Knitting Transfer Unit Toe Closure via Half-Ring Overturning
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Solution Overview
Problem
Existing methods for producing tubular knitted articles, such as socks, are labor-intensive and costly due to complex and unreliable devices for automatically closing the toe of the knitted articles, which require precise mechanical operations and are prone to defects from mechanical inaccuracies.
Innovation Solution
A method and system that utilize a transfer unit with a circular ring of pick-up members divided into two half-rings, allowing for the engagement of needle loops and the formation of joining stitches between sinker loops, reducing mechanical precision requirements and enabling a more reliable and efficient closure of the toe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual picking and sewing methods are used, then labor intensity is high and production costs are high, but the process is simple and reliable
Solution Approach 1:
The patent combines the picking and sewing operations into a single integrated device. The picking device includes pick-up hooks that simultaneously perform the function of picking up the tubular article and providing the basis for sewing the toe closure, eliminating the need for separate picking and sewing machines and reducing overall system complexity while improving productivity
Solution Approach 2:
The pick-up hooks serve multiple functions: they pick up the tubular article from the knitting machine, hold it during transfer, and provide attachment points for sewing the toe closure. This multi-functionality reduces the number of separate components needed and simplifies the overall device while maintaining automated production capabilities
2Extent of automation
If complex picking devices with multiple hooks are used, then automation is improved, but the device becomes particularly complex and expensive
Solution Approach 1:
The patent merges the picking and sewing functions into a single integrated device with pick-up hooks that perform both operations, eliminating the need for separate picking and sewing machines and reducing overall system complexity while maintaining automated production capabilities
Solution Approach 2:
The pick-up hooks are arranged in a uniform circular pattern corresponding to the needle distribution, creating a homogeneous and simple structural design that is easy to manufacture and maintain while achieving full automation
3Manufacturing precision
If joining stitches are formed exactly on needle loops held by pick-up members, then precision is required, but mechanical inaccuracies cause defects
Solution Approach 1:
The patent changes the location parameter for stitch formation from the precise needle loop position to the intermediate space between pick-up members. This parameter change reduces the precision requirements while maintaining reliable toe closure, as the intermediate spaces provide a more forgiving target area that is less sensitive to mechanical inaccuracies
Solution Approach 2:
The intermediate spaces between pick-up members serve as intermediary locations for forming joining stitches. These intermediary positions provide a buffer zone that accommodates mechanical tolerances and inaccuracies, ensuring reliable stitch formation without requiring extreme precision in the positioning system
Data Source
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AI summary
The method for manufacturing tubular knitted articles (M) comprises the steps of: a) knitting a tubular knitted article (M) with the needle cylinder (3); b) transferring loops (MA) of a last-formed course of loops from the needles (5) of the needle cylinder (3) onto the pick-up members (27A, 27B) of a transfer unit (21), divided into two circular half-rings (25A, 25B, 27A, 27B) which can be overturned over each other; c) overturning one of the circular half-rings (25A, 25B, 27A, 27B) of pick-up members (27B) onto the other so as to arrange two edge portions of the final edge of the tubular knitted article (M) one onto the other; d) joining the two edge portions to one another by means of joining stitches (A, B, C, D) formed in intermediate spaces between adjacent pick-up members (27A), whereon the knitted tubular article (M) is retained; e) unloading the knitted tubular article (M) with the closed toe from the transfer unit (21).