Raschel Machine Guide Needle Spacing for Net Weight Reduction
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Solution Overview
Problem
Conventional Raschel machines produce nets with a standard width requiring a high number of warp threads, leading to increased weight and breakage risks, which hampers efficiency and increases production costs.
Innovation Solution
The Raschel machine design features an increased space between guide needles, allowing for a reduced number of warp threads while maintaining strength, using thicker threads to achieve lower weight and reduced breakage, with an optimal space of 50.8 mm balancing efficiency and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a high number of warp threads are used to produce nets with standard width, then the net width and coverage are improved, but the net weight and breakage risk increase
Solution Approach 1:
The patent applies parameter changes by increasing the spacing between guide needles from conventional distances to at least 50.8 mm, which fundamentally alters the production parameters. This allows using fewer warp threads (reducing weight) while maintaining net width through the use of thicker threads, thus resolving the contradiction between net width coverage and net weight
Solution Approach 2:
The patent implements local quality by varying the thread thickness strategically - using thicker threads in regions where structural integrity is needed while maintaining overall net width. This allows reduction in total thread count and weight while preserving the necessary coverage area and strength characteristics
2Area of stationary object
If a high number of warp threads are used to produce nets with standard width, then the net coverage is improved, but the thread breakage risk increases
Solution Approach 1:
The patent changes the critical parameter of guide needle spacing to at least 50.8 mm, which reduces the number of warp threads required. This parameter change allows using fewer but thicker threads, thereby reducing breakage risk while maintaining net coverage
Solution Approach 2:
Instead of increasing thread count to improve coverage and reliability, the patent inverts the approach by decreasing thread count and increasing individual thread thickness. This inversion resolves the contradiction by achieving coverage through fewer, stronger threads rather than many thinner threads
3Ease of manufacture
If conventional guide needle spacing is used, then the manufacturing process is simple, but the production efficiency decreases and production costs increase
Solution Approach 1:
The patent modifies the guide needle spacing parameter to at least 50.8 mm, which directly improves productivity by reducing the number of warp threads needed. This parameter change simplifies the manufacturing process by reducing thread management complexity while simultaneously increasing production efficiency through faster net production and lower material costs
4Weight of moving object
If a reduced number of warp threads are used with increased guide needle spacing, then the net weight is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific minimum spacing parameter of 50.8 mm between guide needles, which provides a clear manufacturing target. This standardized parameter allows for precise positioning while maintaining reduced net weight, as the increased spacing tolerance naturally accommodates manufacturing variations better than tighter spacing would
Data Source
AI summary
A Raschel machine (100) comprises a plurality of first guide needles (110) arranged along a first direction for guiding warp threads (210), a plurality of second guide needles (150) arranged along the first direction for guiding weft threads (220) and a plurality of needles (180) arranged along the first direction for creating interlocked loops formed by threads, whereby the warp threads (210) are created. The first guide needles (110) are held by a first needle bar (120), the second guide needles (150) are held by a second needle bar (160), and the second needle bar (160) is moved back and forth between two respective neighbouring first guide needles (110). The space between neighbouring first guide needles (110) is greater than 25.4 m (1 inch).