Knitting Machine Carriage Sensor for Broken Needle Detection

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Solution Overview

Problem

Existing knitting machines lack the ability to detect broken needles, leading to interruptions in the knit structure and often resulting in discarded components, especially when operating automatically without human oversight.

Innovation Solution

Incorporation of an auxiliary component, such as a sensor, into the knitting machine that can detect broken or stuck needles, allowing for real-time feedback to the control system to adjust operations and prevent damage, using a carriage with a sensor configured to monitor needle positions and an independently movable auxiliary transport device to provide continuous monitoring of needle health.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If knitting machines operate automatically without human oversight, then productivity increases, but broken needles go undetected causing knit structure interruptions and scrap production

Engineering Contradiction:

Improveautomatic operation speedVSAvoidneedle break detection capability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The knitting machine performs self-diagnosis by using the existing carriage and sensor system to automatically detect broken needles during operation, eliminating the need for external monitoring while maintaining high productivity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The sensor detects needle position and provides real-time feedback to the control system, which then adjusts operations or stops the machine to prevent knit structure damage when broken needles are detected

Inventive Principle:

Principle #23Feedback

2Reliability

If sensors are integrated into the carriage to detect needle positions, then broken needle detection capability improves, but device complexity increases

Engineering Contradiction:

Improveneedle break detection capabilityVSAvoidcarriage sensor integration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor in the carriage serves multiple functions: it monitors needle positions for break detection, tracks needle movement during knitting cycles, and provides data for quality control, thereby justifying the added complexity through multiple benefits

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The detection function is merged with the existing carriage structure and sensor system already present in modern knitting machines, rather than adding a completely separate detection mechanism, thus minimizing additional complexity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3601651B1Knitting machine with electronic auxiliary component and knitting method with electronic auxiliary component

Publication Date: 2023.08.23 NIKE INNOVATE CV

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AI summary

A knitting machine may include a needle bed and a carriage that is movable along the needle bed. The carriage may be configured to engage at least one feeder to move a dispensing area of the feeder along the needle bed while dispensing a yarn, where the carriage includes an interface for providing power to an auxiliary component.