4.

Working mechanism and control of knitting machines

Brief content:
4.1 Weft knitting machines (flat, circular; course formation, another actions, working and program controlling mechanisms, shaped products) 4.2 Straight bar frames 4.3 Warp knitting machines

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4.1 Weft knitting machines 4.11 Course formation

How are formed basic structural elements on individually controlled needles? How is insured movement of the needles?

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Remember wave on needles 7 positions. vw working speed, vnc speed of needles relatively to cams 3
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Example (large diameter machine Relanit):

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Movement of the needles: A. Formation of the course of knitted stitches (loops)

In all cased sequence of: clearing position tuck position knocking-over with loop formation. Is there another possibility?
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Yes starting in the tuck position.

Advantage of this solution: The same position of yarn guide for both directions (used on small diameter hosiery machines).
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Movement of the needles: B. Formation of the tuck stitches

Missing comparing to knitted stitch formation: d clearing of the old loop on needle, e knocking-over of the loop after laying the yarn1. Float stitch no movement of the needle.
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Tuck using raising cams:

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Tuck using stitch cams:

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Holding the last loop when needle moves up:

a) By tangential component of take down force Ft b) By throat of clearing sinkers 3 (1 is relative movement of needle 2 towards sinker)

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Using of the clearing sinkers for plush (pile) kinks formation (4 plush, 5 base yarn):

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Modified sinker that enable formation of high quality (evenness) of plush loops:

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Example of knitting of plush fabric:

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4.12 Another working actions of knitting machines

How to transfer loops? Can change of mutual position of needle beds help with loop transfer? How to knit purl structures?

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Loop (stitch) transfer

Moving the loop into opposite needle bed. Wide possibilities of usage:
Relief on fabric surface. Change of double into single structure. Great holes (pores) in the fabric. Cable stitch design. Knitting of purl fabrics. Fashioning (shaping) of the fabric etc.
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Loop (stitch) transfer

The sequence:
a) New needle goes through prepared loop. b) Original needle knocks-over the loop.

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Loop transfer 1 starting position

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Loop transfer 2 latch opening

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Loop transfer 3 the highest needle position

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Loop transfer 4 tuck position (opposite needle)

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Loop transfer 5 latch closing

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Loop transfer 6 loop casting off

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Loop transfer 7 final position

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Loop transfer needle bed racking

a) Makes the process easier (b racking by of needle spacing). b) Enables selection of the new needle.

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Using of double-hooked needles:

No button on the needles 1, need be controlled by sliders 2, 3 and cams 6.

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Examples of double-hooked needles and sliders:

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4.13 Working mechanism of weft knitting machines

What working elements are necessary? How differs flat and circular machines? How the needles moves?

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Example of flat knitting machine (computer):

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Example of flat knitting machine (computer):

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Example of flat knitting machine (mechanical):

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Example of circular knitting machine:

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Example of circular knitting machine:

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Needle beds of knitting machines:

Example flat knitting machine (V-bed).
Take-off force Fto is necessary! Parts: needles, beds with tricks, cams .

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Types of needle beds arrangement:

A. Flat knitting machines:
a) One bed (only single faced structures). b) Two beds type V (double faced, purl, interlock). c) Two beds double hooked needles (purl, others).

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Types of needle beds arrangement:

B. Circular machines (large diameter):
d) One bed - cylinder (only single faced structures). e) Cylinder and dial (double faced, purl, interlock). f) Two Cylinders double hooked needles (purl, others).

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Cams of knitting machines:

Examples: flat knitting machine (b), circular machines (a, c):

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Cams of knitting machines:

Raising cams (1 tuck, 2 clearing). Sinker (stitch) cams 3 (flat machines one for each direction).

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Example of cams (enables loop transfer) four knitting systems:

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Yarn guides on flat machines:

Independent mounting (bar 2, guide carriage 1), guide carrier 8, side stop 5. Feeder: single 3, plating 4 (holes 6,7).

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Yarn guides for intarsia, rollers:

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Yarn guides on circular machines:

Body of the guide:
Brings the yarn. Prevent closing of the latches.

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Yarn guides on circular machines:

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Latch openers:
Passive prevent latch closing at loop clearing. Active opens the latches (after loop transfer etc.). Types: brash, needle, blade.

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Carriage of flat machine:

Bedding of the cams, guide carriers, latch openers Connection of front and rare parts - bow 5. Assistance at machine drive.
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Carriage of flat machine another example:

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Carriage of two knitting systems machine:

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4.14 Programmed control on knitting machines

How to knit more complicated structures and designs, 2D and 3D shaped products etc.? What to prefer: simple cheap machines or expensive machines with more possibilities?

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Programmed control enables:

A. Knitting of different structures and patterns, usually by needle control. B. Knitting in cycles (fashioned knitting etc.). Information about knitting in memory of the system. Centrum of control now computer. Communication with the machine electro-mechanic transducers.
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4.141 Patterning mechanism (group, individual needle selection)

How enable to modify activity of needles? Which structural elements can be used (combined)?

