Intarsia Knitting Method Allocation for Carrier Reduction
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Solution Overview
Problem
It is challenging for knit design experts to determine whether to use intarsia or intarsia jacquard for certain patterns, especially as patterns become more complex, due to the difficulty in differentiating between the two methods and the inefficiencies in carrier allocation and knitting quality.
Innovation Solution
A design device and method that automatically allocates intarsia or intarsia jacquard knitting based on pattern shape and width, using a storage unit to store application conditions and a knitting method allocator to determine the appropriate method for each knitting area, allowing for efficient carrier allocation and improved fabric quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If intarsia jacquard knitting is used to allow different yarn to pass through the rear surface of the knitted fabric, then the number of carriers can be conserved and knitting efficiency is improved, but the fabric quality deteriorates due to the thick knitted fabric created
Solution Approach 1:
The patent applies different knitting methods (intarsia vs. intarsia jacquard) to different knitting areas based on local requirements. The knitting method allocator determines which areas use intarsia jacquard for efficiency and which use intarsia for quality, allowing each region to have the appropriate characteristics for its specific pattern requirements.
2Manufacturing precision
If intarsia knitting is used to maintain high fabric quality, then the fabric quality is improved, but the number of carriers increases and knitting efficiency decreases
Solution Approach 1:
The patent merges the advantages of both intarsia and intarsia jacquard methods by combining them in a single knitting process. The knitting method allocator identifies areas where intarsia jacquard can be used to reduce carrier numbers and merge carrier paths, while maintaining intarsia in areas where quality is paramount, thus combining efficiency and quality benefits.
3Quantity of substance
If the same carrier is used on both left and right-hand side of an intarsia jacquard piece to conserve carriers, then the number of carriers is reduced, but the pattern complexity increases making automatic determination difficult
Solution Approach 1:
The knitting method allocator automatically analyzes the color combination pattern and determines the optimal knitting method for each area without requiring manual expert intervention. The system serves itself by automatically identifying which areas should use intarsia jacquard versus intarsia based on the pattern characteristics, carrier allocation, and quality requirements.
4Reliability
If kicking back operation is performed to change carrier stop position in intarsia knitting, then carrier interference is prevented, but the knitting efficiency is lowered
Solution Approach 1:
The knitting method allocator performs preliminary analysis of the color combination pattern to determine the optimal carrier allocation and knitting method before actual knitting begins. By pre-determining which areas use intarsia jacquard with controlled carrier stop positions, the system eliminates the need for kicking back operations during knitting, thus maintaining both reliability and efficiency.
Data Source
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AI summary
A storage unit is provided to store application conditions for applying intarsia jacquard knitting to color combination patterns in a knitted fabric based on a shape of the pattern and a knitting width. A knitting area satisfying the application conditions for applying intarsia jacquard knitting is used as a floating knitting area. Intarsia jacquard knitting is allocated to a first knitting area with the same color combination on the left and right-hand side in a knitting course direction in the floating knitting area, and intarsia knitting is allocated to a second knitting area with different color combinations on the left and right-hand side in the knitting course direction, while intarsia knitting is also allocated to knitting areas other than the floating knitting area. Knitting areas to be used for intarsia can be differentiated automatically from knitting areas to be used for intarsia jacquard.