Knit Design System for Body-Fit Customization
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Solution Overview
Problem
The existing methods for mass customization of knit wear using flat knitting machines require a large number of design data pieces to be prepared in advance, which is time-consuming and burdensome for operators, as customer bodies vary significantly, necessitating a system to reduce the number of design data pieces needed.
Innovation Solution
A knit design system that includes an input unit for customer measurements, a memory for basic data, a selection unit to match measurements with stored data, calculation units to adjust stitch rows, and a change determination unit to modify design data by adding or deleting stitch rows in variable courses, while maintaining a predetermined design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a huge number of design data pieces are prepared in advance to accommodate various body dimensions, then customization capability is improved, but the time and burden for creating design data increases significantly
Solution Approach 1:
The patent segments design data into a limited set of basic size categories (e.g., S, M, L, XL) with predetermined stitch row configurations. Instead of creating custom design data for every possible body dimension, the system divides the customization space into discrete segments that can be efficiently stored and modified.
Solution Approach 2:
The patent introduces dynamic modification capability that allows automatic adjustment of stitch row numbers based on input body measurements. The system dynamically calculates the required number of stitch rows using reference values and adjustment coefficients, enabling real-time customization without pre-preparing all possible design variants.
2Manufacturing precision
If design data is manually modified for each customer measurement, then customization precision is improved, but productivity decreases
Solution Approach 1:
The patent replaces manual mechanical modification of design data with an automated calculation system. The control unit automatically computes the required stitch row numbers based on input measurements and predetermined formulas, eliminating the need for operators to manually adjust each design data piece while maintaining high precision.
Solution Approach 2:
The patent utilizes parameter-based adjustment where body measurements are converted into specific design parameters (stitch row numbers) through mathematical relationships. By changing the input parameters (body dimensions) and applying predetermined adjustment coefficients, the system automatically generates precise customized design data without manual intervention.
3Manufacturing precision
If the number of stitch rows is freely adjusted to match body measurements, then fit accuracy is improved, but design integrity may be compromised
Solution Approach 1:
The patent applies local quality by allowing stitch row number adjustments only in specific regions where such changes do not affect the overall design pattern. The system modifies local parameters (stitch row counts in non-pattern areas) while preserving the integrity of the knitted fabric design in critical regions.
Solution Approach 2:
The patent performs preliminary action by pre-defining adjustment coefficients and reference values for different body types and design styles. These predetermined parameters guide the automatic calculation process to ensure that modifications maintain design integrity while achieving accurate fit.
Data Source
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AI summary
Provided is a knit design system with which it is possible to knit a knitted fabric that fits to the body of a customer, and reduce the number of pieces of design data to be prepared in advance. The knit design system includes a memory, a selection unit, a first calculation unit, a second calculation unit, a change determination unit, and a creating unit. The memory has design data (basic data) that corresponds to a predetermined number of body dimensions set in advance stored therein. The selection unit selects, from the basic data, possible data that is fitted to the actual measurement of the body of a customer. The second calculation unit calculates, based on a difference between a length dimension obtained by the first calculation unit based on the actual measurement and a length dimension of the possible data, the number of stitch rows along the course direction that are to be used for a change in a length direction. In the basic data, variable courses in which insertion and deletion of stitch rows along the course direction are possible, and a fixed course in which insertion and deletion are prohibited are set. The change determination unit selects the stitch rows from the variable courses. The creating unit creates modification data, by adding or deleting the stitch rows with respect to the possible data.