Study on knitting elements of circular knitting machine (butex)

PRESENTATION ON

Supervised By

DR. SHAIKH MD. MOMINUL ALAMASSOCIATE PROFESSOR & HEAD

Department of Fabric Manufacturing Engineering

Bangladesh University of Textiles

ACKNOWLEDGEMENT

First of all, we would like to express our gratitude to the almighty Allah for enabling us tocomplete the project work successfully.

Bangladesh University of Textiles has given us the opportunity to perform the project work.We are grateful to Prof. Mashud Ahmed, Dean, Faculty of Textile ManufacturingEngineering and Prof. Dr. Nitai Chandra Sutradhar, the Vice-Chancellor of theUniversity for giving us the opportunity to accomplish the project.

Special thanks to our supervising teacher Dr. Shaikh Md. Mominul Alam, Head ofdepartment of Fabric Manufacturing Engineering.

We would like to express our cordial thanks to all the teachers of our university especiallyto Md. Emdad Sarker, Lecturer of Fabric Manufacturing Engineering.

We also like to give our heartiest thanks to MD. Habibur Rahman, AGM, Tosrifaindustries Ltd.; without whose help it would not be possible to complete the projectsuccessfully.

Heartiest thanks goes to Textile Engineers of GMS Composite knitting industries ltd.;FAKIR Knitwears ltd.; Tosrifa industries ltd.; DIRD Composite Textiles ltd.&Cotton group .

INTRODUCTION

The ever increasing demand of knitted apparels has attracted attentionin global niche market. In comparison to woven garment, around50% of the clothing needs are met by the knitted goods.

Needles, sinkers, cams, lubrication systems being the most importantwork elements for knitting machines, suffer permanentimprovements to better satisfy the work conditions and thefunctions they must answer, resulting in a higher quality of theknitted fabrics, the reduce of the production costs, the increase ofthe machine productivity, by higher speeds and less downtimes.

The project concerns the detailed about needles specification, relativecost, lifetime, different types of sinkers, different types of cams,different types of lubrication systems used in knitting machines inour country.

OBJECTIVES

• To find out different types of machine brands used in factory

• Why needles varies during production

• Why sinker varies during production

• Different types of cams used in factory

• Lubrication system of knitting machines

• Effect of elements on fabric

• Different types of relation between needles, sinkers, cams, m/c gauge, no. of feeder etc

Circular knitting machine elements1.Needle:

a. The bearded needle.

b. The latch needle.

c. The compound needle.

2.Cylinder Trick

3.Needle Detector

4.Sinker:

5.Sinker Ring

6.Cylinder

7.Cylinder Balancer:

8.Cam:

i. Engineering cams.

ii. Knitting cams.

a) Knit cam

b) Tuck cam

c) Miss cam

9.Cam Box

Circular knitting machine elements10. Creel11. VDQ Pulley 12. Pulley Belt 13. Brush14. Tension Disk 15. Inlet and Outlet Stop Motion 16. Yarn Guide17. MNF Wheel18. Feeder Ring 19. Positive Feeder 20. Lycra Attachment Device 21. Lycra Stop Motion22. Uniwave Lubrication23. Adjustable Fan24. Spreader25. Air Gun Nozzle

Needles“G00” and “G0” Needles from Groz-beckert, Germany

The standard version G0 is designed to withstand

the normal hook stress levels and is recommended in

cases where excessive stress occurs only rarely.

The special version G00 is a more favourite

alternative in case where frequent needle overloading is

anticipated or when a slightly open needle leads to

unacceptable striping in the fabric.

“LS” litespeed Needles from Groz-beckert,Germany:

“The patented design reduces machine temperature andenergy consumption,increases needle life and isextremely suitable for high machine speeds.”• Substantially reduced carbon footprint.• Energy consumption and machine temperature reducedby up to 20 %.• Significant increase in performance.• Reduced oil consumption due to optimized lubrication.

Main characteristic features of a litespeed needle:• Optimized needle shank geometry due to partialreduction of the needle shank thickness in circularknitting needles.• Reduced needle weight Shank geometry.

Benefits of LS(lite speed) Needles

•Reduced friction

against the trick walls

•Less energy required

for needle movement

• Less oil fogging

•Reduced oil

requirement due to

optimized lubrication

•Up to 20 % lower

energy consumption

of the machine

•Less energy required

to lower the room

temperature

Needle oil

Fig: Conventional needle

Improved oil distribution

Reduced oil resistance

Fig: litespeed needle

Different important parts of a needle

Needle Specifications

For example: Vota 78.60 G.02

The capital letter at the beginning of the word ( “V”), identifiesthe number of butts and the type of tail.

The first part (78 in the example) indicates the whole lengthrounded off to the mm

The second (.60 in the example) part indicates the gauge of theneedle in hundredths of mm (width of the needle).

The first capital letter indicates the needle manufacturer (G forGroz-Beckert).

The next number is used to distinguish a specific needle amongall the needles produced by the same manufacturer.

For other needles, the latch fixing method is indicated by a “0”before the last number.

A “0” indicates that the latch has been fixed with a standardpressed pin; no “0” means that the latch has been fixed with ascrew pin.

The sinker

The sinker is the second primary knitting element (the needle

being the first). It is a thin metal plate with an individual or a

collective action operating approximately at right angles from

the hook side of the needle bed, between adjacent needles.

