The present invention relates to a circular knitting machine with less wear of machine parts, in particular of loop-forming elements, as well as a wider range of possible loop-forming techniques.
Conventional circular knitting machines use tongue needles as central loop-forming elements. These are guided on a rotating needle cylinder and expelled and retracted (moved upwards or downwards) according to their guidance in the locking parts.
When loops are formed on a knitting system of such a circular knitting machine, the tongue of a passing and upwardly expelled tongue needle is first opened by a loop on the needle shaft relative to this downward sliding previously formed loop and then closed again during the looping (Kulieren) and the retraction of the needle from the loop sliding upwards along the needle shaft relative to the needle shaft. The opening and closing processes of the tongue needle take place via a tongue hinge. Due to the frequency of their continuous actuation, possibly with the influence of considerable yarn tensions, the tongue hinges of the tongue needles and with them the tongue needles are naturally particularly prone to wear inside a knitting machine.
The failure of a tongue hinge leads to incorrect loop formation and thus to errors in the knitting ware. The replacement of the affected tongue needle requires the knitting machine to stop. Due to the large number of tongue needles in the needle cylinder, such failures can affect the operation of the knitting machine to a considerable extent. However, the problems are not only the resulting interruptions in operation, but also the relatively high costs for tongue needles, the production of which is expensive due to the required mechanical load capacity.
Therefore, the use of simpler and less damageable needle types in knitting machines is of particular interest. A needle type with a simpler structure, especially without a mechanically movable joint, is the tip needle, whose hook is open at the top of the needle downwards. The needle hook can be closed elastically by external pressure towards the needle shaft.
Such circular knitting machines working with tip needles are described in the document DE 1 635 878 A and DE 361 135.
When knitting in a circular knitting machine with tip needles, the needle hook must be elastically closed from the outside by means of a pressing wheel when the needle is pulled off (during the looping), so that it does not pick up the old loop in addition to the new yarn. Such a pressing wheel is provided outside the needle cylinder and, in order to minimize frictional forces between the passing needle hooks and the pressing wheel, is preferably provided actively or passively co-rotating. Due to the different diameters of the large needle cylinder and the significantly smaller pressing wheel, however, tangential forces acting on the needle cannot be completely avoided. Since such a pressing wheel has to be provided for each knitting system, there is also a considerable space requirement for the pressing wheels, which particularly restricts the possible system density, i.e. the number of knitting systems per inch of the needle cylinder circumference.
Alternatively, each tip needle of such a circular knitting machine can be provided with a needle press running parallel to the needle shaft, which presses on the needle hook during the looping (Kulieren) from the outside and closes it. However, the presence of a large number of pairs of tip needles and needle presses on the needle cylinder may again cause problems with wear susceptibility.
The present invention is therefore based on the problem of creating a circular knitting machine working with tip needles instead of tongue needles, which with the simplest possible construction has a lower susceptibility to wear, in particular with respect to the needles, than the conventional circular knitting machine with tongue needles.
This object is solved by the circular knitting machine of the present invention as defined in claim 1. Further advantageous embodiments can be found in the dependent claims.
The circular knitting machine according to the invention has a needle cylinder rotating around a vertical axis and a sinker ring rotating with the needle cylinder. The needle cylinder is provided in its outer edge portion with vertically controllable, in particular upwards expellable, tip needles having needle hooks opened downwards as loop-forming elements, and for each tip needle, a surrounding sinker, which supports the loop-formation, is held to be displaceable horizontally in radial direction on the needle cylinder. Further, for each tip needle on the needle cylinder, a press sinker on the sinker ring is held to be displaceable horizontally in radial direction, to close the hook tip of the tip needle by pressing the needle tip to the needle shaft. The press sinkers are each arranged on the sinker ring between two adjacent surrounding sinkers, as space-saving as possible and with little or as low clearance as possible.
In the circular knitting machine according to the invention, the loops are formed by the coordinated vertical or horizontal movements of the needles and the corresponding surrounding sinkers for pushing the yarn to the needle shafts. Each surrounding sinker has two horizontal planes in its profile facing the corresponding needle with an intermediate nose projecting towards the needle. The lower of the two support planes serves as a plane on which the knitted ware rests, while the upper support plane guides the new yarn towards the needle shaft and attaches it thereto. The vertical distance between the two planes serves to separate the loop head of the old loop on the sinker plane from the new yarn in the height, thus creating a safety distance over which the needle hook can be closed when the needle is pulled vertically, so that only the new yarn enters the needle hook.
Furthermore, the circular knitting machine according to the invention comprises a further sinker for each needle, namely the press sinker. The press sinker is used to press on the needle hook when the needle is pulled off and to tighten it elastically. The press sinkers rotate with the needles and the surrounding sinkers, so that no tangential forces occur between the press sinker and the needle hook when pressing the needle hook.
The press sinkers are guided together with the surrounding sinkers on the sinker ring co-rotating with the needle cylinder. The alternating adjacent surrounding sinkers and press sinkers are as close as possible to each other, i.e. with the lowest possible clearance. If separation bars are provided between the surrounding sinkers to improve their guidance during expelling and retracting, the press sinkers can also be mounted on these separation bars. The expelling and retraction of the surrounding sinkers on the one hand and the press sinkers on the other are controlled independently of each other.
