Flat Knitting Machine Cam System for Variable-Thickness 3D Fabric
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Solution Overview
Problem
Existing flat knitting machines are limited to knitting three-dimensional fabrics with a single thickness due to fixed knock-over bits, preventing the creation of fabrics with variable thickness.
Innovation Solution
The method involves moving cam groups on needle beds to control knitting needles, using starting, middle, and tail cam systems to adjust the gap size and interweave supporting yarns, allowing for dynamic thickness changes in the knitting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed knock-over bits are used in a flat knitting machine, then the machine structure is simple and stable, but the machine can only knit three-dimensional fabric with a single thickness
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed knock-over bits with movable knock-over bits that can dynamically adjust their positions. The cam systems are designed to be movable and adjustable, allowing the gap size between needle beds to change during the knitting process. This enables the flat knitting machine to produce three-dimensional fabric with variable thickness, transforming a static structure into a dynamic one that can adapt to different knitting requirements.
Solution Approach 2:
The patent applies segmentation by dividing the cam system into multiple independent cam groups (first cam group, second cam group, third cam group, fourth cam group) that can be independently controlled. Each cam group manages specific knock-over bits, allowing selective adjustment of gap sizes at different positions. This segmented approach enables localized thickness variation in the fabric while maintaining overall system manageability.
2Adaptability or versatility
If movable knock-over bits and adjustable cam systems are implemented, then variable thickness fabric can be produced, but the device complexity increases
Solution Approach 1:
The patent applies the self-service principle through the automatic control system that coordinates the movable cam groups and knock-over bits. The control system automatically adjusts the gap sizes and yarn feeding positions based on pre-programmed parameters, reducing the need for manual intervention during operation. This automation helps manage the complexity of the adjustable mechanisms while maintaining ease of operation.
Solution Approach 2:
The patent applies universality by designing the cam groups and knock-over bit system to perform multiple functions: controlling needle movement, adjusting gap sizes, and coordinating yarn feeding. The same mechanical components serve both structural support and active control functions, reducing the need for separate dedicated mechanisms and simplifying the overall manufacturing and operation process.
3Manufacturing precision
If multiple cam groups are used to control gap size, then thickness control precision is improved, but the device complexity increases
Solution Approach 1:
The patent applies local quality by enabling different gap sizes at different positions along the fabric length through the movable cam groups. Each cam group can be independently positioned to create localized thickness variations, allowing precise control of fabric thickness at specific locations. This ensures that each part of the fabric receives the appropriate thickness treatment according to design requirements.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the positions of the knock-over bits and cam groups during the knitting process. The gap size parameter is continuously variable, allowing smooth transitions between different thickness levels. This enables precise thickness control without requiring discrete, fixed-position mechanisms for each possible thickness setting.
Data Source
AI summary
A method for knitting a three-dimensional fabric with variable thickness through a flat knitting machine includes the following steps: moving two cam groups and driving a plurality of knitting needles to knit a first piece of knitting by a starting cam system; moving the two cam groups and driving the plurality of knitting needles to knit a second piece of knitting by a middle cam system; and moving the two cam groups and driving the plurality of knitting needles to knit a supporting yarn by two tail cam systems respectively. The tail cam systems control each of a plurality of knock-over bit cams to move according to a gap size corresponding to a knitting length of the supporting yarn, so as to promptly change a thickness of the three-dimensional fabric along the length change of the supporting yarn.