Controlling movement ranges of knitting needles in a knitting system

Abstract

A system (11) for knitting fibers (20), the system includes: (i) first and second needle assemblies (33), which are configured to be moved alternately in a first direction and in a second direction along a first axis (19), and to knit a garment from a plurality of the fibers, and (ii) first and second eccentric rotatable elements (EREs) (27, 28) having respective different first and second shapes, the first and second EREs are connected to a rotating motor (16) and are configured to rotate about a second axis (18), different from the first axis, and, due to the different first and second shapes, to move the first and second needle assemblies in respective first and second movement ranges that are different from one another.

Description

[0001] CONTROLLING MOVEMENT RANGES OF KNITTING NEEDLES IN A KNITTING SYSTEM

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application 63 / 508,893, filed June 18, 2023, whose disclosure is incorporated herein by reference.

[0004] FIELD OF THE INVENTION

[0005] The present invention relates generally to production of fabrics and garments, and particularly to methods and systems for controlling the movement range of each knitting needle.

[0006] BACKGROUND OF THE INVENTION

[0007] Various techniques for knitting fibers to produce garments and fabrics have been published.

[0008] SUMMARY OF THE INVENTION

[0009] An embodiment of the present invention that is described herein provides a system for knitting fibers, the system includes an eccentric rotatable element (ERE), which is connected to a rotating motor and is configured to rotate about a first axis; first and second needle assemblies, which are configured to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, and to knit a garment from a plurality of the fibers; a first actuator, coupled between the ERE and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis; and a second actuator, coupled between the ERE and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis.

[0010] In some embodiments, the first needle assembly includes a first structure having a first stepped shape including one or more first stairs, the first actuator has a second stepped shape including one or more second stairs configured to fit over at least one of the first stairs when placing the second stepped shape over the first stepped shape, and the first length is determined by a first positioning of the first and second stepped shapes, relative to one another, along the second axis. In other embodiments, the first actuator includes (i) a first structure having a first stepped shape including one or more first stairs, and (ii) a second stepped shape including one or more second stairs configured to fit over at least one of the first stairs when placing the second stepped shape over the first stepped shape, and the first length is determined by a first positioning of the first and second stepped shapes, relative to one another, along the second axis. In yet other embodiments, the first and second stairs have a same size along at least one of the first axis and the second axis.

[0011] In some embodiments, the first and second stairs have a different size along at least one of the first axis and the second axis. In other embodiments, the second actuator includes (i) a second structure having a third stepped shape including one or more third stairs, and (ii) a fourth stepped shape including one or more fourth stairs configured to fit over at least one of the third stairs when placing the fourth stepped shape over the third stepped shape, and the second length is determined by a second positioning of the third and fourth stepped shapes, relative to one another, along the second axis. In yet other embodiments, the second positioning differs from the first positioning.

[0012] In some embodiments, the first and second actuators differ from one another in at least one of (i) a length along the second axis, and (ii) a shape. In other embodiments, the first and second actuators include a shape memory alloy, which is configured to have (i) the first length in response to receiving an electrical signal, and (ii) the second length without receiving the electrical signal, and including a controller, which is configured to apply the electrical signal to the first actuator and not to apply the electrical signal to the second actuator. In yet other embodiments, the first and second actuators are placed in first and second channels, respectively, and in response to applying the electrical signal, the first and second actuators are configured to reach first and second positions along the first and second channels, respectively.

[0013] There is additionally provided, in accordance with an embodiment of the present invention, a method for producing a system for knitting fibers, the method including connecting to a rotating motor configured to rotate about a first axis, an eccentric rotatable element (ERE). First and second needle assemblies that are intended to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, for knitting a garment from a plurality of the fibers, are received. A first actuators is coupled between the ERE and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis. A second actuators is coupled between the ERE and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis. There is further provided, in accordance with an embodiment of the present invention, a system for knitting fibers, the system including (i) first and second needle assemblies, which are configured to be moved alternately in a first direction and in a second direction along a first axis, and to knit a garment from a plurality of the fibers, and (ii) first and second eccentric rotatable elements (EREs) having respective different first and second shapes, the first and second EREs are connected to a rotating motor and are configured to rotate about a second axis, different from the first axis, and, due to the different first and second shapes, to move the first and second needle assemblies in respective first and second movement ranges that are different from one another.

[0014] In some embodiments, the first ERE includes a first recess having a first depth into the first ERE, and the second ERE includes a second recess having a second depth into the second ERE, the first and second depth differ from one another. In other embodiments, the system includes a cap configured to be mounted over the first needle assembly, and to disable the knitting of the garment by the first needle assembly.

[0015] There is additionally provided, in accordance with an embodiment of the present invention, a method for producing a system for knitting fibers, the method including receiving first and second needle assemblies, which are intended to be moved alternately in a first direction and in a second direction along a first axis, for knitting a garment from a plurality of the fibers. First and second eccentric rotatable elements (EREs) having respective different first and second shapes, are connected to a rotating motor configured to rotate about a second axis different from the first axis, and, due to the different first and second shapes, the first and second needle assemblies being moved in respective first and second movement ranges that are different from one another.

[0016] In some embodiments, the method includes forming (i) in the first ERE, a first recess having a first depth into the first ERE, and (ii) in the second ERE, a second recess having a second depth into the second ERE, and the first and second depth differ from one another. In other embodiments, the method includes mounting a cap over the first needle assembly, for disabling the knitting of the garment by the first needle assembly.

