CA1081490A - Method of compensating for charge loss during knitting of sliver multi-color patterned high pile fabric - Google Patents
Method of compensating for charge loss during knitting of sliver multi-color patterned high pile fabricInfo
- Publication number
- CA1081490A CA1081490A CA294,128A CA294128A CA1081490A CA 1081490 A CA1081490 A CA 1081490A CA 294128 A CA294128 A CA 294128A CA 1081490 A CA1081490 A CA 1081490A
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- CA
- Canada
- Prior art keywords
- sliver
- needles
- rate
- fibers
- doffer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B9/00—Circular knitting machines with independently-movable needles
- D04B9/14—Circular knitting machines with independently-movable needles with provision for incorporating loose fibres, e.g. in high-pile fabrics
Abstract
METHOD OF COMPENSATING FOR CHARGE LOSS
DURING KNITTING OF SLIVER MULTI-COLOR PATTERNED HIGH PILE FABRIC
Abstract Method for maintaining constant the fiber charge in a sliver feeding system during the knitting of multi-color patterned sliver high pile fabrics on multi-feed circular knitting machines. In knitting multi-color patterned high pile fabrics, each sliver is advanced at feeding rates pro-portionate to the number of needles selected, the speed of rotation of the needle circle, the selected density of the pile fabric being knit and the approximate rate of fly loss, to maintainthe charge of fibers in each sliver feeding system at a constant level at all times. Sliver feed rolls of each sliver feeding mechanism or card are rotated continuously, to advance each sliver continuously to the main cylinder and doffer at not less than selected minimum rates of feed sufficient to compensate for any depletion of the charge.
This ensures the provision on each doffer of sufficient quan-tities of sliver fiber to meet the demand of needles for fiber while compensating for charge loss resulting from fly loss and either the non-selection of needles or the selection of so few needles that the needle demand for fibers, and hence the rate of sliver feed, falls below the rate of fly loss.
DURING KNITTING OF SLIVER MULTI-COLOR PATTERNED HIGH PILE FABRIC
Abstract Method for maintaining constant the fiber charge in a sliver feeding system during the knitting of multi-color patterned sliver high pile fabrics on multi-feed circular knitting machines. In knitting multi-color patterned high pile fabrics, each sliver is advanced at feeding rates pro-portionate to the number of needles selected, the speed of rotation of the needle circle, the selected density of the pile fabric being knit and the approximate rate of fly loss, to maintainthe charge of fibers in each sliver feeding system at a constant level at all times. Sliver feed rolls of each sliver feeding mechanism or card are rotated continuously, to advance each sliver continuously to the main cylinder and doffer at not less than selected minimum rates of feed sufficient to compensate for any depletion of the charge.
This ensures the provision on each doffer of sufficient quan-tities of sliver fiber to meet the demand of needles for fiber while compensating for charge loss resulting from fly loss and either the non-selection of needles or the selection of so few needles that the needle demand for fibers, and hence the rate of sliver feed, falls below the rate of fly loss.
Description
081~90 Background of the Invention The sliver method of knitting high pile fabrics produces a "fly loss". Such term, as used in the art, refers to all sliver fibers which are not incorporated into a sliver knit high pile fabric during knitting.
Fly loss occurs because the slivers or rovings used in knitting high pile fabrics are composed of relatively fine, short, discrete fibers, which are especially susceptible to diffusion during handling. In sliver knitting, an unavoidable, relatively significant percentage of the fibers is lost as a sliver is transferred from its source of supply to the usual fiber carding and transfer mechanism, and thence to the needles of the knitting machine. Wheelock `~.S. patent 2,993,351 and ~ ~t U.S. patent 3,72~,872 illustrate apparatus designed for use with sliver knitters to recover fiber wasteage through fly loss.
The knitting of sliver high pile fabrics requires that a certain minimum quantity of fibers be in each sliver feeding system at all times, in order to produce fabrics of uniform pile density. This minimum quantity of fibers is defined as the "charge" of fibers in the feeding system necessary to meet the demand of the needles for fibers. The charge is composed of base fibers which tend to nestle within, and be retained by, the wire coverings of the main cylinder and doffer of a sliver feed system, plus the fibers in transit to the needles. The transit fibers of the charge ride upon the base fibers, as they travel to the needles.
To produce pile fabrics of uniform pile density, the charge of fibers in a sliver feeding system must be main-tained at a constant level. This presentæ no serious problemin the knitting of non-patterned work, since fly loss is . .
