Knitting Head Segmentation for Circular Machine Assembly
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Solution Overview
Problem
The existing circular knitting machine assembly process is lengthy and complex due to the integration of the knitting cylinder bearing within the support ring, making setup, adjustment, and maintenance difficult, especially when replacing or converting the knitting head.
Innovation Solution
The knitting head no longer includes its own support ring, instead utilizing a head ring connected to the machine frame via a standardized interface, reducing the weight and complexity of handling and maintenance, allowing for easier assembly and maintenance by integrating the support ring into the machine frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the knitting head includes its own support ring, then the knitting head has sufficient structural rigidity, but the assembly time increases and maintenance becomes difficult
Solution Approach 1:
The knitting head is divided into separate components: the head ring with knitting cylinder and the support ring mounted on the machine frame. This segmentation allows the knitting head to be assembled and disassembled independently from the support ring, reducing assembly time while maintaining structural rigidity when assembled.
Solution Approach 2:
The support ring is extracted from the knitting head assembly and mounted separately on the machine frame. This extraction allows the knitting head to be handled and replaced as a lighter, more manageable component while the support ring remains as a separate structural element.
2Adaptability or versatility
If the knitting head includes its own support ring, then the knitting head is self-contained, but the weight to be handled increases significantly
Solution Approach 1:
The support ring is extracted from the knitting head and mounted separately on the machine frame. This reduces the weight of the movable knitting head component from approximately 600 kg to 350 kg, making handling and replacement significantly easier while the support ring remains as a separate structural element.
3Weight of moving object
If the knitting head is dismantled into individual parts, then the weight is reduced, but the assembly process becomes tedious and requires extraordinary specialist knowledge
Solution Approach 1:
The knitting head is segmented into modular components (head ring, knitting cylinder, needle cam) that can be assembled in a standardized sequence. This segmentation with standardized interfaces reduces assembly complexity compared to complete dismantling, while still allowing weight reduction through selective assembly.
4Adaptability or versatility
If the support ring is integrated into the knitting head, then the knitting head is complete, but the replacement and conversion of knitting heads becomes difficult
Solution Approach 1:
The knitting head components are segmented and connected to the support ring via standardized interfaces. This allows the knitting head to be replaced or converted by simply detaching and reattaching components to different support rings, greatly facilitating replacement and conversion while maintaining structural integrity.
Solution Approach 2:
The support ring with standardized interfaces can accommodate different knitting head configurations and machine types. This universality allows the same support ring structure to serve multiple functions and support various knitting head designs, easing replacement and conversion processes.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A knitting head (11) is proposed for a circular knitting machine (1), which includes the complete cylindrical main bearing (29) and is provided at its lower end with a standardized interface (34) for receiving a support ring (35) on the machine frame. The support ring (35) supports the head ring (30) along its entire circumference, preferably with a continuous, circumferential seating surface (36).