Flat Knitting Machine Insertion Device
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Solution Overview
Problem
Current flat knitting machines require manual insertion of additional elements like sensors, chips, and LEDs into knitted fabrics, leading to increased personnel deployment and production interruptions, which is inefficient and labor-intensive, especially for smart textiles that require complex patterning and design options.
Innovation Solution
A flat knitting machine with a movable carriage and a gripping device that can insert knitted inserts into the fabric without interrupting the knitting process, featuring a magazine for storing inserts and a gripper with contoured jaws that can securely pick up and place inserts below the needle cross, allowing for automated insertion without impeding the knitting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual insertion of inserts is used, then flexibility in handling different insert types is maintained, but personnel deployment increases and production is interrupted
Solution Approach 1:
The system enables self-service automation where the knitting machine itself performs the insert insertion through the gripping device integrated into the carriage, eliminating the need for manual intervention and continuous personnel monitoring while maintaining the ability to handle various insert types
Solution Approach 2:
The gripping device is pre-positioned on the carriage and ready to receive inserts from the magazine before the knitting process requires insertion, allowing the insert to be automatically placed into the fabric without interrupting the overall production flow
2Productivity
If automated insertion device is added, then production continuity is maintained, but device complexity increases
Solution Approach 1:
The gripping device is merged with the existing carriage structure of the knitting machine, utilizing the carriage's movement system to transport the gripping device along the needle beds, thereby avoiding the need for a completely separate automated insertion system and reducing overall device complexity
Solution Approach 2:
The gripping device serves multiple functions: it holds inserts from the magazine, transports them along with the carriage movement, and releases them into the knitted fabric at the correct position, eliminating the need for separate specialized components for each function
3Ease of operation
If gripping device is positioned in the knitting area, then insert insertion is enabled, but thread guide movement is hindered
Solution Approach 1:
The gripping device is designed to be movable relative to the knitting area through the carriage system, allowing it to be positioned precisely where needed for insert insertion while moving out of the way during threading operations to avoid hindering thread guide movement
Solution Approach 2:
The gripping device is segmented from the main knitting mechanism, being mounted on the carriage rather than being fixed to the needle beds, allowing independent movement and positioning that prevents interference with thread guides while maintaining insert insertion functionality
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A flat knitting machine with at least two needle beds and at least one carriage (20, 20') which is movable along the needle beds, and with a device (10) for inserting inserts (70) into a knitted fabric, wherein the device has a magazine (40) for inserts (70) and a gripping device (50) with which inserts (70) can be moved from the magazine (40) to the hed gap (80) between the needle beds and inserted into a knitted fabric produced on the flat knitting machine (100), and wherein the at least the gripping device (50) is arranged on the carriage (20, 20') or on guide elements of the carriage (20, 20') and is movable along the needle beds by the carriage (20, 20') or a separate drive.