The outer structure of the circular knitting machine according to the invention differs from that of conventional circular knitting machines on the one hand by the use of tip needles instead of tongue needles and on the other hand by the additional insertion of press sinkers into the spaces between the surrounding sinkers. The additional space requirement is therefore comparatively small, in particular because of the tight arrangement of the press sinkers between the surrounding sinkers, for example on their separating bars. The press sinkers are arranged largely without lateral clearance between two adjacent surrounding sinkers and, due to their co-rotation with the needles, exert no tangential forces on them during their radial ejection against the needle tip. This thus counteracts excessive wear on the needles and on the surrounding sinkers and press sinkers of the circular knitting machine according to the invention.
A further advantage of the circular knitting machine according to the invention is its usability for the production of knitted fabrics both according to the weft knitting principle and according to the warp knitting principle. In fact, the circular knitting machine can be switched to both loop-forming techniques or at least pre-set. When the needle is in the ejected state, depending on whether the new yarn is guided from the surrounding sinker only to the needle shaft, or whether the surrounding sinker is expelled to a position beyond the radial needle position and thereby presents a loop with the yarn, the loops formed by the machine are generated according to the weft knitting or warp knitting principle. While the yarn is held under tension at the needle shaft before looping in case of weft knitting, in the case of warp knitting, yarn loops are provided under lower tension. Also during the looping process (“Kulieren”), the yarn tension is lower than in weft knitting.
The circular knitting machine according to the invention can therefore be equipped with a control device for controlling the positioning of the individual surrounding sinkers, the individual press sinkers or both sinker types. In this way, the radial displacements of surrounding sinkers can be controlled in such a way that they guide the new yarn to the needle shaft before retracting the respective tip needles, so that the respective loop-forming systems are knitted. The surrounding sinkers can also be controlled so that they guide the new yarn past the needle shaft in the radial direction and thereby provide a loop so that (warp) knitting is carried out at the loop-forming systems.
The circular knitting machine can be operated as a warp knitting machine by appropriate control of the yarn tension on the one hand and the radial retraction movement of its surrounding sinkers on the other hand (with appropriately fixed adjustment of the locking parts of the surrounding sinkers the machine according to the invention can also be operated as a circular warp knitting machine). The optional switching between weft knitting and warp knitting can be done, for example, by means of adjustable sliders, which move the surrounding sinkers in the radial direction, respectively. By appropriate adjustment of the sliders and thus the positioning of the surrounding sinkers in the radial direction, the circular knitting machine according to the invention can also simultaneously generate loops according to weft the knitting process and the warp knitting process on its various systems.
The loop-forming systems of the circular knitting machine according to the invention can be pre-adjusted or controlled or switched during operation so that the respective tip needles form loops from the respective supplied yarn loops according to the weft knitting principle or the warp knitting principle, catch the supplied yarn or remain in circular motion.
During the catching process, the tips of the corresponding loop-forming system are retracted at an earlier time than in the weft knitting or warp knitting process, so that the press sinkers close the hooks of the respective tip needles only when both the supplied yarn and a previous loop have been received within the hook. Alternatively, the catching process can be carried out by moving the press sinkers not so close to the hook of the respective needle as to close it so that both the supplied yarn and the old loop inside the hook can be received.
It turns out that the use of tip needles in the circular knitting machine according to the invention has further advantages. For example, the needle head of a tip needle is generally smaller than that of a tongue needle, so that an undesirable widening of the loops by the needle head is a smaller problem. At the same fineness, smaller loops are possible. Further, the loops cannot be damaged by the opening and closing needle tongues and their hinges. Due to the lower strain on the yarn, undesirable effects such as flattening, excessive pilling tendency, unequal heights of handles in plush or lining as well as twisting of the yarns during plating (by the smaller needle head) are largely avoided.
The use of tip needles also allows an increase of the rotating speed of the needle cylinder, since there is no need to ensure the absorption of the kinetic rotational energy of the needle tongues.
The use of elastically lockable tip needles instead of the tongue needles that can be closed via their tongue hinge also reduces the knitting energy and thus the overall power consumption of the circular knitting machine.
Cost advantages are mainly due to the lower price of tip needles compared to tongue needles; but also the longer needle life of peak needles due to their simpler, less frail construction is another advantageous cost factor. It is also advantageous that the start of the knitting process is simplified after an interruption of the operation when tip needles are used instead of tongue needles; the latter must be checked before start of the knitting to see whether their tongues are in the correct opening or closing state.
In the following, an embodiment as well as further advantages and details of the present invention are described with reference to the attached drawings.
The
In
In
The needle 2 is then pulled down/retracted in
Both in the situation of the warp knitting process in
The circular knitting machine according to the invention is therefore suitable both for weft knitting and for warp knitting. In fact, the machine may have an actuator 15 on the sinker lock 9, with which a sinker lock part 10 can be displaced, whereby the length of the ejection path of the surrounding sinker 3 is switched between a longer path for warp knitting and a shorter path for weft knitting. The sinker lock 9 screwed to the sinker lock support ring 12.
