Angular Orientation Detection for Tubular Knitted Articles
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Solution Overview
Problem
Existing methods for orienting tubular knitted articles, such as socks, for correct sewing or linking of the toe are inefficient due to reliance on color marks that increase production costs and are unreliable, especially on double cylinder circular machines.
Innovation Solution
A method involving stretching the article over a tubular member with detection elements along its edge to determine the angular position of a band surrounding the toe end, allowing precise identification of fabric pockets without rotating sensors, using electrical contacts for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a color mark is knitted using yarns of different colors to differentiate the mark from the remaining part of the edge, then the reference mark can be read by optical sensors for orientation, but the production costs increase and the production rate of the circular machine is reduced
Solution Approach 1:
The invention extracts the orientation reference function from the knitting process itself and relocates it to a post-knitting stage. Instead of incorporating color marks during knitting, the patent uses a separate positioning system with a support element and optical sensors that detect geometric features of the toe pocket after the article is produced. This separates the production process from the orientation detection process, allowing full-speed knitting without interruptions for mark creation.
Solution Approach 2:
The invention introduces an intermediary positioning system consisting of a support element with a positioning element and optical sensors. This intermediary system mediates between the knitted article and the sewing machine, providing orientation information without requiring modifications to the article during knitting. The support element holds the article and the sensors detect the angular position of geometric features, serving as a bridge that enables precise orientation detection without affecting production speed.
2Measurement precision
If a color mark is knitted using yarns of different colors to differentiate the mark from the remaining part of the edge, then the reference mark can be read by optical sensors for orientation, but the production costs increase
Solution Approach 1:
The invention extracts the orientation reference function from the knitting process itself and relocates it to a post-knitting stage. Instead of incorporating color marks during knitting, the patent uses a separate positioning system with a support element and optical sensors that detect geometric features of the toe pocket after the article is produced. This separates the production process from the orientation detection process, allowing full-speed knitting without interruptions for mark creation.
Solution Approach 2:
The invention replaces expensive multi-color yarn combinations with a simple, inexpensive positioning system. The support element and optical sensors provide a cost-effective solution that uses the article's existing geometric features rather than requiring additional materials. This disposable positioning approach (the support element can be discarded or reused) eliminates the need for costly color differentiation materials.
3Measurement precision
If the sock is inserted over a tube and positioned so that the toe pocket projects beyond the edge of the tube, then the optical sensors can detect the toe pocket position, but the operation becomes unreliable and strictly dependent on the unpredictable behavior of the fabric
Solution Approach 1:
The invention applies preliminary action by pre-positioning the article on a support element in a standardized manner before detection. The support element with its positioning element ensures the article is held in a consistent, predetermined position regardless of fabric behavior. This preliminary positioning action eliminates the need for the toe pocket to project unpredictably, as the system is designed to detect features in their natural positioned state.
Solution Approach 2:
The invention enables self-service by using the article's own geometric features (the toe pocket structure) as the detection target rather than requiring external marks or projections. The optical sensors detect the angular position of the toe pocket's geometric features directly, allowing the article to serve its own orientation function without needing to be manipulated into unnatural positions or rely on fabric thickness variations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies and enhances the reliability of orienting tubular knitted articles by eliminating the need for color marks and reducing production costs, ensuring precise alignment of fabric pockets for correct sewing or linking.
Implementation Method 1
detecting the angular position of said band on the tubular member as a function of interaction between said crown of detection elements and said band
Data Source
Figure 1~2
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AI summary
The device comprises: a tubular member (1); means (3, 5, 11) to insert and stretch a tubular knitted article (M) over the outside of said tubular member and over an end thereof; a control unit. It also comprises a crown (101) of detection elements cooperating with the end of the tubular member, and the control unit is programmed to determine the angular position of the tubular article stretched over the tubular member by reading the signal supplied by the detection elements in a definite reciprocal position of said tubular article, of said tubular member and of said detection elements.