[0017] There is additionally provided, in accordance with an embodiment of the present invention, a method for knitting fibers, the method including: in a system including: (i) an eccentric rotatable element (ERE), which is connected to a rotating motor and is configured to rotate about a first axis, (ii) first and second needle assemblies, which are configured to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, and to knit a garment from a plurality of the fibers, (iii) a first actuator, coupled between the ERE and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis, and (iv) a second actuator, coupled between the ERE and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis, rotating the ERE about the first axis. The first and second needle assemblies being moved in the first and second movement ranges, respectively, along the second axis. The garment having a predefined pattern, which is based on the first and second movement ranges, is knitted from the plurality of the fibers.

[0018] There is additionally provided, in accordance with an embodiment of the present invention, a method for knitting fibers, the method including, in a system including (i) first and second needle assemblies, which are configured to be moved alternately in a first direction and in a second direction along a first axis, and to knit a garment from a plurality of the fibers, and (ii) first and second eccentric rotatable elements (EREs) having respective different first and second shapes, the first and second EREs are connected to a rotating motor and are configured to rotate about a second axis, different from the first axis, and, due to the different first and second shapes, to move the first and second needle assemblies in respective first and second movement ranges that are different from one another, rotating the first and second about the second axis. The first and second needle assemblies being moved in the first and second movement ranges, respectively, along the first axis. The garment having a predefined pattern, which is based on the first and second movement ranges, is knitted from the plurality of the fibers.

[0019] The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which:

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Fig. 1 is a schematic side view of a knitting system, in accordance with an embodiment of the present invention;

[0022] Fig. 2 is a schematic side view of a needle assembly of a knitting system, in accordance with an embodiment of the present invention;

[0023] Fig. 3A is a schematic side view of a needle assembly of a knitting system, in accordance with another embodiment of the present invention; Figs. 3B and 3C are schematic side views of the needle assembly of Fig. 3A in two positions, in accordance with embodiments of the present invention;

[0024] Figs. 4A, 4B and 4C are schematic side views of a needle assembly, and an actuator in three positions, in accordance with embodiments of the present invention;

[0025] Fig. 5 is a flow chart that schematically illustrates a method for producing the system of Fig. 1, in accordance with an embodiment of the present invention; and

[0026] Fig. 6 is a flow chart that schematically illustrates a method for producing the system of Fig. 1, in accordance with another embodiment of the present invention.

[0027] DETAILED DESCRIPTION OF EMBODIMENTS

[0028] OVERVIEW

[0029] Various types of knitting systems are used for knitting fabrics and garments. Such systems comprise a series of needles, which are mounted on a carriage and are arranged in a circular or linear configuration. In an example configuration, a carriage of a knitting system may have a rail that leads and moves the needles in a track that combines horizontal sections and inclined sections in order to move the needles horizontally and vertically for the purpose of knitting.

[0030] The knitting system must be able to produce and move knits between needles in order to manipulate the size and / or structure (e.g., texture or pattern) of the manufactured fabric or garment. Some of the knitting systems known in the art do not have this capability, and produce different patterns in different patches, and subsequently, the patches are stitched together in order to obtain a fabric and / or garment having multiple patterns.

[0031] Embodiments of the present invention that are described hereinbelow provide techniques for improving the productivity of knitting systems by enabling seamless and high-speed knitting of multiple patterns in fabrics and garments.

[0032] In some embodiments, a system for knitting garments and / or fabrics comprises (i) an eccentric rotatable element (ERE - also referred to herein as a cam), which is connected to a rotating motor and is configured to rotate about a first axis, and (ii) first and second needle assemblies, which are configured to be moved by the cam alternately in a first direction and in a second direction along a second axis, different from the first axis, and to knit a garment from multiple fibers. The system further comprises (iii) a first actuator, coupled between the cam and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the cam about the first axis, and (iv) a second actuator, coupled between the cam and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the cam about the first axis. Several examples of the actuators and the needle assemblies are described in Figs. 2, 3A, 3B, 3C, 4A, 4B, and 4C below. It is noted that all these needle assemblies are configured to be assembled in system 11, which is described in detail in Fig. 1 below.

[0033] In the context of the present disclosure and in the claims, the terms “garment,” “fabric,” “item of clothing,” grammatical variations thereof, and other sort of items fabricated using a knitting system, are used interchangeably. For example, a claim reciting the term “garment” also refers to any sort of item of clothing, fabric or any other term related to an item produced in a knitting process.

[0034] In other embodiments, the system may comprise: (i) first and second needle assemblies, which are configured to be moved alternately in a first direction and in a second direction along a first axis, and to knit a garment from a plurality of the fibers, and (ii) first and second sections of the cam (or cams disjointed from one another and controlled separately) having respective different first and second shapes (and / or different first and second sizes). As such, the first and second sections of the cam are connected to a rotating motor and are configured to rotate about a second axis, different from the first axis, and, due to the different first and second shapes (and / or sizes), to move the first and second needle assemblies in respective first and second movement ranges that are different from one another. The system and the sections of the cam are described in detail in Fig. 1 below. Moreover, methods for performing the knitting process using the various configurations of the knitting system, cam sections, needle assemblies, and actuators, are described below for selected configurations shown in Figs. 1, 2, and 4A- 4C.