Due the option of switching between the weft knitting function and warp knitting function, the circular knitting machine according to the invention allows an efficient and safe processing of a variety of different yarns. In particular, the warp knitting function allows the use of more sensitive yarns due to the lower yarn tension in the process. In fact, the loop-formation in the warp knitting process according to
In contrast, in weft knitting, the conveying of the new yarn through the yarn guide and the pulling of the yarn through the old loop are simultaneously carried out, whereby the corresponding yarn friction forces add up and together result in a significantly higher yarn tension. Such an addition of yarn forces does not take place in warp knitting due to the temporal offset of the two processing steps, whereby the maximum occurring yarn tensions are lower. The warp knitting process is thus more preserving for both the yarn to be processed and for the loop-forming elements of the circular knitting machine.
The presentation of the yarn loop in the warp knitting process also has the advantage that the loop-forming part in the cylinder lock is relieved. The loop-forming angles therein are less steep than for weft knitting, which in turn reduces the load on the needle guided in the loop-forming part. By using simpler loop-forming parts, needle foot fractures and needle head fractures can be avoided.
In order to allow patterns, the weft knitting or warp knitting systems of a circular knitting machine that can be used for weft knitting and warp knitting should also be able to be adjusted for circular running and catching.
During the circular running, the needle 2 simply remains in its circular running position by appropriate control of the lock parts and is not expelled at all. The new yarn 1 is not even received by the needle hook.
The catching process can be controlled by appropriate control of either the needle retraction or of the displacement of the press sinker 4. Thus, an earlier retraction of the needle 2 can be adjusted so that the press sinker 4 closes the needle hook only when the opening of the needle hook has already passed the old loop lying on the plane 3a (which is therefore already inside the needle hook).
Another possibility to implement the catching process with the circular knitting machine according to the invention is to not at all extend the press sinker 4 on a selected knitting system to close the hook needle, but to maintain it in its retracted position without pressure contact to the needle hook. The corresponding control of the press sinker 4 is done, for example, by a suitable adjustment of the sinker locks on the respective systems.
As shown in
Just like the tip needles 2 having needle feet 6, which run through appropriately pre-set lock channels during rotation, the surrounding sinkers 3 and press sinker 4 also each have sinker feet 7 and 8 which are guided in corresponding channels of the sinker lock part 10. By appropriate presetting of the needle locks and sinker locks, each knitting system can optionally be adjusted so that loops are formed either according to the weft knitting principle or according to the warp knitting principle, catches the new yarn only or remains in a circular running state. In
The space-saving arrangement of the press sinkers 4 between the surrounding sinkers 3 allows a relatively high fineness of the circular knitting machine, i.e. a large number of needles per inch at the cylinder circumference. Another advantage of this space-saving arrangement is that a high number of knitting systems can also be arranged along the circumference of the needle cylinder. Thus, with a circular knitting machine having a needle cylinder circumference of 30 inches, more than 88 knitting systems can be provided, which corresponds to a high system density of 2.9 systems per inch (higher system densities up to 3.2 are also conceivable).
The use of two-piece tip needles can also bring about further cost advantages, if only the more cost-effective needle parts 2′ of the tip needles have to be replaced after wear. Depending on the selection of the manufacturing processes for the needle parts, a complete needle equipment of the circular knitting machine can be more cost-effective. This partition of the needle in two parts, optionally in combination with the optional insertion of the press sinkers 3 between the surrounding sinkers 4, also allows an even easier conversion of a circular knitting machine with wrap knitting function into a conventional circular knitting machine and vice versa.
Alternatively, the present invention can also be applied to circular knitting machines based on the principle of the so-called relative technology. In such machines, the surrounding sinkers are stored in the upper part of the needle cylinder between the needles. Therefore, this machine type does not require a separate sinker ring. The surrounding sinkers can be controlled vertically in height and at the same time perform a pivoting motion around their pivot point. This pivoting motion replaces the horizontal movement of a conventional surrounding sinker. As pressing elements for closing the needle hooks, pressing wheels arranged outside the needle cylinder circumference can be used here (one for each loop-forming system, respectively).
The structure of the circular knitting machine according to the invention is based on a further development of conventional circular knitting machines. The circular knitting machine according to the invention can be manufactured as an independent machine; however, it is also conceivable, for example, to expand a conventional circular knitting machine by simply adding press sinkers into the already existing gaps between the surrounding sinkers as well as by the replacement of tongue needles by tip needles or the replacement of needle parts of corresponding two-piece tongue needles and tip needles.
In any case, the invention provides considerable advantages with regard to the problem of needle wear. In addition, the machine according to the invention allows the choice between weft knitting and warp knitting as the loop-forming techniques within a single machine.
Number | Date | Country | Kind |
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10 2018 117 309.1 | Jul 2018 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2019/069104 | 7/16/2019 | WO | 00 |