Flat Knitting Set-Up Method for Independent Fabric Sections
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Solution Overview
Problem
Existing set-up methods for flat knitting machines are inadequate for knitting fabrics with uneven front and back parts started at different heights, as they fail to apply an appropriate pull-down force, making it difficult to knit tubular fabrics with independent front and back sections.
Innovation Solution
A method involving a flat knitting machine with a pair of front and back needle beds and set-up needles, where specific rows of hooked stitches are knitted and held to allow independent pull-down of each knitted fabric, ensuring each set-up portion is connected only to its respective fabric, enabling independent knitting and viewing of the fabric without removing the yarn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the set-up yarn is connected between the front and back fabrics in the set-up portion, then the set-up portion is closed, but it is not possible to view the inside of the knitted fabric without removing the yarn to be removed
Solution Approach 1:
The set-up portion is divided into separate front and back set-up portions that are not connected to each other. The front set-up portion is connected only to the front knitted fabric, and the back set-up portion is connected only to the back knitted fabric, allowing independent operation and viewing of each fabric section without removing yarn
2Productivity
If both front and back knitted fabrics are connected to the same hooked stitch rows, then the set-up needles pull down both fabrics, but an appropriate pull-down force is not exerted when knitting lengths are different
Solution Approach 1:
The hooked stitch rows are segmented into separate front and back sets. The front knitted fabric is connected to front hooked stitch rows, and the back knitted fabric is connected to back hooked stitch rows. This allows the set-up needles to exert appropriate pull-down force on each fabric independently, even when their knitting lengths differ
Solution Approach 2:
Different hooked stitch rows are assigned to different fabric sections based on their specific knitting length requirements. The front hooked stitch rows are positioned and configured for the front fabric, while the back hooked stitch rows are positioned and configured for the back fabric, ensuring appropriate local pull-down force for each section
3Adaptability or versatility
If the set-up needles hold intersections of set-up yarn from multiple rows, then both fabrics are connected, but independent knitting of front and back fabrics cannot be achieved
Solution Approach 1:
The set-up needles are segmented into front set-up needles and back set-up needles. The front set-up needles hold intersections of set-up yarn from the front knitted fabric only, while the back set-up needles hold intersections of set-up yarn from the back knitted fabric only. This segmentation enables independent knitting operations for each fabric section
Data Source
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AI summary
A first set-up portion (7) in the lower part of one knitted fabric (4) and a second set-up portion (6) in the lower part of another knitted fabric (2) are set up by a flat knitting machine that includes at least a pair of front and back needle beds (F, B) and a plurality of set-up needles (20). A first row of hooked stitches (10) and a second row of hooked stitches (12) that serve as rows of hooked stitches of the first set-up portion (7) are first knitted, and then a third row of hooked stitches (14) and a fourth row of hooked stitches (16) that serve as rows of hooked stitches of the second set-up portion (6) are knitted. A set-up yarn of the first row of hooked stitches (10) and the set-up yarn of the second row of hooked stitches (12) are intersected with each other between the front and back needle beds (F, B), and the set-up yarn of the third row of hooked stitches (14) and the set-up yarn of the fourth row of hooked stitches (16) are intersected with each other between the front and back needle beds (F, B). Thereafter, the intersections between the set-up yarn of the first row of hooked stitches (10) and the set-up yarn of the second row of hooked stitches (12) are held by the set-up needles (20) and the intersections between the set-up yarn of the third row of hooked stitches (14) and the set-up yarn of the fourth row of hooked stitches (16) are held by the set-up needles (20). Furthermore, hooked stitches of the third row of hooked stitches (14) and the fourth row of hooked stitches (16) that are positioned on one needle bed (B) are removed from this needle bed (B), and the remaining hooked stitches that are positioned on the other needle bed (F) are maintained, and hooked stitches of the first row of hooked stitches (10) and the second row of hooked stitches (12) that are positioned on the other needle bed (F) are removed from this needle bed (F) and the remaining hooked stitches that are positioned on the one needle bed (B) are maintained. Thereafter, stitches of the first set-up portion (7) are knitted on the hooked stitches of the first row of hooked stitches (10) and the second row of hooked stitches (12) that are positioned on the one needle bed (B), and stitches of the second set-up portion (6) are knitted on the hooked stitches of the third row of hooked stitches (14) and the fourth row of hooked stitches (16) that are positioned on the other needle bed (F). The front and back knitted fabrics are pulled down independently at the time of setting up.