Circular knitting machine with real-time prompt of knitting machine status

Abstract

To provide a circular knitting machine that prevents defects in recognizing an outer image of a tubular fabric.SOLUTION: A main camera module (24) includes a first central axis (241), and the main camera module (24) takes pictures of a tubular fabric (30) knitted by a circular knitting machine (20). An auxiliary camera module (25) includes a second central axis (251) intersecting with the first central axis (241), and the auxiliary camera module (25) and the main camera module (24) face the same side of the tubular fabric (30). A startup timing of the auxiliary camera module (25) only occurs when one of multiple connecting rods (232) passes between the main camera module (24) and the tubular fabric (30). Data generated by the main camera module (24) and the auxiliary camera module (25) are used to determine the status of the circular knitting machine (20).SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to the technical field of circular knitting machines, and more particularly to a circular knitting machine that can determine the state of knitting needles based on the quality of a tubular knitted product during knitting work. [Background technology]

[0002] The operational quality of a circular knitting machine, in other words, is the presence or absence of knitting defects on the surface of the knitted fabric. The occurrence of knitting defects is closely related to the condition of the knitting needles' feet. If the lower end of the foot of one of the knitting needles is severely worn, one of the knitting needles cannot be raised to the required height, resulting in the latch not fully expanding, the previous loop not being processed and the knitting needle knitting an error with two yarns, or the hook not being able to pick up the new yarn, resulting in a hole in the knitted fabric. Furthermore, if the upper edge of the foot of one of the knitting needles is severely worn, the previous loop cannot be removed reliably, resulting in a hole in the knitted fabric, and unnatural linear patterns appearing in the knitted fabric, or the new loop is smaller than the loops previously knitted, resulting in unnatural linear patterns in the knitted fabric.

[0003] Although there are conventional technical solutions for inspecting the quality of knitted fabrics, such as those disclosed in Patent Documents 1 to 8, these technologies inspect the quality of knitting work after the circular knitting machine has finished knitting, and even if a knitting defect is found in the knitted fabric, it is not possible to identify which of the multiple knitting needles of the circular knitting machine should be replaced. Therefore, in the industry, when a knitting defect is found in the knitted fabric, all of the knitting needles of the circular knitting machine are generally removed. A typical circular knitting machine has 1,500 to 2,640 knitting needles, and removing so many knitting needles at once and evaluating the condition of all of them is a waste of time. The resulting waste of resources also increases production costs.

[0004] Furthermore, Patent Documents 9 to 11 disclose circular knitting machines equipped with a winding structure. The winding structure rotates simultaneously with the knitting operation to wind up the knitted fabric. In this case, the multiple connecting rods provided in the winding structure affect the recognition of an image of the outside of the tubular knitted fabric, and therefore, improvement is required. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] China Published Patent No. CN102778414A [Patent Document 2] China Published Patent No. CN102967606A [Patent Document 3] China Published Patent No. CN103451846A [Patent Document 4] China Published Patent No. CN103604809A [Patent Document 5] China Published Patent No. CN108364291A [Patent Document 6] China Published Patent No. CN108921819A [Patent Document 7] China Published Patent No. CN109696442A [Patent Document 8] China Published Patent No. CN110389130A [Patent Document 9] US Patent No. US04748334A [Patent Document 10] China Published Patent No. CN114808260A [Patent Document 11] China Published Patent No. CN104178907A Summary of the Invention [Problem to be solved by the invention]

[0006] The main object of the present invention is to solve the problems that arise when recognizing an image of the outside of a tubular knitted product in a conventional circular knitting machine provided with a winding structure. [Means for solving the problem]

[0007] The present invention has been made to achieve the above object by providing a circular knitting machine that instantly indicates the state of the knitting machine, the circular knitting machine including a base, a cylinder that rotates relative to the base during knitting, and a winder that rotates relative to the base following the cylinder during knitting, the winder including a winding rod and a plurality of connecting rods connected to the winding rod, the connecting rods displacing relative to the base as the winder rotates. The circular knitting machine further includes a main camera module fixed to the base and a sub-camera module fixed to the base and located near the main camera module. The main camera module includes a first center shaft and takes images of a tubular knitted product that rotates following the cylinder. The sub-camera module includes a second center shaft that is angled relative to the first center shaft, and the activation timing of the sub-camera module is limited to when one of the connecting rods passes between the main camera module and the tubular knitted product. The information generated by the main and sub-photography modules is used to understand the state of the circular knitting machine.