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Cam paths (channel, tracks) at patterning:

3 variants of cam paths selection between knitted, tuck and float stitch. Two-way selection. Three-way selection.

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Cam paths (channel, tracks) at patterning:

Group selection needles divided into 2 or several groups without possibility of change during knitting. Individual selection jacquard.

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A. Group needle selection:

Main used systems:

Different height of needle butts. Different positions of needle butts. Depressed jack principle.

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Different height of needle butts

Positions of cam (example 3 heights): 1 fully in work. 2/3 works only with high and middle butts. 1/3 works only with high butts. 0 out of work.
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Different positions of needle butts

Example 1 one of the beds of interlock machine (odd and even needles alternates).

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Example interlock dial cams:

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Different positions of needle butts

Example 2 more possibilities (4 tracs, general button distribution, only line A with stitch cam).

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Example cylinder cams:

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Depressed jack principle (pressing cams)

Action: perpendicular to the bed. Large possibilities

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A. Individual needle selection:

Function of so called jacquards:

Discontinuous similar as at weaving machines (now used rarely). Continuous selection simultaneously with knitting. Modern system.

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Continuous jacquards:

How to fit with high speed of selection (selection of more then 1000 needles per second!)? Main solutions:
Rolling on the bed (usually cylinder). More cam tracks. Really individual selection electromagnetic.

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Pattern wheels:
Principle: positioned at an inclined angle, replace raising cams. Slots around circumference with small, shaped metal elements (bits). Enables 3-track selection on many knitting systems.

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Pattern wheels - example:

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Pattern wheels - example:

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Pattern wheels pattern formation:

Repetition of pattern in accordance with:
! nK  r J Just one machine revolution means n + 1/3 revolutions of pattern wheel. Pattern motives are in helical line.

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Jacquard with press (push) buttons:

Press button 7 can prevent contact of jack 4 with cam 6. Variants:
Stable buttons position. Controlled buttons position (on each system or central).

Pattern repetition?

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Example for one revolution patterns:

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Example pattern drums:

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Jacquard with press (push) buttons:

Computer continuously controlled press buttons (electromagnetic) unlimited possibilities. If there is B buttons, each control 1., B+1., 2B+1. etc. needle and have enough time to change position.

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Direct electromagnetic selection:

A. Electromagnet 1, 2 selectively attract needle but, then continues permanent magnet 3. Slow for industrial use.

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Direct electromagnetic selection:

B. Electromagnet 1, 2 keeps spring 4 or not it goes to track 5 or 6. 2 combination of electro and permanent magnet (solves the problem of residual magnetism).

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Direct electromagnetic selection example:

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4.142 Machine control

How to control cams, yarn guides, needle beds etc.? How to use computer (Mechanically working machine needs to understand to electrical information)?

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Main functions:

Cyclic change of knitting in accordance with program. Often used to knit pieces (panels) of fabric (fashioned, 2D or 3D shaped etc.). Computer controlled often combined with patterning device.

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What is controlled?
Cams, particularly
Raising cams (change of the structure). Stitch cams (setting of stitch length).

System of yarn feeding, i.e. yarn guides (change of yarns). System of fabric take off. Needle bed racking. Carriage movement (length of the stroke).

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Setting of stitch length step motors:

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Scheme of computer control:

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Where to find systems CAM, CAD? What does it means real time working? What electromechanical transducers could be used?

Scheme of computer control:

Monitoring of machines operation. How to use received information?

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CAD systems:
Main activities:
Read prepared pattern into memory (scanner, camera) or create the design directly on computer (tablet, software). Programming of other machine activities (product shaping, yarn guides change). Storage of the structured programmes. Simulation of product appearance, communication with other CAD systems (clothing).

Quick, large possibilities.

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CAD system, example:

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4.15 Fashioned (shaped) knitted products (2D)

How to save material (production without waste)? What are advantages and disadvantages of used technologies?

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2D-shaping
Widening:
Increasing of number of working needles. Prolongation of yarn lapping.

Narrowing (pure needle withdrawn is not sufficient!):

By knocking-off loops. By loop transfer (inside direction).

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Example of 2D shaping:

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Needle selection at shaping:

Movable cams (described later). Individual needle selection, if there is to disposal. Another suitable equipment of flat knitting machines:
Carriage stroke control. Suitable fabric take-off device.
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4.16 3D shaping
What can provide us with the possibility to insert short courses into the fabric? Which product shapes we can receive?

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The principle of 3D shaping by knitting:

The number of courses, knitted by adjacent needles, is varied (usually at reciprocating knitting). Example knitting of reciprocated heel:

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Reciprocated heel:
The courses are drawn all in horizontal position (as they were knitted), outside of knitted area (pentagon A B C B C) are not interrupted wales!

