Knit Design System for Size Accuracy
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Solution Overview
Problem
Current methods for knitting fabrics of specific sizes often require trial knitting and repeated corrections, leading to inefficiencies and increased time and costs, particularly when attempting to achieve complex structures like side movement patterns.
Innovation Solution
A knit design system that includes a color monitor, manual input device, and display controller to output design data for stitch numbers, types, and connection relationships, along with a calculation unit to estimate fabric size and a design correction unit to reduce errors, allowing for direct correction of stitch positions and loop lengths to achieve the desired size without trial knitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial knitting and repeated corrections are performed to achieve the directed size, then the size accuracy is improved, but the time consumption and production costs increase
Solution Approach 1:
The patent applies preliminary action by calculating the loop lengths and stitch positions before actual knitting occurs. The system computes the required loop lengths for each stitch based on the directed size and knit structure, then uses these pre-calculated values to guide the knitting process, eliminating the need for trial knitting and subsequent corrections.
Solution Approach 2:
The patent replaces the mechanical trial-and-error process with an automated calculation system. Instead of physically knitting trial samples and measuring them to correct design errors, the system uses computational algorithms to predict and determine the correct loop lengths and stitch positions, substituting physical iteration with digital calculation.
2Manufacturing precision
If trial knitting and repeated corrections are performed to achieve the directed size, then the size accuracy is improved, but the production costs increase
Solution Approach 1:
The system performs preliminary calculation of loop lengths and stitch positions before knitting begins. By determining the correct parameters in advance through computational methods, the patent eliminates the need for costly trial knitting and design corrections, thereby reducing production costs while maintaining size accuracy.
Solution Approach 2:
The patent substitutes expensive physical trial knitting with an automated calculation system that determines correct loop lengths and stitch positions computationally. This replacement of mechanical trial-and-error with digital calculation significantly reduces material waste and production costs.
3Shape
If conventional methods are used to estimate knit fabric shape, then the shape simulation is achieved, but the actual size calculation is not obtained
Solution Approach 1:
The patent applies parameter changes by focusing specifically on calculating loop lengths and stitch positions as quantitative parameters. Instead of general shape simulation, the system computes precise numerical values for loop lengths based on the knit structure and directed size, enabling actual size calculation rather than merely visual shape estimation.
Solution Approach 2:
The patent replaces qualitative shape simulation with quantitative size calculation. By using computational algorithms to determine specific loop length values and stitch positions, the system transitions from visual shape estimation to precise numerical size prediction, obtaining actual measurable dimensions.
4Manufacturing precision
If loop length control is applied as in Patent Literature 1, then simple knit fabrics can achieve directed size, but complex structures like side movement cannot be knitted to the directed size
Solution Approach 1:
The patent applies segmentation by dividing the knit fabric into individual stitches and calculating loop lengths for each stitch separately based on its position and the knit structure. This stitch-by-stitch approach allows the system to handle complex structures like side movement, where different stitches require different loop lengths, rather than applying uniform loop length control throughout the fabric.
Solution Approach 2:
The patent implements local quality by assigning different loop lengths to different stitches according to their specific positions and the local knit structure requirements. For complex structures like side movement, the system calculates and applies locally optimized loop lengths for each stitch, enabling precise size control for complex patterns rather than using a single global loop length setting.
Data Source
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AI summary
It is an object of the present invention to enable knitting of a knit fabric according to a directed size without performing trial knitting. Configuration: A knit design system (2) includes a color monitor (6), a manual input device (8), and a display controller (22) configured to perform display on the color monitor (6) and to interpret an input from the manual input device (8). The knit design system (2) is configured to output design data for designating stitch numbers, a stitch type, and connection relationship between stitches in a course direction and a wale direction of a knit fabric, based on inputs of shape data for defining a shape of the knit fabric, gauges of stitches in the course direction and the wale direction, and a knit structure. The knit design system (2) obtains calculation values of the size of a knit fabric after completion that vary depending on a knit structure, based on design data that is output or knit data, compares a directed size of the knit fabric with the calculation values of the size of the knit fabric, and corrects the shape data on the knit fabric, the design data, or the knit data so that a correction error is reduced.