[0008] In one embodiment, the circular knitting machine includes an encoder that generates a plurality of pulse signals when the cylinder rotates, and the plurality of imaging signals of the main imaging module and the sub-imaging module are generated by counting these pulse signals.

[0009] In one embodiment, the imaging signals of the main imaging module are generated by counting a factor of the total number of pulse signals during one rotation of the cylinder.

[0010] In one embodiment, the value of the number of times of photography of the main photography module may be obtained by equally dividing the central angle, or by dividing the total number of knitting needles corresponding to the cylinder.

[0011] In one embodiment, the circular knitting machine includes a data processor that receives a plurality of image data provided by the main and sub-photography modules, and the data processor compares one of the image data with another of the image data located at the same perpendicular line of the tubular knitted fabric.

[0012] In one embodiment, each of the image data generated by the main photography module includes a plurality of loop images, and these loop images located in the same vertical direction correspond to one of a plurality of knitting needles of the circular knitting machine, and the number of loop images included in each of the image data generated by the main photography module is close to or equal to each other, thereby providing a comparison of these image data, and the number of loop images included in each of the image data generated by the sub-photography module is close to or equal to each other, thereby providing a comparison of these image data.

[0013] In one embodiment, when the cylinder rotates once, the sum of the lengths of the vertical loop images in the image data generated by the main camera module and the sub camera module is proportional to the length of the doffing amount of the circular knitting machine.

[0014] In one embodiment, the circular knitting machine is provided with another main photography module, and the two main photography modules face the outside and inside of the tubular knitted fabric, respectively, and the sub-photography module is provided adjacent to the one of the two main photography modules facing the outside, and the sub-photography module faces the outside of the tubular knitted fabric.

[0015] In one embodiment, the two main imaging modules have different horizontal heights.

[0016] In one embodiment, the base comprises a hanging arm for supporting one of the two main imaging modules facing the inside of the tubular knitting.

[0017] In one embodiment, the data processor receives multiple image data provided by the two main and sub-imaging modules, and the data processor compares one of the image data with the other of the image data located on the same perpendicular line of the tubular knitted fabric. [Effects of the Invention]

