Flat Knitting Machine Carriage Lighting Device
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Solution Overview
Problem
The existing lighting in modern flat knitting machines is inadequate for illuminating the working space below the carriage, making it difficult to detect errors such as broken threads or needles due to shadows cast by carriage components, necessitating additional external lighting.
Innovation Solution
Integrating a lighting device on the machine carriage that illuminates the area below, which can be manually or automatically activated, and is adjustable to provide optimal illumination, using LED light strips that are not obstructed by carriage parts or thread guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If lighting is arranged above the carriage, then the general working area is illuminated, but the working space below the carriage remains in shadow due to carriage components blocking the light
Solution Approach 1:
Instead of placing the light source above the carriage (external to the carriage structure), the lighting device is integrated directly on the carriage itself. This inversion of the lighting arrangement allows light to be emitted from the carriage structure, illuminating the needle space below without being blocked by carriage components.
Solution Approach 2:
The lighting device is nested within or integrated into the carriage structure. The light source is housed within the carriage framework, with light-emitting elements positioned to direct illumination downward into the needle space, effectively using the carriage structure itself as the light-carrying medium.
2Illumination intensity
If external lighting is added to illuminate the area below the carriage, then visibility improves, but the device complexity and setup time increase
Solution Approach 1:
The lighting function is merged with the carriage structure. Instead of being separate external components, the lighting device and carriage are integrated into a single unified structure, eliminating the need for separate external lighting arrangements and reducing overall system complexity.
Solution Approach 2:
The carriage provides its own lighting service by incorporating the lighting device within its structure. The carriage becomes self-sufficient for illumination needs, eliminating dependence on external lighting sources and simplifying the overall lighting system.
3Device complexity
If lighting is fixed on the carriage, then the structure is simple, but the lighting cannot be adjusted to illuminate different areas optimally
Solution Approach 1:
The lighting device incorporates adjustable elements that allow dynamic repositioning of light sources or light direction. This enables the lighting to adapt to different working conditions and illuminate various areas of the needle space optimally, while maintaining integration with the carriage structure.
Solution Approach 2:
The lighting device is designed with multi-functionality, capable of illuminating different areas and adapting to various operational requirements. The same integrated lighting system can serve multiple lighting needs by adjusting light direction, intensity, or positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables immediate troubleshooting without external lighting when errors occur, improving visibility and efficiency by ensuring the working area is consistently well-lit, with adjustable brightness and color for various conditions and functions.
Implementation Method 1
If the at least one lighting device is equipped with LEDs as the lighting means, the lighting device requires only little power and at the same time emits a very bright and cold light
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
The machine has machine carriages (30) moved over rear and front needle beds (4, 5) for controlling needle movements. An illumination device (33) is adjustably arranged at the carriages for illuminating a knitting chamber below the carriages. The illumination device is switched manually and/or by a machine controller and/or a knitting program. The illumination device comprises sealing strips. The illumination device is arranged at the carriages over the rear and front needle beds. The illumination device is provided with LEDs as lights.