Knitting Tool Bar Deformable Base Solidification
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Solution Overview
Problem
Warp knitting machines face mechanical stress issues due to high load-bearing requirements, leading to increased mass and reduced working speed, as existing knitting tool bars and holders often rely on single-point support for knitting tools, which is insufficient for absorbing forces effectively.
Innovation Solution
A knitting tool bar design featuring a deformable base with a solidification mechanism, where cover grooves are formed between the clamping cover arrangement and the tools, providing dual-sided support by solidifying into a form-fitting shape during assembly, reducing the need for precise mechanical processing and allowing for easy replacement of the base when tools are changed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tool holder is designed with robust structure to withstand high mechanical stresses, then the strength and load-bearing capacity are improved, but the moving mass increases which negatively impacts operating speed
Solution Approach 1:
The base material undergoes a parameter change from deformable state during assembly to hardened state during operation. The base is applied in a deformable state to allow easy positioning and forming of cover grooves, then hardened in situ to provide robust support with minimal mass, resolving the contradiction between strength and weight.
Solution Approach 2:
The base material experiences a phase transition from deformable to hardened state. This allows the base to be easily manipulated during assembly (deformable phase) and then provide strong structural support (hardened phase), achieving both ease of assembly and high load-bearing capacity with minimal mass.
2Manufacturing precision
If the base is made from rigid material with fixed grooves, then the manufacturing precision and tool support stability are improved, but the adaptability to different tools and ease of replacement are worsened
Solution Approach 1:
The base transitions from a static, fixed-groove design to a dynamic system where the base itself can be deformed and reformed. The deformable base allows grooves to be created on-site to match specific tool geometries, providing both precision support and adaptability for different tool types and easy replacement.
Solution Approach 2:
The base serves itself by being deformable during assembly, allowing the grooves to be formed automatically to match the tool shapes without requiring pre-machined grooves. This self-adjusting capability provides both precision and adaptability, eliminating the need for complex pre-processing.
3Manufacturing precision
If cover grooves are pre-milled into the tool holder, then the manufacturing precision is improved, but the device complexity and manufacturing time are increased
Solution Approach 1:
Instead of pre-milling grooves before assembly, the grooves are formed during the assembly process itself by deforming the base material around the tools. This preliminary action of creating grooves on-site eliminates the need for complex pre-processing steps while maintaining positioning accuracy.
Solution Approach 2:
The groove-forming operation is extracted from the pre-assembly process and integrated into the assembly process itself. By taking out the need for separate groove machining operations and performing deformation during assembly, the manufacturing process is simplified while maintaining precision.
4Stability of the object's composition
If the base is designed as a permanent component, then the structural stability is improved, but the ease of repair and tool replacement are worsened
Solution Approach 1:
The base is designed as a consumable component that can be easily replaced rather than repaired. After extensive use or tool replacement, the entire base can be removed and replaced with a new one, simplifying maintenance while the hardened state during use provides structural stability.
Solution Approach 2:
The base is designed as a separate, replaceable segment rather than an integral permanent part of the tool holder. This segmentation allows the base to be independently replaced without affecting other components, providing both stability during use and ease of replacement during maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the load-bearing capacity of knitting tools while minimizing material usage and mass, improving the operating speed and efficiency of warp knitting machines by distributing support over two areas, thus reducing mechanical stress and allowing for precise adaptation to individual tools.
Implementation Method 1
forming the base, at least in the area of the working tools, from a deformable material with a hardening mechanism
Data Source
Figure 1
AI summary
A working tool bar (1) is described, comprising working tools (5) arranged in receiving grooves (4) and a working tool receptacle (3), and a cover assembly (11) that secures the working tools (5) in the receiving grooves (4). Each working tool (5) has a back (6) adjacent to a groove base (7), a front (8) projecting from the receiving groove (4), and two flanks (9, 10) connecting the front (8) and back (6). The cover assembly (11) acts upon the front (8). The aim is to achieve high load-bearing capacity using simple means. For this purpose, the working tools (5) are designed so that their front (8) projects into a cover groove (13).