[0018] The present invention, as implemented as described above, has the following advantages over the prior art: By providing a main and sub-photography module, the circular knitting machine of the present invention solves the problem of insufficient quality detection due to the presence of a winder. The present invention uses information generated by the main and sub-photography modules to grasp the status of the circular knitting machine, making it possible to identify problematic knitting needles on the circular knitting machine, thereby eliminating the wasteful problem associated with the traditional method of complete replacement. Furthermore, the present invention allows circular knitting machine operators to perform maintenance promptly, avoiding the situation where defects in finished products are discovered only after all knitting operations have been completed. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is a schematic diagram of the local structure of a circular knitting machine of the present invention. [Figure 2] FIG. 2 is a bottom schematic diagram of the local structure of a circular knitting machine of the present invention. [Figure 3] FIG. 3 is a cross-sectional schematic diagram of a local structure of a circular knitting machine of the present invention. [Figure 4] FIG. 4 is a schematic diagram of the bottom surface of the local structure of the circular knitting machine of the present invention. [Figure 5] FIG. 5 is a schematic diagram showing a cross section of a local structure of a circular knitting machine according to the present invention. [Figure 6] FIG. 6 is a diagram showing the unit configuration of a first embodiment of a circular knitting machine according to the present invention. [Figure 7] FIG. 7 is a schematic diagram of image data provided by the main imaging module of the present invention. [Figure 8] FIG. 8 is a diagram showing the unit configuration of a second embodiment of a circular knitting machine according to the present invention. [Figure 9] FIG. 9 is a diagram showing the unit configuration of a third embodiment of a circular knitting machine according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0020] 1 to 3, the present invention provides a circular knitting machine 20. The circular knitting machine 20 can instantly indicate the state of the knitting machine based on the state of the loops of a tubular knitted fabric during knitting operations. First, the basic structure of the circular knitting machine 20 will be described. The circular knitting machine 20 includes a base 21, a cylinder 22, and a winder 23. The cylinder 22 rotates relative to the base 21 during knitting operations and knits a tubular knitted fabric 30 in cooperation with a knitting needle structure on the base 21 (this knitting structure is common technical knowledge in the art and is not shown), and the tubular knitted fabric 30 rotates along with the cylinder 22. The winder 23 is primarily used to wind up the tubular knitted fabric 30, and rotates relative to the base 21 along with the cylinder 22 during knitting operations. The configuration of the winder 23 may be, for example, but is not limited to, that disclosed in CN114808260A. The winder 23 includes a winding rod 231 and a plurality of connecting rods 232 connected to the winding rod 231, and these connecting rods 232 are displaced relative to the base 21 when the winder 23 rotates.

[0021] 1 to 3, the circular knitting machine 20 of the present invention further includes a main camera module 24 and a sub-camera module 25. The main camera module 24 is fixed to the base 21. The main camera module 24 faces one side of the tubular knitted product 30. More specifically, the tubular knitted product 30 has an outer side 301 and an inner side 302, and in this embodiment, the main camera module 24 faces the outer side 301 of the tubular knitted product 30. The main camera module 24 is controlled to capture images of the tubular knitted product 30 rotating along the cylinder 22. The sub-camera module 25 is fixed to the base 21 and is provided near the main camera module 24. When observed from the bottom of the base 21 (FIG. 2), the sub-camera module 25 is not provided parallel to the main camera module 24, and the camera range of the sub-camera module 25 overlaps with that of the main camera module 24. Furthermore, the main imaging module 24 has a first center axis 241, and the sub imaging module 25 has a second center axis 251, which is angled with the first center axis 241. The sub imaging module 25 and the main imaging module 24 face the same side of the tubular knitting material 30, that is, the sub imaging module 25 faces the outside 301 of the tubular knitting material 30. The activation timing of the sub imaging module 25 is different from that of the main imaging module 24, and is limited to when one of these connecting rods 232 passes between the main imaging module 24 and the tubular knitting material 30. The sub imaging module 25 is provided to solve the problem of the main imaging module 24 being blocked by one of these connecting rods 232 and being unable to image the tubular knitting material 30.

[0022] Furthermore, when the circular knitting machine 20 performs knitting work, the tubular knitted product 30 rotates along with the cylinder 22, and the main photography module 24 is controlled to take pictures of the tubular knitted product 30 in succession, as shown in Figures 4 and 5. Since the main photography module 24 is fixed and the winder 23 rotates relative to the cylinder 22, as shown in Figures 2 and 3, when the winder 23 is rotating to the extent that it affects the main photography module 24 taking pictures of the tubular knitted product 30, the sub photography module 25 is triggered to take pictures of the tubular knitted product 30 at least once. The data generated by the main photography module 24 and the sub photography module 25 is used to understand the status of multiple knitting needles on the circular knitting machine 20. The data generated by the sub-camera module 25 compensates for the portion of the image that the main camera module 24 was unable to capture due to being blocked by one of these connecting rods 232, and the data generated by the main camera module 24 and the sub-camera module 25 makes it possible to grasp the status of multiple knitting needles (not shown) on the circular knitting machine 20 through the loops on the tubular knitted fabric 30, and further allows for immediate maintenance, thereby avoiding the situation where defects in the finished product are only discovered after all knitting work has been completed. Furthermore, the present invention solves the problem of the prior art that resources are wasted when all of the knitting needles on the circular knitting machine have to be replaced because the status of each of the knitting needles cannot be checked one by one.