[0035] The disclosed techniques improve the productivity of knitting systems by enabling (i) substantially higher speed and continuity of the knitting process (e.g., by rotating the eccentric rotatable element at about 2500 revolutions per minute), and (ii) seamless knitting of different patterns in the garments (e.g., using different movement ranges for different respective needle assemblies of the knitting system.

[0036] SYSTEM DESCRIPTION

[0037] Fig. 1 is a schematic side view of a knitting system 11, in accordance with an embodiment of the present invention. Knitting system 11 is also referred to herein as system 11, for brevity, and is configured to knit garments and / or fabrics. In some embodiments, system 11 comprises an eccentric rotatable element, also referred to herein as a cam 22, which is connected to a rotating motor 16 and is configured to rotate about an axis 18 (e.g., parallel to a Y-axis of an XYZ coordinate system) at a selected rotating speed, e.g., about 2,500 rounds per minute (RPM). In the present example, cam 22 has an irregularshaped cross section with a cylindrical shaft having recesses 13 and protrusions 15 formed on the outer surface of cam 22.

[0038] Reference is now made to inset 24 and inset 26 showing sectional views of respective sections 27 and 28 of cam 22. In some embodiments, both sections 27 and 28 have an eccentric and irregular shape, the eccentricity is shown by the position of axis 18, and the irregular shape is shown by (i) shallow recesses 13a and 13b separated by a shallow protrusion 15a of section 27, and (ii) a pair of recesses 13c (deeper than recesses 13a and 13b), separated by a protrusion 15b of section 28 (larger than protrusion 15a). Moreover, examples of the irregularity of the sections of cam 22 are shown by recesses 13a and 13b having a different shape from one another, and recesses 13c having the same shape. In the present example, cam 22 comprises multiple sections, such as sections 27 and 28 coupled to one another along axis 18. In other embodiments, at least one of the sections (e.g., section 27 and / or section 28) may be separated and being moved using a suitable apparatus (e.g., instead of cam 22).

[0039] Reference is now made back to the general view of Fig. 1. In some embodiments, system 11 comprises multiple needle assemblies 33, which are configured to be moved, by the recesses 13 and protrusions 15 of cam 22, alternately in a first direction and in a second direction along an axis 19 (e.g., parallel to a Z-axis of the XYZ coordinate system), and to knit a garment (not shown) from multiple fibers 20 supplied by multiple fiber holders 14, respectively. More specifically, when cam 22 rotates, a given needle assembly 33 (i) meets a first protrusion 15 that moves the needle assembly 33 in the first direction toward fiber holder 14 to pick up a first fiber 20, and subsequently, (ii) the given needle assembly 33 is pushed toward cam 22 to meet a first recess 13 while producing a knit (shown for example in Fig. 2 below). This sequence repeats by each needle assembly 33 in each revolution of cam 22, and thereby, allows high speed knitting (e.g., of about 2500 knits per minute by each needle assembly) using the plurality of needle assemblies 33. In some embodiments, system 11 comprises a motor 12, which is configured to supply fibers 20 to fiber holders 14, respectively.

[0040] In some embodiments, the irregular shape of the cross-section of cam 22 is intended to set a respective movement range of each needle assembly 33 during the knitting process. As such, the movement range of the needle assembly 33 being moved by section 28 is larger than that of the needle assembly 33 being moved by section 27. In some embodiments, the difference in shape and / or size of sections 27 and 28 results in a difference in the movement range of needle assembly 33 along the Z-axis, and thereby, producing a desired pattern of the garment by system 11. Moreover, system 11 comprises a controller 25, which is configured to control motors 12 and 16, and other components of system 11.

[0041] In other words, first and second needle assemblies 33, are configured (i) to be moved alternately in a first direction and in a second direction (e.g., up, and down) along the Z-axis, and (ii) to knit a garment from a plurality of the fibers. Sections 27 and 28 of cam 22 that (a) are connected to motor 16, (b) have respective different first and second shapes, and (c) are configured to rotate about a second axis, different from the first axis. As such, due to the different first and second shapes, sections 27 and 28 are configured to move the first and second needle assemblies 33 (e.g., along the Z-axis), in respective first and second movement ranges that are different from one another.

[0042] Reference is now made to an inset 4. In some cases, the pattern of the garment intended to be knitted requires deactivation of one or more needle assemblies 33. In some embodiments, one or more needle assemblies 33 may be temporarily deactivated by mounting a cap 21 over the respective needle assembly 33, or using any other suitable technique to prevent picking up a fiber 20 from a respective fiber holder 14.

[0043] This particular configuration of system 11 is shown by way of example, in order to illustrate certain problems that are addressed by embodiments of the present invention and to demonstrate the application of these embodiments in enhancing the performance of such a system. Embodiments of the present invention, however, are by no means limited to this specific sort of example system, and the principles described herein may similarly be applied to other sorts of knitting systems.

[0044] In some embodiments, system 11 may be used in a method for knitting a garment having a predefined pattern, which is produced by:

[0045] • controller 25, which controls rotating motor 16 to rotate cam 22 to at a suitable selected rotational speed (e.g., about 2500 RPM),

[0046] • while rotating cam 22, needle assemblies 33 are being moved along axis 19, up and down, by respective protrusions 15 and recesses 13, e.g., of sections 27 and 28 of cam 22, as described above, and

[0047] • At a garment knitting step that concludes the method, when each needle assembly 33 is being moved toward fiber holders 14, needle hook 34 of the respective needle assembly 33 picks one fiber 20 and produces a knit using any suitable knitting technique. It is noted that the pattern of the garment requires different movement ranges between at least two needle assemblies 33, which is obtained by the different shape and / or size of sections 27 and 28 of cam 22.

