Flat Knitting Machine Cutting Element Bed Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing circular knitting machines for cutting stitches are complex to manufacture, limit stitch formation possibilities, and impair functional reliability, particularly when used for double-faced knitted fabrics.
Innovation Solution
A flat knitting machine design with two oppositely arranged needle beds and a separate cutting element bed allows for precise control and separation of stitches or tuck loops without affecting stitch formation, enabling the production of single- and double-surface knitted fabrics in plush quality, including tubular fabrics, with high functional reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutting elements are integrated into the needle beds of circular knitting machines, then stitch cutting is achieved, but device complexity increases and stitch formation possibilities are limited
Solution Approach 1:
The cutting function is segmented from the knitting function by introducing a separate cutting element bed. This cutting element bed operates independently above the needle beds, allowing stitch cutting without interfering with the knitting process. The segmentation resolves the contradiction by eliminating the need to integrate cutting elements into the needle beds, thereby maintaining manufacturing simplicity while achieving reliable stitch cutting.
Solution Approach 2:
The cutting function is extracted from the needle bed structure and placed in a dedicated cutting element bed. This extraction allows the knitting machine to perform both knitting and cutting operations without the complexity of integrated cutting elements in the needle beds. The cutting elements are taken out as a separate functional unit that can operate independently.
2Adaptability or versatility
If cutting elements are integrated into the needle beds, then stitch cutting is enabled, but stitch formation possibilities are restricted
Solution Approach 1:
By segmenting the cutting function into a separate cutting element bed, the needle beds remain dedicated solely to stitch formation. This allows full versatility in stitch formation patterns without the structural constraints that would arise from integrating cutting elements into the needle beds. The separation enables independent optimization of both knitting and cutting functions.
Solution Approach 2:
The separate cutting element bed provides universal cutting capability that can be applied to various stitch types and knitting patterns without limiting the needle bed's versatility. The cutting elements can interact with different stitch formations (single-surface, double-surface, tubular) while the needle beds maintain their full range of stitch formation possibilities.
3Ease of operation
If needles are equipped with cutting knives in circular knitting machines, then stitch separation is achieved, but functional reliability is impaired
Solution Approach 1:
The cutting function is segmented from the needle structure and placed in a separate cutting element bed. This separation ensures that the needles' primary function of stitch formation remains reliable, while the cutting elements provide dedicated stitch separation capability. The segmentation prevents the reliability issues that arise from equipping needles with cutting knives.
Solution Approach 2:
The cutting function is extracted from the needle structure and implemented as a separate cutting element bed. This extraction maintains the functional reliability of the needles for stitch formation while providing the necessary stitch separation capability through dedicated cutting elements that operate independently.
4Productivity
If cutting elements are placed in the same bed as needles, then lateral offset is required for cutting, but device complexity increases
Solution Approach 1:
By placing cutting elements in a separate cutting element bed positioned above the needle beds, the cutting operation is segmented from the knitting operation. This eliminates the need for lateral offset mechanisms within the same bed, as cutting elements can be positioned directly above the corresponding needles or stitch locations. The segmentation simplifies the bed structure while maintaining cutting efficiency.
Solution Approach 2:
The cutting elements are positioned in a different spatial dimension (above the needle beds in the vertical direction) rather than in the same horizontal plane. This dimensional change eliminates the need for lateral offset mechanisms, as cutting elements can be moved vertically or positioned directly above target stitches. The vertical arrangement simplifies the overall device structure while maintaining productive cutting operations.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
The machine has two oppositely arranged needle beds provided with multiple grooves in which needles (3) are longitudinally displaceably mounted. Cutting element beds are arranged next to each other above the needle beds, and provided with multiple grooves in which cutting elements (5) are longitudinally displaceably arranged for separation of loops (7) or tuck loops that are formed on the needles. Length of each cutting element bed is equal length of the needle beds. A groove division of each cutting element bed corresponds to a groove division of each needle bed.