Circular Knitting Machine Shaped Sinker Control for Complex Terry Stitches
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Solution Overview
Problem
Existing circular knitting machines lack flexibility in producing terry stitches, as the movements of terry stitch mechanisms are limited by structural constraints, requiring replacement of all knockover sinkers for different stitch shapes, which is costly and time-consuming, and are not suitable for manufacturing complex fabrics with varied features.
Innovation Solution
A circular knitting machine design featuring independently movable shaped sinkers and knockover sinkers, with selectors and actuators allowing precise control over sinker movements, enabling the production of complex terry stitches without reconfiguring the machine, and allowing for easy switching between different stitch types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If knockover sinkers are made as one piece with integral nose and pin for making terry stitches, then the structure is simple and robust, but the flexibility to produce different stitch shapes is limited and replacement is costly
Solution Approach 1:
The sinker is divided into separate components: the main body with pin and the nose are no longer integral but can be separated. This allows the nose to be replaced independently to change stitch characteristics while keeping the main sinker structure, resolving the contradiction between structural simplicity and adaptability.
Solution Approach 2:
The sinker design transitions from a static, fixed configuration to a dynamic, adjustable system where the nose can be selectively positioned or replaced. This enables the same sinker body to produce different stitch shapes by changing the nose configuration, achieving versatility without sacrificing structural integrity.
2Adaptability or versatility
If all knockover sinkers are replaced to produce different stitch shapes, then the desired stitch variety is achieved, but the time and cost required increases significantly
Solution Approach 1:
By segmenting the sinker into replaceable nose components and a permanent main body, the system allows quick interchange of only the necessary part (nose) rather than replacing the entire sinker. This dramatically reduces replacement time and cost while maintaining full stitch shape variety.
Solution Approach 2:
Multiple nose components with different geometries can be prepared in advance as copies, allowing rapid switching between stitch types without manufacturing new components during operation. This minimizes downtime and enables quick adaptation to different production requirements.
3Adaptability or versatility
If selectors and actuators are added to control sinker movements independently, then the precision and flexibility of stitch production is improved, but the device complexity increases
Solution Approach 1:
A selector mechanism acts as an intermediary between the control system and the sinker, translating control signals into precise sinker positioning. This intermediary component enables independent control of sinker movements without requiring complex direct actuation of each sinker, managing the complexity while maintaining flexibility.
Solution Approach 2:
The selector and actuator system is designed to control multiple sinkers using a unified control mechanism. This multi-functional approach allows a single control system to manage various sinker positions and movements, reducing overall complexity compared to individual control systems for each sinker while maintaining precision and flexibility.
Data Source
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AI summary
A circular knitting machine comprises a plurality of knockover sinkers (7), each housed in a radial groove (6) and having a pin (13) configured for cooperating the needles (3) so as to manufacture a knitted fabric, a shaped sinker (8) placed beside each of the knockover sinkers (7), wherein the shaped sinker (8) is movable with respect to the respective knockover sinker (7) and independently from the respective knockover sinker (7), wherein the shaped sinker (8) has a nose (16) placed above the respective knockover sinker (7) and configured for making a terry stitch cooperating with a needle (3). A selector (10) is operatively coupled with each shaped sinker (8) and is oscillating in a radial plane between a rest position and an operating position, wherein in the operating position the selector (10) acts directly or indirectly upon the shaped sinker (8) so as to deviate the trajectory of the shaped sinker (8). A selecting actuator (26) can be engaged upon command with the selectors (10) and is configured for causing the selectors (10) to switch from the rest position to the operating position.