[0048] Fig. 2 is a schematic side view of one needle assembly 30, in accordance with an embodiment of the present invention. Needle assembly 30 may replace, for example, at least one needle assembly 33 in system 11 shown and described in Fig. 1 above, or in any other suitable type of knitting system as will be described herein.

[0049] In some embodiments, needle assembly 30 is configured to knit the garment. Needle assembly 30 comprises a needle 23, and a needle hook 34, which is extended from needle 23. It is noted that needle 23, and needle hook 34 are typically (but not necessarily) made from one part. Needle hook 34 is configured to pick up fiber 20 from fiber holder 14 (as shown in Fig. 1 above). Needle assembly 30 further comprises a latch 32 configured to rotate about an X axis of the XYZ coordinate system (e.g., using a hinge 9 or any other suitable apparatus) for (i) holding the picked fiber 20, and (ii) producing (together with hook 34 and needle 24) a knit (not shown) from the picked fiber 20. Needle assembly 30 further comprises a butt 31 placed in contact with an actuator 44 whose structure and functionality are described in detail herein.

[0050] In some embodiments, actuator 44, which is coupled between cam 22 and needle assembly 30, has an adjustable length for moving actuator 44 along the Z axis (with)in a movement range 8, in response to the rotation of cam 22 about axis 18 (e.g., parallel to the Y- axis). In the present example, actuator 44 comprises a U-shaped track 35, and a rod 38 configured to be inserted through an opening 7 and to be moved by the rotation of cam 22 along a channel 36 (of track 35) having length 8 along the Z-axis. In some embodiments, rod 38 (of actuator 44) is made from a shape-memory alloy, such as nitinol (an alloy of nickel and titanium) or any other suitable shape-memory alloy. In some embodiments, in response to applying an electrical signal and / or heat to rod 38, an edge 37 of rod 38 expands and has sufficient friction with the wall of track 35, to be stopped at a position 6 within channel 36. In an example implementation, edge 37 may have a forked edge configured to expand in response to the applied electrical signal and / or heat. In another example implementation, at least a section of rod 38 that is extended from edge 37, is configured to expand for positioning edge 37 at position 6. Additionally, or alternatively, rod 38 may be shaped as a screw or may have a telescopic structure, or may have any other suitable structure configured to set edge 37 at position 6 as described above. It is noted that the total length of actuator 44 is set by the length (size) of rod 38 along the Z-axis, and the location of position 6 (in which edge 37 is stopped) within length In some embodiments, in a knitting system, such as system 11, a respective actuator 44 is coupled between each needle assembly 30 and cam 22, but the position of rod 38 within channel 36 may be different in at least two of the actuators 44. In other words, (i) a first actuator 44, which is coupled between cam 22 and a first needle assembly 30, may have a first length for moving the first actuator 44 along the Z-axis in a first movement range, in response to the rotation of cam 22 about axis 18, and (ii) a second actuator 44, which is coupled between cam 22 and the second needle assembly 30, has a second length, different from the first length, for moving the second actuator 44 along the Z-axis, in a second movement range different from the first movement range, in response to the rotation of cam 22 about axis 18. In such embodiments, the rods 38 and tracks 35 of the first and second actuators 44 may have a different shape or size, and / or may receive a different electrical signal or heat, for setting the different movement ranges among the first and second actuators 44.

[0051] In some embodiments, controller 25 is configured to apply the electrical signals described above, and / or to control the delivery of the heat for controlling the temperature, and therefore, at least one of the length and the shape of the first and second actuators 44.

[0052] In the present example, cam 22 has a regular shape, e.g., of an ellipse, but in other embodiments, at least one of sections 27 and 28 (having irregular shape) may be used for moving rod 38.

[0053] In some embodiments, one or more actuators 44 that are coupled with needle assemblies 30 may be used in system 11 in a method for knitting a garment having a predefined pattern, which is produced by:

[0054] • controller 25, which controls rotating motor 16 to rotate cam 22 to at a suitable selected rotational speed (e.g., about 2500 RPM),

[0055] • while rotating cam 22, needle assemblies 30 and respective actuators 44, are being moved along axis 19, up and down, based on the different lengths among actuators 44, as described above, and

[0056] • At a garment knitting step that concludes the method, when each needle assembly 30 is being moved toward fiber holders 14, needle hook 34 of the respective needle assembly 30 picks one fiber 20 and produces a knit using any suitable knitting technique. It is noted that the pattern of the garment requires different movement ranges between at least two needle assemblies 30, which is obtained by the different lengths among different actuators 44, as described above.

[0057] Fig. 3A is a schematic side view of a needle assembly 40, in accordance with another embodiment of the present invention. Needle assembly 40 may replace, for example, at least one needle assembly 33 in system 11 shown and described in Fig. 1 above, or in any other suitable type of knitting system. Needle assembly 40 comprises hook 34, latch 32 and butt 31 described in detail in Fig. 2 above. In some embodiments, the butt 31 of needle assembly 40 is coupled with a wire 42 made from nitinol or from any other suitable shape-memory alloy. In the present configuration, wire 42 is coupled between butt 31 and cam 22, and configured to set the movement range of needle assembly 40 along the Z-axis as will be described herein.

