Knitted Tubular Article Closure via Loop Superimposition
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Solution Overview
Problem
Current methods for closing knitted tubular manufactures on circular hosiery knitting machines either significantly reduce machine productivity or require complex and imprecise transfer operations, increasing production costs and cycle time.
Innovation Solution
A method involving initial loop retention, individual gripping, transfer to a sewing station, and precise superimposition of loops using a semiannular handling device for automated closure, optimizing machine commands and device movements to enhance productivity and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the closure operation is performed directly on the knitting machine, then the closure is completed in one location, but the machine productivity is significantly reduced because the machine cannot produce a new manufacture during the closing operation
Solution Approach 1:
The system is divided into two independent parts: the knitting machine that produces tubular manufactures and the separate linking station that performs closure operations. This segmentation allows the knitting machine to continue producing while the closure is performed independently on the manufactured item, resolving the productivity loss caused by integrated closure operations.
Solution Approach 2:
A transfer mechanism acts as an intermediary between the knitting machine and the linking station. This intermediary efficiently moves the tubular manufacture from the knitting machine to the linking station and back, enabling continuous production without requiring the knitting machine to stop for closure operations.
2Productivity
If the closure operation is performed in a separate linking station, then machine productivity is maintained, but complex apparatuses are required that must ensure extremely precise operation during transfer
Solution Approach 1:
The transfer mechanism is designed to automatically pick up the tubular manufacture directly from the knitting needles and transport it to the linking station without requiring complex manual intervention or highly sophisticated positioning systems. The system uses the existing structure of the knitting machine to its advantage, simplifying the transfer apparatus while maintaining precision.
3Manufacturing precision
If complex apparatuses are used for transfer operations, then precise transfer can be achieved, but the total transfer time increases and costs increase
Solution Approach 1:
The transfer mechanism is designed to operate continuously and efficiently, moving the tubular manufacture from the knitting machine to the linking station in a streamlined manner. The transfer process is optimized to minimize idle time and ensure that the manufacture is quickly positioned for closure operations, reducing total transfer time while maintaining precision through careful mechanical design rather than complex control systems.
Data Source
AI summary
A method for closing a knitted tubular manufacture at an axial end thereof, comprising:—producing the manufacture up to execution of the last course of knitting;—gripping the loops;—removing the manufacture, retaining each loop of the last course formed;—positioning the manufacture at a sewing station;—transitioning the loops from pickup elements to spikes of a handling device;—inverting the manufacture retained by the handling device;—superimposing each one of the loops of one half course of knitting on a corresponding loop of the other half course of the last course of knitting;—sewing pairs of loops of knitting that are mutually superimposed;—disengaging the manufacture from the handling device, the s removal step of the manufacture comprising a first extraction preparation step, a second manufacture extraction step, and a third manufacture transfer step.