Direct Injection Lubrication for Knitting Machines
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Solution Overview
Problem
Current lubrication systems for knitting machines are costly, difficult to repair, inefficient in lubricant distribution, and require excessive compressed air, leading to high energy consumption and environmental contamination.
Innovation Solution
A direct injection lubrication system that allows for both spray and pulse oil lubrication from a single unit, using a common nozzle design and central oil supply, reducing the need for compressed air and individual oil tanks, and featuring a 'no drip' nozzle tip to prevent oil breakup into mist or fog.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray lubrication system is used, then lubricant distribution is improved, but compressed air consumption increases and energy cost rises
Solution Approach 1:
The patent changes the physical parameters of the lubrication system by switching between spray mode (for better distribution) and pulse mode (for lower air consumption). The system allows parameter adjustment based on operational needs, using compressed air only when spray lubrication is required, thereby resolving the contradiction between lubricant distribution quality and energy consumption.
Solution Approach 2:
The system dynamically switches between two lubrication modes (spray and pulse) depending on the knitting machine's operational requirements. This dynamic adaptability allows the system to optimize both lubricant distribution and compressed air consumption by selecting the appropriate mode for each operating condition.
2Object-affected harmful factors
If anti-fog nozzles are used to re-condense oil, then environmental contamination is reduced, but system cost increases
Solution Approach 1:
The patent extracts and eliminates the need for expensive anti-fog nozzles by using an alternative approach: compressed air pulses that efficiently deliver lubricant directly to the knitting elements without creating excessive mist. This extraction of the problematic component (anti-fog nozzles) reduces system cost while still minimizing environmental contamination through controlled pulse delivery.
Solution Approach 2:
The system replaces expensive anti-fog nozzles with simpler, more economical pulse delivery mechanisms. The pulse mode uses brief, controlled bursts of compressed air to deliver lubricant efficiently, avoiding the need for costly anti-fog technology while maintaining environmental acceptability.
3Reliability
If individual oil tanks are used for each lubricator, then lubrication independence is ensured, but device complexity and cost increase
Solution Approach 1:
The patent segments the lubrication system into modular units, each capable of independent operation with its own oil tank. This segmentation allows each lubricator to function independently while maintaining the option for centralized oil supply through the pulse mode, thereby ensuring reliability without mandating high complexity.
Solution Approach 2:
The system is designed with universal components that can function in both spray and pulse modes. The common nozzle design and interchangeable tubing allow a single lubricator unit to serve multiple functions, reducing overall system complexity while maintaining lubrication independence through the modular architecture.
4Manufacturing precision
If spray nozzles are used for mist lubrication, then lubricant distribution is improved, but repair difficulty increases when clogs occur
Solution Approach 1:
The patent inverts the traditional approach by making the pulse mode (with simpler nozzle requirements) the primary delivery method, using spray mode only when distribution optimization is needed. This inversion reduces the frequency of clog-related repairs while maintaining the ability to achieve excellent oil distribution when required.
Solution Approach 2:
The system uses simpler nozzle designs in pulse mode that are less prone to clogging and easier to replace if needed. The interchangeable tubing and common nozzle design allow for quick replacement of potentially clogged components, reducing repair difficulty and downtime.
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
The system provides cost-effective, efficient lubrication with reduced maintenance needs, even distribution of lubricant, and minimized environmental contamination, while allowing for a wide range of lubricant viscosities and easier repair.
Implementation Method 1
a solenoid valve that is controlled by a pulse timer that can be set to opening the valve in a pulse manner several times per minute
Implementation Method 2
The air then enters a regulator with gauge so that the air pressure can be set to whatever the operator prefers
Implementation Method 3
The oil then enters the oil chamber of the 'Direct Inject Oil Generator'... Due to the special design of the nozzle tip, the nozzle will allow oil spray to eject the oil several centimeters (inches) from the tip without causing wasteful oil dripping at the exit point
Implementation Method 4
a pulse timer that can be set to opening the valve in a pulse manner several times per minute depending on what volume of output is required
Implementation Method 5
The air then enters the oil chamber of the 'Direct Inject Oil Generator' that is shown in drawing marked Direct Inject Oil Generator
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
An oil spray lubricator system for knitting machines, operable with a source of compressed air and a source of lubricating oil under pressure, comprising: a. an air flow filter that receives compressed air from said source thereof and reduces water in the air flow, b. a valve that controls said air flow, c. a first regulator that sets selected pressure of said air flow, and d. a second regulator that receives oil flow from said source thereof and sets selected pressure of said oil flow, g. a pulse timer that ejects said oil flow in selected frequency of pulses, h. a multi-port oil generator having an oil chamber having oil and air inlets and multiple oil ducts each of which has an inlet and an outlet and is situated within a larger bore diameter air duct that surrounds and creates an annular passageway between said oil and air ducts, and i. at least one ejection nozzle.