arc plates 4 are installed in a specific directional sequence, a uniform and continuous network of expansion joints 7 is naturally formed in the area of ​​the slotted telescopic end 6.

[0026] like Figure 1 , Figure 2 As shown, considering the potential cumulative errors from arranging a large number of precision ceramic parts on a circumference, and to provide tolerance for final adjustments during installation, this invention introduces a field-cast section 8 within the mounting groove. After most of the ceramic guide arc plates 4 are installed and bonded in their designed positions, a gap is left on the ring; this gap becomes the casting cavity. Subsequently, a specially formulated wear-resistant casting material is poured into this cavity, and after curing, it forms the casting section 8, which is tightly bonded to the adjacent ceramic guide arc plates 4. The casting material can be a composite material made of epoxy resin or modified acrylic resin as the matrix, mixed with a high proportion of alumina or silicon carbide wear-resistant particles. This material has good fluidity and wettability in its liquid state, perfectly filling complex gaps; after curing, it has high hardness, wear resistance, and moderate toughness. The introduction of casting section 8 eliminates the need for the final precast ceramic guide arc plate 4 to be dimensionally perfect during installation. Instead, the "flexible" casting material adapts to the cumulative errors of the "rigid" material, easily achieving the final closure of the wear ring and significantly improving the success rate and error tolerance of installation. Its beneficial effects are directly reflected in a substantial reduction in installation time and an effective increase in the yield rate.

[0027] Example 2: A method for installing an anti-wear structure for the cylinder of a circular knitting machine, used to install the aforementioned anti-wear structure for the cylinder of a circular knitting machine. Its core lies in introducing a pre-assembly mold system, such as... Figure 6 , Figure 7As shown, the irreversible risks of on-site installation are addressed by addressing them in a repeatable and observable simulation process. In S1, the pre-assembly mold consists of two parts: a concave mold 9 and a convex mold 10. The convex mold 10 is precisely machined to match the inner contour of the first mounting groove 2 or the second mounting groove 3 on the syringe body 1, and can be considered as a "movable standard part for syringe mounting grooves". The concave mold 9 has a cavity that precisely matches the outer surface of the convex mold 10. The convex mold 10 is divided into multiple segments to avoid friction caused by excessive contact area between a single convex mold 10 and the concave mold 9, which would make it difficult to remove the convex mold 10. A handle is fixedly connected to the side of the convex mold 10 away from the bottom surface of the concave mold 9 to facilitate the removal of the convex mold 10. The first step of installation is not to operate directly on the syringe, but to conduct a simulation. The operator embeds the convex mold 10 into the concave mold 9, thus simulating the constraint environment of the ceramic guide arc plate 4 in the actual mounting groove. Subsequently, all the ceramic guide arc plates 4 are trial-assembled around the convex mold 10 inside the concave mold 9. During the trial assembly, a gap was intentionally left between the first and last ceramic guide arc plates 4. This gap simulates the precast cavity that will be filled by the casting section 8 in the future.

[0028] During trial assembly, to more realistically simulate the final bonding state, a very thin pad film can be temporarily applied to the inner wall of the concave mold 9. The thickness of this pad film is calculated to equivalently replace the average thickness of the adhesive layer during formal installation. The specific dimensions can be varied according to different actual adhesive requirements. In this way, the tightness and joint condition of the arc ring assembled in the trial are highly consistent with the final cured state, exposing potential interference or looseness problems caused by the thickness of the adhesive layer in advance. For easy observation, both the concave mold 9 and the pad film can be made of transparent polycarbonate or acrylic materials. The operator can check 360 degrees without blind spots whether each expansion joint 7 is uniform, whether the contact between the ceramic guide arc plates 4 is in place, and the roundness and end face flatness of the entire simulation ring. Only after the simulation is completely successful will the formal installation stage of the syringe body 1 begin. This "simulation first, then actual operation" process completely isolates the risk of installation failure and the possible costly losses in the simulation stage, ensuring the success rate of each formal installation.

[0029] After the simulation was successful, the operator recorded the precise order and orientation of each ceramic guide arc piece 4 within the concave mold 9. Then, in S2, the punch 10 was removed from the actual syringe mounting slot, and a high-performance epoxy structural adhesive was evenly applied to the inner wall of the mounting slot (mainly the bottom and part of the sidewalls). Next, in S3, based on the simulation record, the ceramic guide arc pieces 4 were precisely placed one by one into the syringe mounting slot, following the exact same order and orientation, as if transferring them from the mold. During this transfer and installation process, to ensure that the reserved expansion joint 7 is not blocked by overflowing adhesive, a water-soluble material (such as polyvinyl alcohol film) anti-overflow sheet can be inserted at the expansion joint 7 between adjacent ceramic guide arc pieces 4. This anti-overflow sheet temporarily occupies the gap space during the adhesive curing stage, preventing the adhesive from flowing in.

