Flat Knitting Machine Take-off Curves for Double-Surfaced Fabric
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Solution Overview
Problem
Existing flat knitting machines are limited in producing double-surfaced knitted fabrics, such as filigree knits, as they require multiple knitting systems and struggle with stability and stitch capacity, while single-surface knits are the maximum output with a single system.
Innovation Solution
A flat knitting machine with a single knitting system featuring two different take-off curves for needles, allowing separate thread guides for binding and pattern threads, enabling the production of double-surfaced knitted fabrics by guiding needles into specific insertion positions, and utilizing multiple needle beds for enhanced stitch formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple knitting systems are used to produce double-surfaced knitted fabrics, then fabric variety and pattern capability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The single knitting system is segmented into two distinct needle beds (first and second needle beds) with separate take-off curves. This segmentation allows independent control of needle movements to achieve different fabric surfaces and patterns simultaneously, resolving the contradiction by providing fabric variety through functional division rather than multiple complete knitting systems.
Solution Approach 2:
The single knitting system is designed with multi-functionality to produce various double-surfaced knitted fabrics (filigree knits, lined knits, plush patterns) using one integrated system. The universal design incorporates multiple take-off curves and selectable needle beds that can be configured for different fabric types, eliminating the need for multiple separate knitting systems while maintaining fabric variety.
2Adaptability or versatility
If stitches are transferred to create openwork patterns, then pattern variety is improved, but stitch capacity and fabric stability deteriorate
Solution Approach 1:
The take-off curves are designed in advance with specific geometric configurations that predetermined the movement paths of needles. By preparing the needle trajectories before knitting occurs, the system ensures stable stitch formation and fabric structure while enabling pattern variety through the preliminary design of different take-off curve configurations for different needle beds.
3Productivity
If a single knitting system is used to maximize machine capacity, then productivity is improved, but fabric variety and pattern capability deteriorate
Solution Approach 1:
The knitting system incorporates dynamic elements through selectable needle beds and configurable take-off curves that can be adjusted during operation. This dynamic capability allows the single knitting system to adapt to different fabric types and patterns while maintaining high productivity, as the system can reconfigure needle movements without requiring physical reinstallation of multiple knitting systems.
4Manufacturing precision
If needles are drawn into specific take-off curves for thread insertion, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The take-off curves are defined by specific geometric parameters (angles, distances, positions) that can be precisely controlled. By changing these parameters to create different curve configurations for different needle beds, the system achieves high needle positioning accuracy for thread insertion while managing cam mechanism complexity through parameter-based design rather than purely geometric complexity.
Data Source
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Figure 1b
Figure 1c
AI summary
The invention relates to a flat knitting machine with a knitting system (100, 100', 100"), which has at least one first knitting lock (101, 101', 101") associated with a first needle bed (V) for producing knitted fabrics formed from at least one first yarn and at least one second yarn, wherein the at least one first yarn and the at least one second yarn can be fed by separate yarn guides (F1, F2), wherein the first knitting lock (101, 101', 101") is provided with two different take-up curves (23, 24) for the first and second needles, wherein the first take-up curve (23) pulls the first needles into a first and a second yarn insertion position (E1, E2) and the second take-up curve (24) pulls the second needles only into the first yarn insertion position (E1), and wherein the second take-up curve (24) is located in the area of a limiting lock part. (20) has two differently oriented non-horizontal sections (21', 22').