Circular Knitting Machine Open-Work Sinkers
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Solution Overview
Problem
Existing circular knitting machines are limited in manufacturing complex open-work knitted fabrics with varying features and are not flexible enough to rapidly produce different types of open-work areas, as the elements used to create open work are guided by cams and follow preset movements, making it difficult to change the number, arrangement, and features of open work in the fabric.
Innovation Solution
A circular knitting machine with a rotating needle-holding cylinder and circular crown that uses alternating rotary motion to move open-work sinkers and needles, allowing for the selection of specific sinkers and yarn feeds to create elongated interstitches and interloops, enabling the production of complex and varied open-work fabrics without reconfiguring the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional sinkers guided by cams are used to create open-work areas, then the machine can produce open-work knitted fabrics, but the number, arrangement, and features of open work are preset and difficult to change
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed cam-guided sinkers with dynamically controllable sinkers that can be selectively activated. The sinkers are no longer constrained to preset trajectories but can be individually controlled through a digital selection system, allowing the machine to adapt its configuration dynamically without physical reconfiguration. This enables flexible production of different open-work fabric types while maintaining a consistent machine structure.
Solution Approach 2:
The patent implements parameter changes by introducing digital control parameters that determine which sinkers are activated and how they move. Instead of changing the physical machine configuration, the system changes operational parameters (selection of specific sinkers, their movement timing and position) to produce different open-work patterns. This allows rapid switching between fabric types by modifying control parameters rather than reconfiguring the machine.
2Productivity
If preset cam-guided movements are used for open-work sinkers, then the machine structure remains simple, but the manufacturing time for complex open-work fabrics increases
Solution Approach 1:
The dynamic control system allows the machine to rapidly switch between different open-work fabric productions by electronically selecting which sinkers to activate and how to move them, eliminating the time-consuming mechanical reconfiguration process. This dramatically reduces setup time between different fabric types while maintaining the ability to produce complex patterns.
Solution Approach 2:
The system performs preliminary action by pre-programming sinker selection and movement patterns for different fabric types. When a fabric type change is required, the control system can immediately load the appropriate parameters without physical reconfiguration, effectively preparing the machine in advance for the next production run.
3Manufacturing precision
If multiple different sinker paths are provided for open-work sinkers, then complex open-work fabrics can be produced, but the guiding ring and trajectory management become more complex
Solution Approach 1:
The patent replaces the complex mechanical guiding ring system with multiple paths with a digital control system that manages sinker trajectories. Instead of providing multiple physical guiding paths in the mechanical structure, the system uses electronic control to direct sinkers along appropriate trajectories, simplifying the mechanical guiding ring while maintaining precise control over open-work pattern formation.
Data Source
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AI summary
A method for manufacturing open-work knitted fabric in a circular knitting machine comprises: rotating in a first direction of rotation a needle-holding cylinder (2) and a circular crown (4) by moving selected open-work sinkers (9, 10) towards a central axis (X-X) of the machine and towards a respective forward position; lifting and then lowering the needles (3) beside the selected open-work sinkers (9, 10) placed in the forward position, while the needle-holding cylinder (2) and the circular crown (4) rotate in the first direction of rotation and move on a yarn feed so as to load a textile yarn fed by the yarn feed onto protrusions (15) of the selected open-work sinkers (9, 10) so as to make elongated interstitches; rotating in a second direction of rotation, opposed to the first one, the needle-holding cylinder (2) and the circular crown (4) by radially moving the selected open-work sinkers (9, 10) away from the central axis (X-X), towards a respective backward position, lifting the needles (3) at least in a withdrawn position, so as to unload the interstitch on the protrusions (15) within the heads (3A) of the needles (3), and continuing rotating in the second direction of rotation until the yarn feed is passed over and then lowering the needles (3) while the selected open-work sinkers (9 10) are in the respective backward position. A circular intarsia knitted open-work fabric can be obtained.