[0023] In addition, since the main camera module 24 of the present invention does not continuously capture images of the tubular knitted product 30, no video data is generated, and the main camera module 24 does not capture images of the tubular knitted product 30 during doffing unless instructed to do so.

[0024] 6 , in one embodiment, the circular knitting machine 20 includes an encoder 26 that generates a plurality of pulse signals 261 as the cylinder 22 rotates. The plurality of capture signals of the main capture module 24 and the sub capture module 25 are generated by counting the pulse signals 261. The main capture module 24 may be activated at successive intervals to capture images, and the capture signals of the main capture module 24 may be activated when a specific number of pulse signals 261 is calculated to have been generated. In one embodiment, to alleviate the difficulty of subsequent data comparison, the capture signals of the main capture module 24 are generated by counting a factor of the total number of pulse signals 261 generated during one rotation of the cylinder 22. For example, if the total number of pulse signals 261 generated by the encoder 26 during one rotation of the cylinder 22 is 2640, the count value may be selected to be a value that divides 2640, such as 88, and the main capture module 24 or the part for controlling the main capture module 24 will capture an image every time it receives 88 pulse signals 261. Therefore, the number of times the main imaging module 24 takes images is the quotient obtained by dividing the total number of these pulse signals 261 by the count value. In the above example, when the cylinder 22 rotates once, the main imaging module 24 takes 30 images. Alternatively, the value of the number of times the main imaging module 24 takes images may be obtained by equally dividing the central angle, which prevents repeated imaging from affecting subsequent analysis and distinguishes the specific positions of each imaging, making it easier to perform maintenance immediately afterwards.

[0025] 6 , in one embodiment, the main imaging module 24 includes a controller 242 and a camera 243 controlled by the controller 242, the main imaging module 24 is connected to the encoder 26 to receive pulse signals 261, and the controller 242 controls the camera 243 to be activated to capture images based on the pulse signals 261. The secondary imaging module 25 includes a controller 252 and a camera 253 controlled by the controller 252, the secondary imaging module 25 is connected to the encoder 26 to receive pulse signals 261, and the controller 252 controls the camera 253 to be activated to capture images based on the pulse signals 261. The main imaging module 24 and the secondary imaging module 25 may be controlled by an external control device, which is connected to the encoder 26 to receive pulse signals 261 and controls the main imaging module 24 and the secondary imaging module 25 to capture images based on the pulse signals 261.

[0026] 6 and 7, the data generated by the main and sub-camera modules 24 and 25 may be analyzed by an external computing device or a computing element on the circular knitting machine 20. In one embodiment, the circular knitting machine 20 includes a data processor 27, which stores a plurality of computing programs and is connected to the main and sub-camera modules 24 and 25. The data processor 27 receives the plurality of image data 244, 254 captured and generated by the main and sub-camera modules 24 and 25, and computes and compares these data using its own computing programs. Furthermore, the data processor 27 compares each of these image data 244, 254 only with the other image data 244, 254 that is located on the same perpendicular line 303 of the tubular knitted fabric 30. Specifically, if one of these image data 244 (A in FIG. 7) is the 24th image data captured by the main camera module 24 during one rotation of the cylinder 22, its comparison target is the 24th image data captured by the main camera module 24 during the previous rotation of the cylinder 22 (B in FIG. 7). Two of these image data 244 are continuous along a perpendicular line 303. After comparing these two, the data processor 27 indicates the state of the knitting machine if a difference is found, because the difference does not mean that there is a problem with at least one of the knitting needles on the circular knitting machine 20, resulting in a different finished product. The comparison by the data processor 27 may be a comparison using chromatic pixels, or may use other image recognition calculation programs. In addition, in one embodiment, these image data 254 generated by the secondary imaging module 25 are judged independently, that is, these image data 254 generated by the secondary imaging module 25 are not combined with these image data 244 generated by the primary imaging module 24 to form an image showing the state of one revolution of the tubular knitting material 30, thereby simplifying the calculation program of the data processor 27 and avoiding misjudgment caused by stitching together images.Referring to FIG. 8, in one embodiment, the data processor 27 may be connected to the encoder 26 to receive these pulse signals 261, and further control the main imaging module 24 and the sub imaging module 25 to perform imaging.

