Yarn Carrier Tension Control via Vertical Frame Movement
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Solution Overview
Problem
Existing flat knitting machines fail to control yarn tension in a timely manner, leading to non-uniform stitch sizes and flaws at the edge of knitted pieces due to the uncontrolled yarn tension when the carriage turns.
Innovation Solution
A yarn carrier device with a carriage connector, a yarn guide sliding rod, a fixing frame, and a contact sensor system that allows the fixing frame to ascend or descend along vertical sliding grooves to control yarn tension, ensuring uniform distribution of yarn across knitting needles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tension devices are disposed on the side face of the knitting machine to recycle unknitted yarn, then yarn recycling is achieved, but the yarn tension cannot be controlled in time due to the high turning speed of the carriage and untimely response of the tension devices
Solution Approach 1:
The yarn guide is designed with a preliminary action mechanism where the unknitted yarn is guided and positioned in advance before the carriage completes its turn. The tension control device acts on the yarn during the carriage turning process rather than after, ensuring timely tension control that matches the high-speed carriage operation
Solution Approach 2:
A yarn guide component serves as an intermediary between the carriage and the yarn source. This intermediary device actively manages the unknitted yarn portion during carriage movement, providing continuous tension control through guided yarn path management and coordinated movement with the carriage
2Productivity
If the yarn guide returns to knit the next line of yarn without recycling unknitted yarn, then the knitting process continues, but the yarn tension becomes larger resulting in non-uniform stitch sizes at the edge of the knitted piece
Solution Approach 1:
The yarn guide system maintains continuous useful action by actively managing the unknitted yarn throughout the entire carriage cycle. Instead of allowing yarn tension to build up during carriage return, the system continuously guides and tensions the yarn, ensuring uniform stitch formation across all knitting lines without interruption to productivity
Solution Approach 2:
The yarn guide system incorporates feedback mechanisms where the position and tension state of the yarn are continuously monitored during carriage movement. This feedback enables real-time adjustment of yarn guidance and tension to maintain uniform stitch sizes at the edges of knitted pieces while preserving knitting continuity
Data Source
AI summary
This application relates to a yarn carrier device with a yarn tension control function for a flat knitting machine, and a yarn tension control method. At the moment a carriage is connected to a yarn carrier device, a fixing frame carrying a bobbin ascends or descends on sliding rails installed on the yarn carrier device. The ascending or descending speed, time and distance of the fixing frame can be calculated directly according to a yarn carrier stop, the quantity of an unknitted portion of the yarn and the speed of the carriage. When the carriage contacts a yarn carrier, the fixing frame is controlled to ascend along the sliding rails. When the carriage drives the yarn carrier to enter a knitting area, the fixing frame is controlled to descend.