Fiber-Reinforced Plastic Bending Joint for Warp Knitting Machine
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Solution Overview
Problem
Knitting machines face limitations in achieving high working speeds due to the high mass of traditional roller bearings used in articulated connections, which are subjected to high alternating loads and accelerations, leading to potential damage and reduced operational efficiency.
Innovation Solution
A bending joint formed from fiber-reinforced plastic is used to create a flexible and lightweight connection between the ram and support lever, allowing for efficient transmission of forces and enabling high-speed operation without material fatigue, with the joint being designed as a one-piece component of the ram and connected via a torque-resistant mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roller bearings are used to create articulated connection between ram and lever, then the connection can withstand rotational movement, but the mass of the connection increases leading to reduced working speed
Solution Approach 1:
The patent changes the material parameters by using fiber-reinforced plastic instead of metal roller bearings. This material substitution maintains the necessary mechanical properties for withstanding alternating loads while significantly reducing the mass of the bending joint, thereby resolving the contradiction between connection durability and working speed.
Solution Approach 2:
The patent employs composite materials (fiber-reinforced plastic) to create the bending joint. The fiber reinforcement provides the necessary strength and fatigue resistance to withstand high alternating loads, while the plastic matrix reduces overall density and mass compared to traditional metal bearings, enabling high-speed operation.
2Strength
If larger masses are used in articulated connection, then the connection can withstand high alternating loads, but the forces required for acceleration increase limiting working speed
Solution Approach 1:
The fiber-reinforced plastic composite provides high strength-to-weight ratio. The fiber orientation and distribution are optimized to withstand the high alternating loads (accelerations over 1000 m/s²) while keeping the mass low, thus enabling high working speeds of several thousand revolutions per minute without excessive acceleration forces.
Solution Approach 2:
The patent changes the material parameters by selecting fiber-reinforced plastic with specific mechanical properties that provide sufficient strength for load withstanding while maintaining low density. This parameter optimization allows the bending joint to withstand high alternating loads without requiring large masses, thereby maintaining high productivity.
3Weight of moving object
If fiber-reinforced plastic bending joint is used, then the mass is reduced enabling high-speed operation, but the connection must withstand very high alternating loads and accelerations
Solution Approach 1:
The fiber-reinforced plastic composite material is specifically chosen for its fatigue resistance properties. The fiber reinforcement (such as glass or carbon fibers) embedded in the plastic matrix provides enhanced durability and resistance to material fatigue under the extremely high alternating loads and accelerations (over 1000 m/s²) experienced during high-speed operation.
Solution Approach 2:
The patent optimizes the material parameters of the fiber-reinforced plastic, including fiber type, fiber orientation, fiber volume fraction, and matrix composition, to achieve the necessary fatigue resistance. These parameter adjustments ensure the bending joint can withstand the harsh operating conditions while maintaining low mass for high-speed operation.
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 use of a fiber-reinforced plastic bending joint reduces the mass of the connection, enabling high-speed operation while maintaining the ability to withstand repeated loads and transmit forces effectively, thus enhancing the knitting machine's performance and longevity.
Implementation Method 1
A fiber-reinforced plastic can be bent within certain limits over a large number of cycles without material fatigue or breakage occurring
Data Source
Figure 1
Figure 2~4
AI summary
The machine has knitting tool bars (17) arranged at supporting arms (16), where the supporting arms are connected with a plunger (6) by a torsion-resistant connection (23). The plunger has a bending joint (22) that is made from fiber-reinforced plastic. The plunger and the supporting arms are fixed in different positions relative to each other in longitudinal direction of the plunger. The plunger is moved back and forth by a mechanical linkage that is arranged in a machine base, and the supporting arms are pivotable around a fixed axis (19).