Functions:

It may perform one or more of the following functions,

dependent upon the machine’s knitting action and consequent

sinker shape and movement:

Loop formation

Holding-down

Knocking-over

Different important parts of the sinker

The CAM

Cam is the second primary knitting element. The cams arethe mechanical devices which convert the rotary machinedrive into suitable reciprocating action for the needles orother elements. Because all needles have a reciprocatingaction either serially or seriatim, except on the beardedneedle sinker wheel and loop wheel frames where thefixed needle circle merely revolves. The cams are carefullyprofiled to produce precisely-timed movement and dwellperiods and are of two types:

i. Engineering cams.ii. Knitting cams.a) Knit camb) Tuck camc) Miss cam Fig: Knit, Tuck & Miss Cam

Lubrication SystemPulsonic Lubrication System:The PULSONIC lubrication system precisely meters a small amount of oil per pulse to ensure that oil is only distributed to the points required.

Advantages:■■ Uniform distribution of oil over the entire cylinder.■■ Fewer oil spots on fabric.

■■ Individual lubrication programmes forneedles and sinkers.

■■ Lower oil consumption thanks to precisionmetering.

■■ No unhealthy, harmful oil mist.

■■ Lower power costs due to savings in compressed air.

■■ Dry surfaces ensure less lint build-up.

■■ Electronic monitoring of oil supply to lubrication points. If no oil is present,the knitting machine is shut down.

■■Yearly oil consumption can be calculated accurately.

Fig. Pulsonic lubrication

system

Power Supply 24V (20-33 V) 50/60 Hz

Run signal (machine is running) 10 – 30 V AC

Max. power 72 VA

Displacement per pump stroke 4.2 – 25 mm³

Adjustable oil dose per lubrication point: 0.3 – 24 ml/h

Max. oil consumption (with all nozzles operating):

Pulsonic (12 oil outlets) 288 ml/h

Pulsonic (24 oil outlets) 576 ml/h

Oil reservoir capacity: 3.5 litre

Weight: 3 kg (approx.)

With optional NKS needle head lubrication the following

are also required:

Compressed air supply 3 bar (max.) (dry - no condensate)

Compressed air consumption at 1.5 bar 0.5 N m³/h for 3 NKS nozzles

Technical data

Uniwave Lubrication System:

The PROJECTILE lubricator provides uniform lubrication to

needles, cam tracks, sinkers and other knitting machine

components. The patented nozzle construction separates the

air-oil mixture into air and droplets of oil.

Advantages:

■■ The patented atomizing and nozzle system enables a major

reduction in compressed air consumption. This enables

considerable savings in power and operating costs.

■■ The PROJECTILE 419 supplies each of the 20 lubrication

points with the exactly the same amount of oil

■■ The knitting machine gearbox can be lubricated from the

two low-flow connections on the PROJECTILE unit.

■■ Strong construction.

■■ No oil mist health hazard in production areas.

Technical data:

1. 20 lubrication points.

2. Two, low-flow connections.

3. Compact oil reservoir.

4. Long, reliable service life guaranteed.

Lubrication System

Fig. Uniwave

Lubrication System

Effect of knitting elements on different types of fabrics

In knitting machine practical action:

Effect of knitting elements on different types of fabrics

Needles used in this project

Cams used in this project

Knit Miss Tuck

Sinkers used in this project

Details Investigation

18G

26G

34G

42G

0

1000

2000

3000

4000

5000

6000

16" 18" 20" 22" 24" 26" 28" 32" 36" 40"

n

e

e

d

l

e

s

n

u

m

b

e

r

DIA

18G

20G

22G

24G

26G

28G

30G

32G

34G

36G

38G

40G

42G

Chart-1: DIA AND GAUGE RELATIONSHIP WITH NUMBER OF NEEDLES

Chart-2: Different types of needles brands used in factory


0.356

0.358

0.36

0.362

0.364

0.366

0.368

0.37

18 24 28 30

ho

ok

dia

(mm

)

gauge

Hook width(mm)

Chart-3: Relation between machine gauge & hook width


Chart-4: Relation between gauge & stitch length


Chart-5: Relation between gauge &needle


Needle BrandsChart-6: Cost of different brands needles


Chart-7:Groz-Beckert Needle Price


Chart-8: Latch length directly proportional to loop length


Chart-9: Relation between gauge ,sinker length and thickness


Chart-10: Data analysis of cam


0

5

10

15

20

25

30

35

40

45

28 28 28 28 24

Ya

rn C

ou

nt

M/C Gauge

Count


Chart-11: Relation between m/c gauge and yarn count

Result & Discusions

From the above discussion we have found the following results:

With the increase of cylinder and gauge no. of needles are also increased.

We have found that GROZ-BECKERT needles are mainly used in the

factory.

Machine gauge is inversely related with needle hook width.

Machine gauge is inversely related with stitch length.

Machine gauge is inversely related with needle thickness.

We have found that GROZ-BECKERT is most costly.

Needle latch length is directly proportional to loop length.

Machine gauge is directly proportional to sinker length and inversely

proportional to sinker thickness.

From cam dimensions knit, tuck and miss cams are found in the graph.

For finer yarn count finer gauge m/c required.

LS needle Optimized needle shank geometry and reduced needle weight.

Conclusion

The main purpose of this project is to determine what type of

needles are used in different brand of machines, relation

between the cylinder dia and the number of needles, also

relation between the hook width and the machine gauge, also

the relation between the latch length and the loop length.

The investigation is conducted a snap study to analyze the

relation between the machine gauge to sinker length and to

sinker thickness.

The investigation also review the dimensions of knit, tuck and

miss cams, also details about needle shank geometry and

needle weight.

And finally, the lubrication system of knitting machines.

Study on knitting elements of circular knitting machine (butex)

Education

Transcript of Study on knitting elements of circular knitting machine (butex)