Double Bar Knitting Machine Load Distribution
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Solution Overview
Problem
Double-sided warp knitting machines face limitations in productivity due to uneven load distribution between main shafts, leading to speed fluctuations and increased wear, which are exacerbated by the need to minimize drive units for economic and space constraints, resulting in reduced working speed and increased downtime.
Innovation Solution
The loads from the bar assembly are evenly shared between two main shafts, with drive units arranged in a point-symmetrical configuration along the length of the bar, allowing for distributed support points and synchronized operation of the main shafts, and the use of gearboxes with offset sections to manage torque and speed fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of drive units per bar is increased to improve productivity and support stability, then the working speed and support points increase, but the noise, friction, component costs, assembly costs, and installation space requirements increase
Solution Approach 1:
The patent divides the drive system into two separate main shafts, each responsible for driving a subset of bars. This segmentation allows the system to achieve high productivity through multiple drive units without concentrating all complexity in a single shaft, thereby managing device complexity while maintaining high working speeds
2Device complexity
If one main shaft drives the bar arrangement to simplify the drive system, then the structure is simpler, but the torque fluctuations and speed fluctuations increase due to uneven load distribution
Solution Approach 1:
The drive system is segmented into two independent main shafts that share the load of driving the bar arrangement. This segmentation distributes the torque fluctuations across two shafts, reducing speed fluctuations and improving reliability while maintaining structural simplicity through modular design
3Device complexity
If a single gearbox is used to drive both main shafts to reduce components, then the component count decreases, but the wear increases leading to more downtime
Solution Approach 1:
The patent employs two separate gearboxes, with each gearbox dedicated to driving one main shaft. This segmentation prevents the excessive wear that would occur in a single gearbox driving both shafts, thereby reducing downtime and improving reliability while maintaining acceptable device complexity through standardized modular components
4Productivity
If the bar arrangement is driven with high speed to increase productivity, then the output increases, but the forces per support point increase reducing stability
Solution Approach 1:
The bar arrangement is divided into multiple groups, with each group driven by a dedicated drive unit on the respective main shafts. This segmentation creates multiple support points that distribute the forces, maintaining bar arrangement stability even at high working speeds and thereby enabling high productivity
Data Source
Figure 1~2
Figure 3
AI summary
A double-fed warp knitting machine (1) is described, comprising a first needle fedge (2) with a first knitting tool arrangement comprising several knitting tool types (4, 6, 8), each connected to a first main shaft (10) via drive units (11, 12, 13); a second needle fedge (3) with a second knitting tool arrangement comprising several knitting tool types (14, 16, 18), each connected to a second main shaft (20) via drive units (21, 22, 23); and a bar arrangement (24) movable between the first needle fedge (2) and the second needle fedge (3). The aim is to achieve a high-productivity double-fed warp knitting machine.For this purpose, it is provided that the bar arrangement (24) is operatively connected to the first main shaft (10) via first drive units (29, 31) and to the second main shaft (20) via second drive units (30, 32), which effect the same movement of the bar arrangement (24) as the first drive units (29, 31).