Flat Knitting Insert Magazine With Interchangeable Containers
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Solution Overview
Problem
Current flat knitting machines face challenges in automating the insertion of diverse and differently shaped inserts, such as sensors, batteries, and LEDs, into knitted fabrics during production, requiring manual intervention and increased personnel deployment.
Innovation Solution
A device comprising a magazine with interchangeable containers and a gripping system that allows for the automated insertion of various inserts of different sizes, shapes, and materials, featuring a separating mechanism, positioning devices, and monitoring systems to ensure accurate placement, which can be spatially separate from the knitting machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion of inserts is used during knitting production, then production can continue with simple equipment, but personnel deployment increases and production efficiency decreases
Solution Approach 1:
The device is divided into functionally independent modules: a magazine system with interchangeable containers for different insert types, a gripping device with adjustable grippers, a transport mechanism with positioning devices, and a control system. This modular segmentation allows each component to be optimized independently while maintaining overall system flexibility and ease of operation.
2Extent of automation
If automated insertion is implemented, then personnel requirements are reduced, but the knitting machine must stop at insertion points
Solution Approach 1:
Multiple types of inserts are pre-loaded into different containers within the magazine system before the knitting process begins. The control system pre-plans the insertion sequence based on the knit pattern requirements. This preliminary preparation allows inserts to be quickly exchanged and inserted during knitting without requiring machine shutdown, as all necessary components are ready in advance.
3Adaptability or versatility
If a fixed magazine design is used, then the structure is simple, but it cannot accommodate different types and shapes of inserts
Solution Approach 1:
The magazine system incorporates movable and interchangeable components, including replaceable containers that can be quickly swapped to accommodate different insert types and sizes. The gripping device features adjustable grippers that can be repositioned and reconfigured. This dynamic adaptability allows the same base structure to handle diverse insert varieties without requiring complete system redesign.
4Manufacturing precision
If monitoring devices are added to check insert positioning, then insertion accuracy is improved, but device complexity increases
Solution Approach 1:
Optical sensors and monitoring devices are integrated into the magazine and gripping system to detect the presence, position, and orientation of inserts in real-time. This feedback information is continuously monitored by the control system, which automatically adjusts the positioning and gripping force to ensure accurate insert placement. The feedback loop maintains high precision without requiring complex mechanical adjustment mechanisms.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Magazine for inserts (70) for a knitted fabric produced on a flat knitting machine, which is part of a device (10) for inserting inserts (70) of a flat knitting machine (100), wherein the device (10) also includes a gripping device (50) with a gripper (51) for receiving inserts (70) from the magazine (40), wherein different types of inserts (70) can be stored in the magazine (40) and can be dispensed to the gripper (51).