Warp Knitting Pattern Loading Control to Avoid Needle Collision
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Solution Overview
Problem
The operation of loading a novel pattern on a high speed double needle bar warp knitting machine is complicated, often resulting in needle collision, yarn breakage, and increased work intensity due to the need to frequently dismount and reconnect the transmission mechanism of the rear needle bar, which is not suitable for high speed machines.
Innovation Solution
A control system that calculates the required shogging displacement of each guide bar based on their current and target positions, using a shog controller with data cache regions to send precise instructions for moving guide bars to their starting positions during pattern loading, avoiding collisions and simplifying the loading process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the guide bars are moved directly to the starting position of the novel pattern during high speed knitting, then the productivity is improved, but needle collision and yarn breakage occur
Solution Approach 1:
The control system performs preliminary calculations to determine the safe starting position of guide bars based on the current position of needle bars. Before moving guide bars to the novel pattern starting position, the system pre-computes the trajectory and timing to ensure guide bars only move when needle bars are in safe positions, preventing collisions and yarn breakage while maintaining high productivity
Solution Approach 2:
The control system continuously monitors the real-time positions of both guide bars and needle bars. Based on this feedback, the system dynamically adjusts the movement timing and position of guide bars during pattern loading, ensuring that guide bars are only positioned when needle bars are in safe positions, thus preventing collisions while enabling fast pattern loading
2Ease of operation
If the transmission mechanism of the rear needle bar is disconnected to enable pattern loading, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the traditional mechanical approach of disconnecting transmission mechanisms with a control system that uses electronic calculation and automated positioning. The control system computes safe movement trajectories and automatically positions guide bars during knitting cycles, eliminating the need for manual disconnection and reconnection of transmission mechanisms, thus improving ease of operation without adding mechanical complexity
Solution Approach 2:
The control system performs self-service by automatically calculating and executing the safe positioning of guide bars during pattern loading. The system monitors needle bar positions, determines safe windows for guide bar movement, and executes the positioning without requiring operator intervention to disconnect or reconnect transmission mechanisms, thereby simplifying the overall system while improving operability
Data Source
AI summary
The disclosure discloses a control method of pattern loading for a high speed double needle bar warp knitting machine. Through disposing two or more than two high speed FIFO pattern data cache regions on a shog controller, a data read-write conversion function of each cache region continuously and automatically is respectively realized. Needle collision caused by guide bar shogging during pattern loading is avoided. Pattern loading steps of the double needle bar warp knitting machine are simplified; the work intensity is reduced; and the work reliability is improved.