Needle Bed Insert Dimples Reduce Friction
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Solution Overview
Problem
Conventional circular knitting machines face challenges in reducing frictional force between insert pieces and knitting tools, leading to increased power consumption and processing complexity, with existing solutions either being costly or ineffective in maintaining dimension accuracy.
Innovation Solution
A needle bed with insert pieces featuring a rectangular plate shape and multiple small dimples in the short- and long-side directions, reducing the contact area and frictional force without altering the structure of the knitting tool or insert piece, while effectively retaining lubricant and maintaining processing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the contact area between insert pieces and knitting tools is reduced to decrease frictional force, then power consumption is reduced, but the structural complexity of insert pieces increases
Solution Approach 1:
The insert pieces are designed with a porous structure containing multiple voids distributed throughout the material. This porous configuration reduces the effective contact area between the insert pieces and knitting tools, thereby decreasing frictional force and power consumption while maintaining the overall structural integrity of the insert pieces
Solution Approach 2:
The porous structure creates local variations in contact properties across the insert piece surface. Specific regions with higher void density provide reduced friction zones where knitting tools make contact, while other regions maintain sufficient structural support, achieving localized optimization of friction reduction without compromising overall strength
2Object-affected harmful factors
If conventional methods are used to reduce frictional force, then contact area is reduced, but manufacturing precision and dimension accuracy deteriorate
Solution Approach 1:
The porous structure with controlled void distribution reduces frictional force through decreased contact area while maintaining manufacturing precision. The voids are strategically positioned to affect friction properties without compromising the dimensional accuracy or structural integrity of the insert pieces
Solution Approach 2:
The porous structure is pre-formed in the insert pieces before assembly, establishing the friction-reducing contact characteristics in advance. This preliminary configuration ensures that dimension accuracy is maintained during subsequent knitting operations while the friction reduction effect is already in place
3Object-affected harmful factors
If insert pieces are designed with complex structures to reduce friction, then frictional force decreases, but ease of manufacture deteriorates
Solution Approach 1:
The porous structure can be formed using standard manufacturing techniques such as foam insertion, drilling and blasting, or chemical etching, making the friction-reducing design compatible with existing production processes and maintaining ease of manufacture while achieving the desired friction reduction
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
The solution effectively reduces frictional force, leading to decreased power consumption and operational costs, with a 14.5% reduction in power usage demonstrated, while maintaining the structural integrity and accuracy of the knitting process.
Implementation Method 1
the cylinder needle slides between the insert pieces, so that a frictional force is generated between the cylinder needle and each insert piece
Implementation Method 2
it is necessary to reduce the frictional force
Data Source
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AI summary
To provide a needle bed for a circular knitting machine in which, an insert piece for forming a groove for slidably storing the knitting tool, the contact area between the knitting tool and the insert piece is reduced. A needle bed which is mountable to the circular knitting machine is configured to slidably store a knitting tool in a groove of which both side surfaces are formed by opposed plate surfaces of adjacent insert pieces 50 having a rectangular plate shape, wherein each insert piece 50 has a plurality of dimples 53 formed in a short-side direction X and a long-side direction Y on the plate surfaces.