Contactless Power Supply for Flat Knitting Machine Moving Bodies
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Solution Overview
Problem
Existing flat knitting machines face power supply issues due to oil and dust contamination in contact-based power systems, leading to potential failures and inefficiencies.
Innovation Solution
A contactless power supply system using a primary coil and secondary coil arrangement, where the primary coil is positioned below the rail and braced to maintain alignment, allowing electromagnetic induction for power transfer to moving bodies like yarn feeders, which also includes tension sensors and optical wireless transceivers for data communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact power supply is used to supply power to moving bodies, then power can be supplied to the moving body, but power supply may be hindered if oil or dust becomes affixed to the contact location or if the contact location becomes worn down
Solution Approach 1:
The patent replaces the mechanical contact-based power supply system with an electromagnetic induction-based contactless power supply system. A primary coil is installed on the rail and a secondary coil on the moving body, eliminating physical contact between power supply components. This substitution resolves the contamination and wear issues inherent in contact-based systems while maintaining reliable power supply to moving bodies.
2Reliability
If a contactless power supply system is implemented, then power supply reliability is improved and contact failures are eliminated, but device complexity increases due to the addition of coils and control circuits
Solution Approach 1:
The patent extracts the power supply function from the mechanical contact system and implements it separately through electromagnetic induction. The primary coil is integrated into the rail structure while the secondary coil and control circuit are mounted on the moving body, distributing the system complexity across different components and locations.
Solution Approach 2:
The primary coil on the rail serves multiple purposes: it provides power supply through electromagnetic induction and can potentially serve as part of the positioning or communication infrastructure. The control circuit on the moving body integrates power management, positioning, and communication functions, reducing overall system complexity.
3Volume of moving object
If the primary coil is positioned below the rail, then the machine size is not increased and no design changes are required, but the primary coil requires bracing to maintain alignment parallel with the rail
Solution Approach 1:
The patent merges the bracing function with the existing rail structure. The rail serves both as a support structure for the moving body and as a mounting structure for the primary coil. The holding member integrates the coil support and alignment functions, eliminating the need for separate bracing components.
Solution Approach 2:
The patent positions the primary coil in the vertical dimension below the rail, utilizing the available space in this dimension rather than expanding the horizontal footprint. This dimensional arrangement maintains compact machine size while providing adequate space for coil installation and bracing.
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
This solution ensures reliable power supply to moving bodies in a compact form, eliminating contact failures, enabling precise yarn tension measurement and efficient data exchange without increasing machine size or requiring design changes.
Implementation Method 1
a secondary coil that is wound around the tubular member and receives electrical power from the primary coil through electromagnetic induction
Data Source
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AI summary
A flat knitting machine that contactlessly supplies electrical power to moving bodies of the flat knitting machine is provided. The flat knitting machine includes needle beds in which multiple knitting needles are arranged side-by-side, and moving bodies 2 that are involved in the knitting of a knitted fabric by traveling along a rail 1R. This flat knitting machine includes: a primary coil 31 that is connected to a power supply of the flat knitting machine and has an axis that is held parallel with the axis of the rail 1R; a tubular member 34 that is provided on each of the moving bodies 2, the primary coil 31 passing through the tubular member 34; a secondary coil 32 that is wound around the tubular member 34 and receives electrical power from the primary coil 31 through electromagnetic induction; a control circuit 20 that is provided on each of the movingbodies 2 and is connected to the secondary coil 32; and at least one electrical device 6 that is provided on each of the moving bodies 2 and operates under control of the control circuit 20.