[0030] In step S4, after all prefabricated ceramic guide arc plates 4 are installed and the adhesive has fully cured, the operator needs to confirm that all seamless working ends 5 are tightly abutting each other as designed. Finally, the prepared wear-resistant casting composite material is poured into the reserved casting cavity. Due to the precision control of the preliminary simulation and formal installation, the size and shape of the casting cavity are highly defined at this point, making the casting process highly controllable. After the casting material cures, it firmly bonds with the ceramic guide arc plates 4 on both sides, forming a complete wear-resistant ring. Finally, through spraying or soaking, the water-soluble anti-overflow plate dissolves in water, and the protected expansion joint 7 is revealed, with a clean interior free of colloid blockage. At this point, a dual-path wear-resistant structure with high wear resistance, thermal expansion resistance, and high operational stability is installed. This installation method, through a series of steps including mold simulation, state transition, process protection, and final casting closure, systematically ensures the assemblability and reliability of complex and precise structures. Its beneficial effects are reflected in a comprehensive improvement in multiple dimensions, including installation efficiency, first-time success rate, and long-term operational stability.

[0031] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A wear-resistant structure for a circular knitting machine cylinder, comprising a cylinder body (1), characterized in that: A first annular mounting groove (2) is provided on the sinker movement path of the syringe body (1), and a second annular mounting groove (3) is provided on the needle movement path of the syringe body (1). Several ceramic guide arc plates (4) are arranged circumferentially in the first mounting groove (2) and the second mounting groove (3). Each ceramic guide arc plate (4) has a seamless working end (5) and a slotted telescopic end (6) opposite to the seamless working end (5). The slotted telescopic end (6) fits the bottom surface of the first mounting groove (2) or the bottom surface of the second mounting groove (3). Adjacent ceramic guide arc plates (4) are tightly abutted against each other along the circumference of the needle body (1) at the seamless working end (5). An expansion joint (7) for thermal expansion compensation is reserved between adjacent ceramic guide arc plates (4) and the slotted telescopic end (6). The seamless working end (5) is used to limit the contact between the sinker or the needle and the needle body (1).

2. The anti-wear structure for the needle cylinder of a circular knitting machine according to claim 1, characterized in that: The number of ceramic guide arc plates (4) is at least 30, and the width of the expansion joint (7) is 0.02mm-0.2mm.

3. The anti-wear structure for the needle cylinder of a circular knitting machine according to claim 1, characterized in that: Along the circumference of the syringe body (1), the seamless working end (5) and the slotted telescopic end (6) are flush with one end of the ceramic guide arc plate (4) and form an expansion joint (7) at the other end of the ceramic guide arc plate (4).

4. The anti-wear structure for the needle cylinder of a circular knitting machine according to claim 1, characterized in that: The first mounting groove (2) and the second mounting groove (3) are each provided with a casting section (8), which is filled between two adjacent ceramic guide arc plates (4).

5. A method for installing an anti-wear structure for a circular knitting machine cylinder, used to install the anti-wear structure for a circular knitting machine cylinder as described in any one of claims 1-4, characterized in that, Includes the following steps: S1. Provide two sets of pre-assembly molds, corresponding to the first mounting groove (2) and the second mounting groove (3) respectively, including a cavity mold (9) and a punch mold (10) that fit together. Insert the corresponding punch mold (10) into the first mounting groove (2) and the second mounting groove (3) respectively. Perform trial assembly of ceramic guide arc plate (4) in the corresponding cavity mold (9). During the trial assembly, a pre-cast cavity is left between the first ceramic guide arc plate (4) and the last ceramic guide arc plate (4). After the trial assembly, check the surface flatness of the ring formed by the ceramic guide arc plate (4). If it is qualified, proceed to S2. Otherwise, troubleshoot the problem and replace the unqualified ceramic guide arc plate (4). S2. Remove the punch (10) from the first mounting groove (2) and the second mounting groove (3), and apply adhesive to the inner walls of the first mounting groove (2) and the second mounting groove (3); S3. The ceramic guide arc plate (4) is transferred to the corresponding first mounting groove (2) or second mounting groove (3) in the order of its arrangement in the die (9) to form a casting cavity in the first mounting groove (2) and the second mounting groove (3); S4. After the adhesive has cured, confirm that the seamless working ends (5) of the adjacent ceramic guide arc plates (4) are pressed together, and pour the casting section (8) into the casting cavity.

6. The installation method of the anti-wear structure for the needle cylinder of a circular knitting machine according to claim 5, characterized in that: In S1, when the ceramic guide arc plate (4) is trial-assembled in the corresponding cavity (9), a pad film for simulating adhesive is detachably connected to the inner wall of the cavity (9).

7. The installation method of the anti-wear structure for the needle cylinder of a circular knitting machine according to claim 6, characterized in that: Both the concave mold (9) and the gasket are made of transparent material.

8. The installation method of the anti-wear structure for the cylinder of a circular knitting machine according to claim 5, characterized in that: In S3, during the installation of ceramic guide arc plates (4), water-soluble anti-overflow plates are inserted at the corresponding expansion joints (7) between adjacent ceramic guide arc plates (4). In S4, after the pouring is completed, the water-soluble anti-overflow plates are removed by rinsing.

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