[0058] In some embodiments, needle assembly 40 and wire 42 are placed within a trench 46 of a track 45 configured to guide needle assembly 40 along the Z-axis during the operation of the knitting system (e.g., system 11) in which cam is rotated for moving wire 42 and needle assembly 40 along the Z-axis, as described in Figs. 1 and 2 above.

[0059] Figs. 3B and 3C are schematic side views of needle assembly 40, in accordance with embodiments of the present invention. In some embodiments, wire 42 is configured to alter its length along the Z-axis in response to receiving an electrical signal that alters (e.g., increases) the temperature of wire 42. In the example of Fig. 3B, wire 42 does not receive the electrical signal and remains in a collapsed position, and in the example of Fig. 3C, wire 42 expands along the Z-axis in response to receiving the electrical signal.

[0060] In some embodiments, in the example of Fig. 3B, when cam 22 rotates about axis 18, and no electrical signal applied to wire 42, needle assembly 40 is moved along trench 46, but all the parts of needle assembly 40 remain within the trench 46 of track 45. In the example of Fig. 3C, when cam 22 rotates about axis 18, and the electrical signal is applied to wire 42, needle assembly 40 is moved along trench 46, and at least hook 34 of needle assembly 40 extends out of the trench 46 of track 45 to pick a fiber 20, as described in detail in Fig. 1 above.

[0061] In alternative embodiments, hook 34 of needle assembly 40 extends out of the trench 46 to pick a fiber 20 in both Figs. 3B and 3C, but the movement range along the Z-axis is longer in Fig. 3C compared to that of Fig. 3B.

[0062] In such embodiments, wire 42 has the same functionality as actuator 44 of Fig. 2 above, so that in response to an increase of the temperature (e.g., using the electrical signal or any other suitable technique), wire 42 is configured to have an increased length along the Z-axis, and thereby, increases the movement range of needle assembly 40 along the Z-axis.

[0063] In some embodiments, controller 25 is configured to apply the electrical signals described above, and / or to control the delivery of the heat for controlling the temperature, and therefore, at least one of the length and the shape of wires 42 that function as actuators, as described above. In the present example, cam 22 has a regular shape, e.g., of an ellipse, but in other embodiments, at least one of sections 27 and 28 (having irregular shape) may be used for moving wire 42.

[0064] Figs. 4A, 4B and 4C are schematic side views of a needle assembly 55 and an actuator 66 in three respective positions, in accordance with embodiments of the present invention. The combination of needle assembly 55 and actuator 66 may replace, for example, at least one of needle assemblies 33 in system 11 of Fig. 1 above.

[0065] Reference is now made to Fig. 4A. In some embodiments, needle assembly 55 comprises hook 34, latch 32 described in detail in Fig. 2 above, and a needle 23. In some embodiments, instead of or in addition to the butt described in Figs. 2, and 3A-3C above, needle assembly 55 comprises a structure 56 typically made from a suitable stiff material, such as but not limited to stainless steel, aluminum alloy, a polymer such as but not limited to polyether ether ketone (PEEK). In some embodiments, structure 56 has a stepped shape comprising any suitable number of steps. In the present example, structure 56 comprises at least steps 77a, 77b, and 77c (also referred to herein as stairs 77a, 77b, and 77c), and the size of steps 77a, 77b, and 77c is approximately similar to one another along at least one of (and typically all of) the X-, Y- and Z-axes. In alternative embodiments, the size of at least two of steps 77a, 77b, and 77c differs from one another in at least one of the X-, Y- and Z-axes.

[0066] In some embodiments, actuator 66 is made from a suitable stiff material such as but not limited to stainless steel, aluminum alloy, a polymer such as but not limited to polyether ether ketone (PEEK). Moreover, actuator 66 has a stepped shape comprising any suitable number of steps. In the present example, actuator 66 comprises at least steps 88a, 88b, and 88c (also referred to herein as stairs 88a, 88b, and 88c), and the size of steps 88a, 88b, and 88c is approximately similar to one another along at least one of (and typically all of) the X-, Y- and Z-axes. In alternative embodiments, the size of at least two of steps 88a, 88b, and 88c differ from one another along at least one of the X-, Y- and Z-axes.

[0067] In alternative embodiments, actuator 66 may have another configuration. For example, actuator 66 may comprise both (i) stairs 88a, 88b, and 88c, and (ii) structure 55 having stairs 77a, 77b, and 77c. As such, all the embodiments described in Figs. 4A-4C are applicable, mutatis mutandis, to the configuration of actuator 66 described in these alternative embodiments.

[0068] In some embodiments, the size and shape of the stairs in structure 56 and actuator 66 are adjusted to each other, so that each of stairs 77a, 77b, and 77c corresponds to each of stairs 88a, 88b, and 88c. In such embodiments, each of stairs 88a, 88b, and 88c may be placed over each of stairs 77a, 77b, and 77c, so that stairs 88a, 88b, and 88c of actuator 66 are configured to be fitted over stairs 77a, 77b, and 77c of structure 56. Moreover, structure 56 and actuator 66 are configured to be moved relative to one another to a desired position in which at least a portion of the stepped shape of actuator 66 is fitted over at least a portion of the stepped shape of structure 56. Moreover, after being fitted to one another, actuator 66 over structure 56 may be coupled to one another using any suitable coupling (e.g., gluing, or using screws) and / or locking technique. Alternatively, actuator 66 and structure 56 are fitted together without being coupled, so that the step shape is sufficient to keep them attached to one another.