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Reciprocated heel:
The same in stitches:

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Reciprocated heel:
The courses in real mutual position:

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Reciprocated heel:
Tuck stitches at the end of reciprocal courses improve product quality:

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Example of sock:

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Cap (similar principle):

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Example of product pullover, uses both 2D and 3D shaping:

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Principle of knitting of two double-faced fabrics (alternating of odd and even needles).
Used for Whole Garment knitting etc.

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4.17 Production of hosiery

How to knit socks, stockings etc. on automatic circular machines of small diameter? How to reduce costs on making-up of the products?

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Machines:
Small diameter circular machines (body diameters) Main types:
Single cylinder (single faced product!)
Fine stockings, tights Course socks etc.

Double cylinder, usually course (socks, children products ).

Both types are equipped with sinkers.

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Single cylinder machine:

Able to knit double welt (no curling), is equipped with transfer elements 3. One of the commencing courses is caught by these elements and yarn kinks later transfered back on the needles (b, c).
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Double cylinder machine:

Equipped with double-hooked needles (able to knit purl structures, but also single and double side structures. Sinkers 2 are shaped into bow (saving of the space inside the cylinder).

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Example of sock and stocking or tights:

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4.2 Straight bar frames

Course formation on bearded needle:

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4.2 Straight bar frames

To receive an even fabric, first phase of sinking is carried on only even sinkers.

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Loops transfer:
Needle 2 for loop transfer overtakes the yarn from bearded needle and after change of the position transfer this loop onto another needle.

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Welts on straight bar frames:

b, c rib welt, knitted on double bed machine d tubular welt

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4.3 Warp knitting machines

How to use known types of knitting needles for warp structure formation? What are advantages and imperfections of different needles? How to knit particular structure or pattern?
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4.3 Warp knitting machines

Main types:
Tricot knitting machines (warp frames), bearded or compound needles, sinkers with combined action (clearing and knock-over). Raschel machines, latch needles, clearing sinkers.

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4.31 Course formation

All loops in the course are formed simultaneously. Yarns lapping (composed of two phases underlapping and overlapping) has already been described.

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4.32 Warp knitting mechanism

Examples show the scheme of knitting mechanism and working diagrams for one knitting cycle (i.e. knitting of one course) for:
Warp frame with bearded needles. Raschel machines (with 1 and 2 beds). Warp frame with compound needles.

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Tricot machines with bearded needles:

Parts (left Fig.): 1. Bearded needles. 2. Sinkers. 3. Guides placed in guide bars. 4. Bearded needles presser.
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Tricot machines with bearded needles:

Phases: 1. Rest position. The needles have risen to 2/3 of their full height from knock-over 2. Backward swing and overlap shog
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Tricot machines with bearded needles:

3. The return swing and second rise. Newly-formed overlaps slip off the beards onto the stem above the old overlaps. 4. Needle bar descents, open beards cover the new overlaps. 5. Pressing. There is a slight pause whilst the presser advances and closes the beards. 5. Landing (with pressing). As the sinkers withdraw, the upward curve of their belies lands the old overlaps onto the closed beards. 6. Knock-over and underlap shog. The sinkers now move forward to keep the fabric down in next cycle.
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Raschel with 1 and 2 needle beds:

a 1 bed: uses sinkers 4, loops are formed on ribs 3. b 2 beds: alternate action of the beds. Not active bed keeps the fabric down instead of the sinkers.
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Working diagrams of single bed raschel:

1. Holding down (1). The sinkers hold the fabric down. Clearing (1). Needle bar rises to its full height. Old overlaps slip down ontu the stems.

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Working diagrams of single bed raschel:

2. Overlap (2). Return swing. Latch closing. 3. Knock-over (3) and underlap.

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Working diagrams of double bed raschel:

2 courses (one machine revolution) needs 3 swings of guide bars.

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Tricot machines with compound needles:

1. Needles rise (phase 1), hooks 1 faster then tongues 2. Guide bar swings.

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Tricot machines with compound needles:

2. The overlap and return swing. Tongues descent more slowly and thus close the hooks. 3. Landing and knock-over. Advantage: lower yarn stress, shorter needles stroke. For extremely quick machines.

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Connection of knitting elements (needles, guides, sinkers etc.):

By needle etc. so called leads (Fig.). Individual connection (not frequent).

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Example of warp knitting machine:

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Example of warp knitting machine:

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Example of warp knitting machine:

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Example of warp knitting machine:

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4.33 Programming of warp knitting machines

Movement of guide bars:
Regular swing. Programmed shog, usually twice per knitting cycle (four time on double bed machines): overlap and underlap.

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Control of guide bars:

Double expansion bearings 2 on the shaft 3 insure guide bars swing. Shog is controlled by the cam 6 or chain of links of different height 7 (corresponds with numeric description of lapping ).

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Example - chain of links (large pattern):

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Example - chain of links (large pattern):

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