[0027] Each of the image data 244 generated by the main imaging module 24 includes a plurality of loop images, among which, the loop images positioned in the same vertical direction correspond to one of the knitting needles of the circular knitting machine 20. Thus, by comparing the differences between the loop images in the image data 244, it is possible to identify which of the knitting needles has a problem and should be replaced. Furthermore, the numbers of horizontal loop images included in the image data 244 generated by the main imaging module 24 are close to or equal to each other, thereby providing a comparison of the image data 244. Each of the image data 254 generated by the sub-imaging module 25 also includes a plurality of loop images, among which, the loop images positioned in the same vertical direction correspond to one of the knitting needles of the circular knitting machine 20. Furthermore, the numbers of loop images included in the image data 254 generated by the sub-imaging module 25 are close to or equal to each other, thereby providing a comparison of the image data 254. In addition, when the cylinder 22 rotates once, the sum of the lengths of these vertical loop images in the image data 244, 254 generated by the main imaging module 24 and the sub imaging module 25 is proportional to the length of the doffing amount of the circular knitting machine.

[0028] 1 to 3 and 9 , in one embodiment, the circular knitting machine 20 includes two main imaging modules 24, which face the outer side 301 and the inner side 302 of the tubular knitted fabric 30, respectively. A sub-imaging module 25 is provided adjacent to the one of the two main imaging modules 24 facing the outer side 301, and the sub-imaging module 25 faces the outer side 301 of the tubular knitted fabric 30. In one embodiment, the two main imaging modules 24 have different horizontal heights. The one of the two main imaging modules 24 facing the inner side 302 is suspended within the range surrounded by the cylinder 22, i.e., suspended inside the tubular knitted fabric 30. In one embodiment, the base 21 includes a suspension arm 211 for supporting the one of the two main imaging modules 24 facing the inner side 302 of the tubular knitted fabric 30. Control of imaging by the two main imaging modules 24 is the same as described above, and therefore a detailed description thereof will be omitted here. In this embodiment, when the above-described structure is used in a circular knitting machine 20 for knitting a double knitted fabric, it is possible to immediately determine whether the knitting needles or associated knitting parts used for double knitting on the circular knitting machine 20 are broken or have been operated incorrectly, based on the quality of the tubular knitted fabric 30.

[0029] Furthermore, the image data 244 generated by the two main imaging modules 24 do not necessarily need to be compared at the same time. That is, the image data 244 may be calculated separately for the outer portion 301 and the inner portion 302. Of course, when comparing the image data 244 generated by the two main imaging modules 24 at the same time, the data processor 27 must use a calculation program to associate and compare two opposing sets of image data 244 showing the same portion of the tubular knitted fabric 30. [Explanation of symbols]

[0030] 20 Circular knitting machine 21 Base 211 Hanging arm 22 cylinders 23 Winder 231 Winding rod 232 Connecting rod 24 Main Camera Module 241 1st center axis 242 Controller 243 Camera 244 image data 25 Secondary Photography Module 251 2nd center axis 252 Controller 253 Camera 254 image data 26 Encoder 261 Pulse Signal 27 Data Processor 30 Tubular knitting 301 Outside 302 Inside 303 Perpendicular A and B comparison