[0069] In some embodiments, the size and shape of (i) each of steps 77a, 77b, and 77c, and (ii) each of steps 88a, 88b, and 88c, may be similar to one another along at least one of the X-, Y- and Z-axes. In other embodiments, at least two of the steps among steps 77a, 77b, 77c, 88a, 88b, and 88c may differ from one another along at least one of the X-, Y- and Z-axes.

[0070] In some embodiments, in the position shown in Fig. 4A, step 88a is placed over step 77b, and step 88b is placed over step 77c. Moreover, (i) in the position shown in Fig. 4B, step 88a is placed over step 77a, step 88b is placed over step 77b, and step 88c is placed over step 77c, and (ii) in the position shown in Fig. 4C, step 88b is placed over step 77a, and step 88c is placed over step 77b. In some embodiments, actuator 66 is placed (e.g., coupled) between cam 22 and needle assembly 55, such that an edge 90 of actuator is placed in contact with cam 22, which is configured to rotate, and thereby, to move actuator 66 and needle assembly 55 along the Z-axis.

[0071] In such embodiments, in the configurations shown in Figs. 4A, 4B and 4C, cam 22 has the same rotation position in all of Figs. 4A, 4B and 4C, and the distal edge of hook 34 reaches positions 72, 74, and 76, respectively, along the Z-axis. In other words, the combination of needle assembly 55 and actuator 66 has a different length along the Z-axis in the fitting positions and / or configurations shown in Figs. 4A, 4B and 4C.

[0072] In some embodiments, the configurations shown in Figs. 4A, 4B and 4C may replace, for example, three respective needle assemblies 33 in system 11 of Fig. 1 above. In such embodiments, the length of needle assembly 55 along the Z-axis is similar among all the configurations of Figs. 4A, 4B and 4C, but the actual length of the combined structure of needle assembly 55 and actuator 66, along the Z-axis, is different among the configurations shown in Figs. 4A, 4B and 4C. Thus, at the same rotation position of cam 22, the movement range of the combined structure of needle assembly 55 and actuator 66 is different from one another. More specifically, the configurations shown in Fig. 4A has the longest movement range, and the configurations shown in Fig. 4C has the shortest movement range among the three configurations shown in Figs. 4A, 4B and 4C. In some embodiments, the configurations shown in Figs. 4A, 4B and 4C may be altered for at least one of and typically all the combined structures (of needle assembly 55 and actuator 66) used in system 11. For example, (i) in order to knit a first pattern in a garment, the configurations shown in Figs. 4A, 4B and 4C may be applied to the first, second and third needle assemblies along the Y-axis of system 11, respectively, and (ii) in order to knit in a garment, a second pattern, different from the first pattern, the configurations shown in Figs. 4A, 4B and 4C may be applied to the first, third and second needle assemblies along the Y-axis of system 11, respectively. Moreover, the length, and the movement range of the combination of actuator 66 and needle assembly 55 along the Z-axis, may be altered by (i) moving actuator 66 and structure

[0073] 55 relative to one another to a desired position (e.g., selected among the positions shown in the configurations of Figs. 3 A, 3B and 3C above), and subsequently, (ii) coupling between actuator 66 and structure 55 at the selected configuration, to prevent relative movement therebetween (e.g., in response to the rotation of cam 22). As such, in order to change the pattern of the garment being knitted, an operator of system 11 may either (i) assemble each configuration at a preassigned position along the Y-axis of system 11, or (ii) adjust the position of actuator 66 and needle assembly 55 relative to one another at one or more of the combined structures (of actuator 66 and needle assembly 55) positioned along the Y-axis of system 11.

[0074] In the present example, cam 22 has a regular shape, e.g., of an ellipse, but in other embodiments, at least one of sections 27 and 28 (having irregular shape) of cam 22 may be used for moving actuator 66 in at least one of the configurations shown in Figs. 4A-4C. For example, the configuration shown in at least one of Figs. 4A-4C may be implemented by moving actuator 66 using, for example, section 27 or section 28 of cam 22.

[0075] In some embodiments, controller 25 is configured to control the relative positioning between structure 56 and actuator 66, e.g., by controlling an apparatus (not shown) configured to move structure 56 and actuator 66, or by displaying the required relative positions of structure

[0076] 56 and actuator 66 to a technician intended to assemble and couple structure 56 and actuator 66 to one another.

[0077] The configuration of each of actuator 66 and needle assembly 55, and the combination thereof, is provided by way of example, in order to illustrate certain problems that are addressed by embodiments of the present invention and to demonstrate the application of these embodiments in enhancing the performance of such a knitting system. Embodiments of the present invention, however, are by no means limited to this specific sort of example knitting actuator and needle assembly integrated in a knitting system, and the principles described herein may similarly be applied to other sorts of actuators, needles, needle assemblies, and knitting systems.

