Knitted Article Gauge Determination via Aspect Ratio Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for determining the number of stitches in knitted articles, such as those described in Patent Document 1, do not always yield optimal gauges, leading to size inconsistencies, especially when knitting parts with different aspect ratios, requiring adjustments in the number of knitting courses after the article is knitted.
Innovation Solution
A method and system that involve knitting samples with varying aspect ratios to establish a relationship between aspect ratio and stitch size, allowing for the determination of the number of knitting courses and needles needed to achieve target dimensions by correcting for the impact of aspect ratios on stitch size, using a flat knitting machine and associated design system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If texture samples are knitted with constant width to determine gauge, then the measurement process is simplified, but the determination of optimal gauges becomes inaccurate for parts with different aspect ratios
Solution Approach 1:
The invention divides the gauge determination process into two stages: first determining a base gauge from a texture sample with constant width, then calculating adjusted gauges for different aspect ratios using a correction formula. This segmentation allows maintaining measurement simplicity while achieving accurate gauge determination for various part geometries.
Solution Approach 2:
The invention introduces an aspect ratio correction parameter to adjust the base gauge value. By changing the gauge parameter based on the aspect ratio of different knitted parts, the system achieves accurate gauge determination for various geometries without complicating the fundamental measurement process.
2Adaptability or versatility
If the number of knitting courses is adjusted after knitting to achieve target size, then flexibility in size adjustment is maintained, but production time and efficiency are reduced
Solution Approach 1:
The invention performs gauge determination and calculation of knitting course numbers before the actual knitting process. By pre-calculating the exact number of knitting courses needed based on the aspect ratio correction method, the system eliminates post-knitting adjustments, thereby improving production efficiency while maintaining size accuracy.
3Manufacturing precision
If texture samples with different aspect ratios are knitted to determine optimal gauges, then accurate gauge determination for various parts is achieved, but the number of samples and measurement work increase
Solution Approach 1:
The invention uses a single texture sample as a reference model to derive base gauge information, then mathematically calculates the gauges for different aspect ratios through correction formulas. This copying approach allows obtaining accurate gauge data for various part geometries without physically creating and measuring multiple diverse samples.
4Ease of manufacture
If the aspect ratio impact on stitch size is not corrected, then the knitting process is simpler, but the final article size deviates from target dimensions
Solution Approach 1:
The invention replaces complex mechanical adjustments during knitting with a mathematical correction system. By using aspect ratio-based correction formulas to calculate the appropriate number of knitting courses, the system maintains knitting process simplicity while achieving high article size accuracy through computational rather than mechanical means.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is a method for determining the gauge of a knitted article 40, including the steps of: knitting a plurality of samples (12, 13, 14) that are smaller than the knitted article (40) and have different aspect ratios, by using a flat knitting machine (10); measuring the width and height of each of the samples (12, 13, 14); obtaining a correction function for correcting the size of stitches on the basis of the ratio between the measured width and height; and determining the number of knitting courses and the number of needles for each of parts of the knitted article 40, from the size of the stitches obtained from each sample (12, 13, 14), the obtained correction function, and target width and height of each of the parts of the knitted article 40. Accordingly, the number of knitting courses for the knitted article (40) can be determined easily and reliably.