Claims

1. A circular knitting machine comprising a base, a cylinder that rotates relative to the base during a knitting operation, and a winder that rotates relative to the base following the cylinder during a knitting operation, the winder 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 winder rotates, a main photography module fixed to the base, including a first center axis, for photographing a cylindrical knitted article that rotates along the cylinder; a sub-photography module fixed to the base and provided near the main photography module, the sub-photography module having a second center axis that is angled with the first center axis, the sub-photography module and the main photography module facing the same side of the tubular knitting material, and the timing of activation of the sub-photography module is limited to when one of the connecting rods passes between the main photography module and the tubular knitting material; A circular knitting machine that instantly indicates the state of the knitting machine, characterized in that the data generated by the main photography module and the sub photography module is used to grasp the state of the circular knitting machine.

2. 2. The circular knitting machine according to claim 1, further comprising an encoder that generates a plurality of pulse signals when the cylinder rotates, and the plurality of imaging signals of the main imaging module and the sub imaging module are generated by counting these pulse signals.

3. 3. A circular knitting machine according to claim 2, wherein the imaging signals of the main imaging module are generated by counting a factor of the total number of pulse signals when the cylinder rotates once.

4. 3. A circular knitting machine that instantly indicates the state of the knitting machine according to claim 2, wherein the value of the number of times the main camera module has taken photographs may be obtained by equally dividing the central angle or by dividing the total number of knitting needles corresponding to the cylinder.

5. 5. A circular knitting machine for instantly indicating the state of the knitting machine according to any one of claims 1 to 4, further comprising a data processor which receives a plurality of image data provided by the main and sub-photography modules, and which compares one of the image data with the other of the image data located at the same perpendicular line of the tubular knitted fabric.

6. 6. A circular knitting machine that instantly indicates the state of a knitting machine, as described in claim 5, characterized in that the image data includes a plurality of loop images, and these loop images located in the same vertical direction correspond to one of a plurality of knitting needles of the circular knitting machine, and the comparison of these image data is provided by the fact that the numbers of these loop images included in each of these image data generated by the main photography module are close to or equal to each other, and the comparison of these image data is provided by the fact that the numbers of these loop images included in each of these image data generated by the sub photography module are close to or equal to each other.

7. 7. The circular knitting machine according to claim 6, wherein the sum of the vertical lengths of the loop images among the image data generated by the main camera module and the sub camera module when the cylinder rotates one revolution is proportional to the length of the doffing amount of the circular knitting machine.

8. A circular knitting machine that instantly indicates the state of the knitting machine described in any one of claims 1 to 4, characterized in that it is provided with another main photography module, the two main photography modules facing the outside and inside of the tubular knitted fabric, respectively, and the sub-photography module is provided adjacent to the one of the two main photography modules facing the outside, and the sub-photography module faces the outside of the tubular knitted fabric.

9. The circular knitting machine according to claim 8, characterized in that the two main photographing modules are at different horizontal heights.

10. The circular knitting machine according to claim 9, characterized in that the base is provided with a hanging arm for mounting one of the two main photography modules facing the inside of the tubular knitted fabric.

11. 9. A circular knitting machine according to claim 8, further comprising a data processor that receives a plurality of image data provided by the two main and sub-photography modules, and that compares one of the image data with another of the images located at the same perpendicular line of the tubular knitted fabric.

12. 12. A circular knitting machine for instantly indicating the state of a knitting machine, as described in claim 11, characterized in that each of these image data includes a plurality of loop images, and these loop images located in the same vertical direction correspond to one of a plurality of knitting needles of the circular knitting machine, and the comparison of these image data is provided by the fact that the numbers of these horizontal loop images included in each of these image data generated by the main photography module are close to or equal to each other, and the comparison of these image data is provided by the fact that the numbers of these horizontal loop images included in each of these image data generated by the sub photography module are close to or equal to each other.

13. 13. The circular knitting machine according to claim 12, wherein the sum of the lengths of the vertical loop images among the image data generated by the main camera module and the sub camera module when the cylinder rotates one revolution is proportional to the length of the doffing amount of the circular knitting machine.

Images