Flat Knitting Needle Bed Layout for Standard-Gauge 3D Knitting
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Solution Overview
Problem
Traditional flat knitting machines face inefficiencies and high production costs due to complex processes and structural limitations, particularly in achieving normal gauge and stitch density for three-dimensional knitting, requiring high-strength yarn and complex structures.
Innovation Solution
A needle bed and needle combination with double needle beds, featuring two knitting needles arranged between every two sinkers, and a needle selection mechanism with elastic stitch elements and jacks, allowing for parallel or angled arrangements, and a control system to selectively operate on these elements for knit, tuck, and loop transfer stitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If every other needle is used for three-dimensional knitting, then productivity is improved, but manufacturing precision deteriorates due to increased needle distance and low stitch density
Solution Approach 1:
The needle bed is divided into multiple independent needle grooves, with two knitting needles arranged in each groove. This segmentation allows each needle to operate independently while maintaining proper spacing, achieving both high productivity and standard stitch density without requiring every other needle to be used.
Solution Approach 2:
Two knitting needles are arranged in the width direction within each needle groove, adding a lateral dimension to the needle arrangement. This dimensional change allows double the number of needles to be effectively utilized without increasing the distance between functional knitting points, thereby maintaining stitch density while improving productivity.
2Productivity
If two knitting needles are arranged in parallel in one needle groove, then productivity is improved, but device complexity increases due to needle selection mechanism
Solution Approach 1:
The needle selection unit utilizes the existing cam mechanism and stitch element structure to control the selection of knitting needles. The control stitch element and elastic stitch element work together with the cam's inherent motion to automatically select and control which needle performs the knitting action, reducing the need for additional complex control systems.
Solution Approach 2:
The cam mechanism serves multiple functions: it provides the rhythmic motion for stitch formation, controls the timing of needle selection, and coordinates the interaction between control stitch elements and elastic stitch elements. This multi-functionality reduces device complexity by eliminating the need for separate control mechanisms.
3Ease of operation
If control stitch element is positioned above elastic stitch elements, then ease of operation is improved, but device complexity increases due to additional structural components
Solution Approach 1:
The control stitch element is positioned in the height direction above the elastic stitch elements, utilizing the vertical dimension for control functionality. This spatial arrangement allows the control element to engage with and disengage from the elastic element cleanly, providing intuitive needle selection while maintaining a compact overall structure.
Solution Approach 2:
The control stitch element acts as an intermediary between the cam mechanism and the elastic stitch element. It translates the cam's motion into selective engagement or disengagement of the elastic element, thereby controlling needle selection without requiring direct mechanical connection between the cam and each needle.
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
Enables standard gauge three-dimensional knitting with increased needle density, simplifying the process, reducing yarn requirements, and lowering production costs while maintaining stitch quality.
Implementation Method 1
The needle selection unit is provided above the two elastic stitch elements, and is configured to operate on the elastic stitch elements. When being operated on, the elastic stitch element is deformed elastically to disengage from the control stitch element
Data Source
AI summary
A needle bed and needle combination for a flat knitting machine includes a needle bed, a plurality of parallel sinkers provided at a front end of the needle bed, knitting needles and stitch elements provided in needle grooves, and a needle selection unit. Two knitting needles are arranged in parallel in the needle groove between every two adjacent sinkers, and are separately configured to make a knit stitch, a tuck stitch and a loop transfer stitch. The stitch element includes a control stitch element and elastic stitch elements. The control stitch element, the elastic stitch elements and the needle selection unit form the needle selection mechanism. Two elastic stitch elements are connected to the two knitting needles, respectively. The control stitch element is located above and engaged with the two elastic stitch elements. The needle selection unit is provided above the two elastic stitch elements.