[0078] In some embodiments, actuators 66 in different configurations, such as the configurations shown Figs. 4A-4C, which are coupled with respective needle assemblies 55, may be used in system 11 in a method for knitting a garment having a predefined pattern, which is produced by:

[0079] • controller 25, which controls rotating motor 16 to rotate cam 22 to at a suitable selected rotational speed (e.g., about 2500 RPM),

[0080] • while rotating cam 22, needle assemblies 55 and the respective actuators 66, are being moved along axis 19, up and down, based on the different lengths among actuators 66, as described in Figs. 4A-4C above, and

[0081] • At a garment knitting step that concludes the method, when each needle assembly 55 is being moved toward fiber holders 14, needle hook 34 of the respective needle assembly 55 picks one fiber 20 and produces a knit using any suitable knitting technique. It is noted that the pattern of the garment requires different movement ranges between at least two needle assemblies 55, which is obtained by the different lengths among different actuators 66, as described in detail above.

[0082] Fig. 5 is a flow chart that schematically illustrates a method for producing system 11 of Fig. 1, in accordance with an embodiment of the present invention.

[0083] The method begins at an eccentric rotatable element (ERE) connecting step 100, with connecting cam 22 to rotatable motor 16, which are described in detail in Fig. 1 above. At a needle assembly receiving step 102, any of the needle assemblies of Figs. 1-4C above are received. In the present example, needle assemblies 55 of Figs. 4A-4C above.

[0084] At a first actuator coupling step 104, actuator 66 of Fig. 4A, is coupled between cam 22 and needle assembly 55, as described in detail in Fig. 4A above.

[0085] At a second actuator coupling step 106 that concludes the method, actuator 66 of Fig. 4B, is coupled between cam 22 and needle assembly 55, as described in detail in Fig. 4B above.

[0086] Fig. 6 is a flow chart that schematically illustrates a method for producing knitting system 11, in accordance with another embodiment of the present invention.

[0087] The method begins at needle assembly receiving step 200, with receiving any of the needle assemblies of Figs. 1-4C above. In the present example, receiving first and second needle assemblies 55 of Figs. 4A and 4C above. At a cam producing step 202, sections 27 and 28 of cam 22 are produced by forming recesses 13a, 13b and 13c, and protrusions 15a and 15b having size and / or geometry different from one another, as described in detail in Fig. 1 above.

[0088] At a connecting step 204 that concludes the method, sections 27 and 28 of cam 22 are connected to rotatable motor 16 for moving the first and second needle assemblies 55 in respective first and second movement ranges that are different from one another, as described in detail in Figs. 1, and in Figs. 4A-4C above.

[0089] It will be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art. Documents incorporated by reference in the present patent application are to be considered an integral part of the application except that to the extent any terms are defined in these incorporated documents in a manner that conflicts with the definitions made explicitly or implicitly in the present specification, only the definitions in the present specification should be considered.

Claims

CLAIMS1. A system for knitting fibers, the system comprising: an eccentric rotatable element (ERE), which is connected to a rotating motor and is configured to rotate about a first axis; first and second needle assemblies, which are configured to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, and to knit a garment from a plurality of the fibers; a first actuator, coupled between the ERE and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis; and a second actuator, coupled between the ERE and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis.

2. The system according to claim 1, wherein the first needle assembly comprises a first structure having a first stepped shape comprising one or more first stairs, wherein the first actuator has a second stepped shape comprising one or more second stairs configured to fit over at least one of the first stairs when placing the second stepped shape over the first stepped shape, and wherein the first length is determined by a first positioning of the first and second stepped shapes, relative to one another, along the second axis.

3. The system according to claim 1, wherein the first actuator comprises (i) a first structure having a first stepped shape comprising one or more first stairs, and (ii) a second stepped shape comprising one or more second stairs configured to fit over at least one of the first stairs when placing the second stepped shape over the first stepped shape, and wherein the first length is determined by a first positioning of the first and second stepped shapes, relative to one another, along the second axis.

4. The system according to claim 2 or 3, wherein the first and second stairs have a same size along at least one of the first axis and the second axis.

5. The system according to claim 2 or 3, wherein the first and second stairs have a different size along at least one of the first axis and the second axis.

6. The system according to claim 2 or 3, wherein the second actuator comprises (i) a second structure having a third stepped shape comprising one or more third stairs, and (ii) a fourthstepped shape comprising one or more fourth stairs configured to fit over at least one of the third stairs when placing the fourth stepped shape over the third stepped shape, and wherein the second length is determined by a second positioning of the third and fourth stepped shapes, relative to one another, along the second axis.

7. The system according to claim 6, wherein the second positioning differs from the first positioning.

8. The system according to claim 6, wherein the first and second actuators differ from one another in at least one of (i) a length along the second axis, and (ii) a shape.

9. The system according to claim 1, wherein the first and second actuators comprise a shape memory alloy, which is configured to have (i) the first length in response to receiving an electrical signal, and (ii) the second length without receiving the electrical signal, and comprising a controller, which is configured to apply the electrical signal to the first actuator and not to apply the electrical signal to the second actuator.

10. The system according to claim 9, wherein the first and second actuators are placed in first and second channels, respectively, and wherein in response to applying the electrical signal, the first and second actuators are configured to reach first and second positions along the first and second channels, respectively.

11. A method for producing a system for knitting fibers, the method comprising: connecting, to a rotating motor configured to rotate about a first axis, an eccentric rotatable element (ERE); receiving first and second needle assemblies that are intended to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, for knitting a garment from a plurality of the fibers; coupling, between the ERE and the first needle assembly, a first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis; and coupling, between the ERE and the second needle assembly, a second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis.

