Knitting Machine Guide Channel Surface Structure for Lubricant Retention
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Solution Overview
Problem
Existing knitting machines with irregularly fissured surface structures in guide channels and knitting elements face issues with uneven lubricant distribution, leading to dry spots and increased friction, temperature, and energy consumption, especially during initial operation.
Innovation Solution
A knitting machine with a guide channel and knitting element featuring a surface structure with a material content of 50% at a cutting height of 0.4 μm to 3 μm, which forms a uniform capillary structure for even oil retention and distribution, preventing dry spots and ensuring a consistent lubricant film between the knitting element and guide channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If an irregularly textured surface structure with high material content (50% at cutting height ≥40 μm) is used in the guide channel and knitting element, then lubricant retention capacity is improved, but uneven lubricant distribution occurs leading to dry spots and insufficient lubrication
Solution Approach 1:
The patent applies parameter changes by reducing the cutting height from ≥40 μm to 1-10 μm and adjusting the material content to 5-20%. This parameter optimization transforms the surface structure to create adequate lubricant retention while ensuring uniform distribution, preventing both insufficient retention and uneven distribution problems
Solution Approach 2:
The patent applies local quality by creating a controlled surface structure with specific protrusions and depressions that are uniformly distributed. The depressions serve as localized lubricant reservoirs while the protrusions ensure consistent contact points, creating local lubrication zones that collectively provide uniform overall lubrication
2Quantity of substance
If an irregularly fractured surface structure is used to create capillary structures for oil retention, then lubricant storage is improved, but rapid abrasion of the surface roughness occurs at the beginning of operation
Solution Approach 1:
The patent applies parameter changes by optimizing the cutting height to 1-10 μm and material content to 5-20%, creating a finer surface structure that is less prone to rapid abrasion. This controlled parameter range maintains lubricant storage capability while significantly improving the durability of the surface structure during initial operation
Solution Approach 2:
The patent applies preliminary action by pre-forming a uniform surface structure with controlled material content and cutting height before operation begins. This pre-optimized structure ensures that lubricant is evenly distributed from the start, preventing the rapid wear that occurs when uneven surfaces are first subjected to operational loads
3Quantity of substance
If an irregularly textured surface structure with high material content is used, then lubricant reservoirs are formed, but temperature increase and energy consumption increase occur due to insufficient lubrication in certain areas
Solution Approach 1:
The patent applies parameter changes by optimizing the cutting height to 1-10 μm and material content to 5-20%, ensuring that lubricant reservoirs are formed uniformly without creating dry spots. This optimized parameter range maintains adequate lubricant storage while ensuring complete coverage, preventing temperature increases and excessive energy consumption
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
The solution ensures optimal lubrication and reduced friction, preventing rapid abrasion and energy consumption increases by maintaining a uniform lubricant film, even during initial operation, and can be applied to various knitting elements, including those for delicate fabrics like women's tights.
Implementation Method 1
the surface structure, preferably irregularly fractured, forms a uniform capillary structure which, due to the capillary forces acting there, is able to retain the oil everywhere in the lateral wall area
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a knitting machine with a guide channel and a knitting element guided therein, wherein the knitting element is accommodated and guided in the guide channel in a substantially moveable and interlocking manner. In addition, when viewed in the manufacturing state or in the production and output state, the knitting element (3) is designed with a surface structure at least in sections on at least one opposing knitting element side flank (3a, 3b) when viewed in cross-section and/or the guide channel (4) is formed with a surface structure at least in sections on at least one channel side wall (4a, 4b) facing the knitting element side flanks (3a, 3b), wherein the surface structure has a plurality of elevations (1) spaced apart from one another, which are arranged and designed so that they contact punctiformly and/or linearly on the respective facing area of the knitting element side flanks (3a, 3b) and/or the channel side walls (4a, 4b) during operation, and wherein the surface structure additionally has a plurality of depressions (2) spaced apart from one another which are arranged and designed so that they form a plurality of lubricant reservoirs spaced apart from one another, in which a part of a fluid lubricant, in particular a lubricant oil, introduced into the guide channel (4) is accommodated, and thus forms a lubricant film in the area between the knitting element side flanks (3a, 3b) and the channel side walls (4a, 4b) during operation. According to the invention, the surface structure has a material ratio (Rmr) of 50% at a cutting height (c) of 0.4 μm to 3 μm, preferably only at a cutting height (c) of 0.6 μm to 1.6 μm, according to DIN EN ISO 4287.