Circular Knitting Machine Camera Timing for Needle Defect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional circular knitting machines struggle with real-time quality inspection during knitting operations, leading to defects in the fabric and inefficient replacement of knitting needles, resulting in resource waste and increased production costs.
Innovation Solution
The circular knitting machine incorporates a main camera module and an auxiliary camera module to capture images of the tubular fabric in real-time, allowing for the determination of knitting needle status and enabling real-time monitoring and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If quality inspection is performed after knitting is completed, then fabric defects can be detected, but it is impossible to judge which specific knitting needles need replacement, resulting in replacement of all needles (1500-2640 needles) and resource waste
Solution Approach 1:
The patent divides the knitting machine into individual needle units (1500-2640 separate knitting needles) and implements independent status monitoring for each needle through image recognition technology. This allows identification of specific defective needles rather than treating the entire machine as one unit, enabling selective replacement of only the problematic needles (typically 1-5 needles) instead of replacing all needles.
Solution Approach 2:
The patent implements real-time feedback by continuously monitoring knitting needle status during the knitting process through image capture and analysis. The system provides immediate feedback on needle conditions (such as latch opening status, yarn loop formation) allowing operators to identify and replace specific defective needles promptly, preventing defect propagation and avoiding unnecessary mass replacement of all needles.
2Productivity
If a cloth rolling mechanism is used to wind up fabric during knitting, then fabric production efficiency is improved, but the connecting rods in the cloth rolling mechanism obstruct image recognition of the tubular fabric
Solution Approach 1:
The patent employs dynamic image capture timing that coordinates with the periodic motion of the cloth rolling mechanism. The system captures images at specific moments when the connecting rods are in positions that minimize obstruction, allowing continuous monitoring of fabric quality while maintaining the efficiency benefits of the cloth rolling mechanism.
Solution Approach 2:
The patent implements periodic image capture synchronized with the rotational cycle of the cloth rolling mechanism. By capturing images at regular intervals when connecting rods are in favorable positions, the system maintains continuous quality monitoring capability while the cloth rolling mechanism operates continuously to maximize productivity.
Data Source
AI summary
A circular knitting machine with real-time prompt of a knitting machine status. The circular knitting machine includes a base, a cloth rolling machine that rotates relative to the base during knitting operation process, a main camera module fixed on the base, and an auxiliary camera module fixed on the base and disposed close to the main camera module. The main camera module includes a first central axis, and the main camera module takes pictures of a tubular fabric knitted by the circular knitting machine. The auxiliary camera module includes a second central axis intersecting with the first central axis. The auxiliary camera module and the main camera module face a same side of the tubular fabric. A startup timing of the auxiliary camera module only occurs when one of the plurality of connecting rods passes between the main camera module and the tubular fabric.