Circular Knitting Machine Calibration Using Standardized Fabric Files
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Solution Overview
Problem
Conventional circular knitting machines require manual calibration, which is time-consuming and prone to variations between operators, making subsequent maintenance and calibration difficult, and existing automatic control systems only address fine adjustments during the knitting process, not initial settings.
Innovation Solution
A fabric file release system that automatically calibrates circular knitting machines using a file memorizing unit and communication modules to transfer standardized fabric files to a controlled terminal, allowing for automatic mapping and control of knitting machine parameters such as rolling tension, yarn feeding length, and stitch adjustments without format conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is performed for each circular knitting machine, then the machine can be set up for new fabrics, but the manufacturing time is delayed and the calibration varies between operators
Solution Approach 1:
The patent creates a master calibration file that contains standardized calibration data, which is then copied and applied to multiple circular knitting machines. This eliminates the need for manual recalibration of each machine, ensuring consistent calibration across all machines while significantly reducing the time required for setup.
Solution Approach 2:
The calibration data is prepared in advance as a standardized master file, containing all necessary calibration parameters for different fabric types. This preliminary preparation allows for rapid deployment to multiple machines without repeated manual calibration processes.
2Ease of manufacture
If manual calibration is performed for each circular knitting machine, then the machine can be set up for new fabrics, but subsequent maintenance and calibration become difficult
Solution Approach 1:
The standardized master calibration file serves as a reference copy that can be repeatedly copied to any machine requiring maintenance or recalibration. This ensures that maintenance personnel can quickly restore machines to the correct calibration state without needing to perform complex manual adjustments.
3Extent of automation
If existing automatic control systems are used, then fine adjustment during knitting is achieved, but initial setting calibration is not addressed
Solution Approach 1:
The system performs preliminary automatic calibration by loading the master calibration file into the knitting machine's control system before production begins. This preliminary automatic setting eliminates the need for manual initial calibration, while the existing automatic control systems continue to handle fine adjustments during the knitting process.
Data Source
AI summary
A fabric file release system for automatically calibrating a circular knitting machine includes a file release end which memorizes a plurality of fabric file and a controlled terminal in information connection with the file release end. Each of the plurality of fabric file comprises a plurality of knitting machine working marks and a plurality of setting parameter values respectively corresponding to one of the knitting machine working marks. The controlled terminal comprises a setting file of knitting machine working including the plurality of knitting machine working marks and a plurality of working parameter values respectively corresponding to one of the knitting machine working marks. The controlled terminal receives one of the fabric file and maps the setting parameter values corresponding to each of the knitting machine working marks to the working parameter values corresponding to each of the knitting machine working marks in the setting file of knitting machine working.