12. The method according to claim 11, wherein the first needle assembly comprises a first structure having a first stepped shape comprising one or more first stairs, wherein the firstactuator has a second stepped shape comprising one or more second stairs, wherein coupling the first actuator comprises placing the second stepped shape over the first stepped shape and fitting the one or more second stairs over at least one of the first stairs, and determining the first length by controlling a first positioning of the first and second stepped shapes, relative to one another, along the second axis.

13. The method according to claim 11, wherein the first actuator comprises (i) a first structure having a first stepped shape comprising one or more first stairs, and (ii) a second stepped shape comprising one or more second stairs, wherein coupling the first actuator comprises placing the second stepped shape over the first stepped shape and fitting the one or more second stairs over at least one of the first stairs, and determining the first length by controlling a first positioning of the first and second stepped shapes, relative to one another, along the second axis.

14. The method according to claim 12 or 13, wherein coupling the first actuator comprises coupling the first and second stairs having a same size along at least one of the first axis and the second axis.

15. The method according to claim 12 or 13, wherein coupling the first actuator comprises coupling the first and second stairs having a different size along at least one of the first axis and the second axis.

16. The method according to claim 12 or 13, wherein the second actuator comprises (i) a second structure having a third stepped shape comprising one or more third stairs, and (ii) a fourth stepped shape comprising one or more fourth stairs, wherein coupling the second actuator comprises placing the fourth stepped shape over the third stepped shape and fitting the one or more fourth stairs over at least one of the third stairs, and determining the first length by controlling a second positioning of the third and fourth stepped shapes, relative to one another, along the second axis.

17. The method according to claim 16, wherein the second positioning differs from the first positioning.

18. The method according to claim 16, wherein coupling the first and second actuators comprises coupling the first and second actuators different from one another in at least one of (i) a length along the second axis, and (ii) a shape.

19. The method according to claim 11, wherein the first and second actuators comprise a shape memory alloy, having (i) the first length in response to receiving an electrical signal, and(ii) the second length without receiving the electrical signal, and comprising applying the electrical signal to the first actuator and not applying the electrical signal to the second actuator.

20. The method according to claim 19, and comprising, placing the first and second actuators in first and second channels, respectively, and wherein applying the electrical signal, comprises reaching, by the first and second actuators, first and second positions along the first and second channels, respectively.

21. A system for knitting fibers, the system comprising: first and second needle assemblies, which are configured to be moved alternately in a first direction and in a second direction along a first axis, and to knit a garment from a plurality of the fibers; and first and second eccentric rotatable elements (EREs) having respective different first and second shapes, wherein the first and second EREs are connected to a rotating motor and are configured to rotate about a second axis, different from the first axis, and, due to the different first and second shapes, to move the first and second needle assemblies in respective first and second movement ranges that are different from one another.

22. The system according to claim 21, wherein the first ERE comprises a first recess having a first depth into the first ERE, and the second ERE comprises a second recess having a second depth into the second ERE, wherein the first and second depth differ from one another.

23. The system according to claim 21, and comprising a cap configured to be mounted over the first needle assembly, and to disable the knitting of the garment by the first needle assembly.

24. A method for producing a system for knitting fibers, the method comprising: receiving, first and second needle assemblies, which are intended to be moved alternately in a first direction and in a second direction along a first axis, for knitting a garment from a plurality of the fibers; and connecting, to a rotating motor configured to rotate about a second axis different from the first axis, first and second eccentric rotatable elements (EREs) having respective different first and second shapes, and, due to the different first and second shapes, moving the first and second needle assemblies in respective first and second movement ranges that are different from one another.

25. The method according to claim 24, and comprising forming (i) in the first ERE, a first recess having a first depth into the first ERE, and (ii) in the second ERE, a second recess having a second depth into the second ERE, wherein the first and second depth differ from one another.

26. The method according to claim 21, and comprising mounting a cap over the first needle assembly, for disabling the knitting of the garment by the first needle assembly.

27. A method for knitting fibers, the method comprising: in a system comprising: an eccentric rotatable element (ERE), which is connected to a rotating motor and is configured to rotate about a first axis; first and second needle assemblies, which are configured to be moved by the ERE alternately in a first direction and in a second direction along a second axis, different from the first axis, and to knit a garment from a plurality of the fibers; a first actuator, coupled between the ERE and the first needle assembly, the first actuator having a first length for moving the first actuator along the second axis in a first movement range, in response to rotation of the ERE about the first axis; and a second actuator, coupled between the ERE and the second needle assembly, the second actuator having a second length, different from the first length, for moving the second actuator along the second axis, in a second movement range different from the first movement range, in response to rotation of the ERE about the first axis, rotating the ERE about the first axis; moving the first and second needle assemblies in the first and second movement ranges, respectively, along the second axis; and knitting from the plurality of the fibers the garment having a predefined pattern, which is based on the first and second movement ranges.

28. A method for knitting fibers, the method comprising:In a system comprising: first and second needle assemblies, which are configured to be moved alternately in a first direction and in a second direction along a first axis, and to knit a garment from a plurality of the fibers; and first and second eccentric rotatable elements (EREs) having respective different first and second shapes, wherein the first and second EREs are connected to a rotating motor and are configured to rotate about a second axis, different from the first axis, and, due to the different first and second shapes, to move the first and second needle assemblies in respective first and second movement ranges that are different from one another, rotating the first and second about the second axis;moving the first and second needle assemblies in the first and second movement ranges, respectively, along the first axis; and knitting from the plurality of the fibers the garment having a predefined pattern, which is based on the first and second movement ranges.

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