'` 1081490 rel~tively constant. The rate of sliver input by sliver feed rolls is easily adjusted to feed sliver at a rate sufficient to produce fabric of selected pile density, while compensating for fly loss. In the knitting of non-patterned sliver high pile fabrics, it is possible to ignore fly loss altogether, and produce satisfactory fabric of uniform density. The finished ~-fabric simply is of somewhat less pile density than would be the case if the fly loss either had been compensated for, or had not occurred.
However, in the knitting of multi-color patterned sliver high pile fabrics, which require selective feeding of various ~ ;
slivers either at variable rates or intermittently, a new problem arises. In knitting such fabrics, the sliver feed rolls cease feeding sliver altogther when needles are not selected. Where only relatively few needles are selected, thereby diminishing the demand of the needles for fibers, the rate at which sliver is fed by the sliver feed rolls to the main cylinder and doffer may fall below the rate of fly loss.
In such situations, the fly loss may create charge loss, i.e.
may cause depletion of the fiber charge on the doffer and main cylinder in the sliver feeding system, thereby creating faults in the fabric being knitted. Charge loss results from fly loss and either the non-selection of needles or the minimal selection of needles. Charge loss may be defined as fly loss extending over a period of time, when no additional fibers are added to the sliver feeding system, or insufficient fibers are added to compensate for fly loss.
In knitting multi-color sliver pile fabrics having intricate designs, it is essential, in order to obtain uniform pile density, to harmonize the rates at which selected slivers are fed by the doffer to selected needles with the demand of the needles for fibers, in accordance with the fabric pattern selected. When, during the knitting of multi-color patterned fabrics, feeding of a sliver is stopped completely, or is B ~ 3 ~ -- , .~ . . .
.
~ 1081~0 reduced to a very low feeding rate, fly loss may cause partial or even complete depletion of the charge fibers from the sliver feeding system and particularly from the rapidly rotating doffer.
Where no sliver fibers are fed to a card for a sus-tained period, the doffer and even the main cylinder might empty completely of charge fibers through fly loss. If this occurs, the first needles eventually selected to receive fibers at such doffer may take no fibers at all, causing a fault in the fabric.
If, due to reduced needle selection, sliver fibers are fed at a minimal rate to the doffer, the rate of feed may be less than the rate of fly loss, thereby reducing the fiber charge in the card. As a result, the few needles selected may draw an insufficient supply of fibers, causing a fault in the fabric.
Usually, fly loss presentsno problem when a large number of needles are selected to rake sliver fibers from a s~sfem B doffer, because the level of the charge in the sliver feeding~
remains constant. It is only when relatively.few needles are selected, or none are selected, and the rate of sliver feeding varies accordingly, that the problem arises.
Summary of the Invention The primary object of this invention is to provide a new and improved method of knitting multi-color~ patterned sliver high pile fabrics on circular knitting machines, which compensates for charge loss during knitting.
A further object of the invention is to provide a new and improved method for feeding sliver to a high pile fabric circular knitting machine in which the rate of sliver feed is proportioned automatically to harmonize with the demand of selected needles for sliver fibers, while compensating for charge loss resulting from fly loss and the non-selection or minimal selection of needles.
A further object is to provide a new and improved method for knitting a patterned multi-color sliver high pile fabric on a multi-feed circular knitting machine whereby a minimum quantity of sliver fibers are maintained on each doffer during knitting, to ensure that sufficient quantities of pile fibers are avail-able at all times to meet the demand of selected needles for fibers, to ensure the production of high quality fabric ofuniform pile density.
A further object is to provide a new and improved method for knitting sliver high pile fabrics having intricate designs on multi-feed circular knitting machines whereby the rate of feed of each sliver to the needles is proportionate to the number of needles selected according to the design, the speed of rotation of the circle of needles, the selected pile density of the fabric and the rate of fly loss, but not less than a rate sufficient to compensate for any depletion of the charge fibers in the sliver feeding system.
In accordance with an aspect of the invention there is provided a method for maintaining constant the fiber charge~in a sliver feeding system during knitting of multi-color patterned sliver high pile fabric on a multi-feed circular knitting machine, to provide patterned high pile fabric of substantially uniform pile density throughout the pattern, said sliver feeding system including a rotatable doffer for delivering fibers to the needles and, a pair of selectively rotatable sliver feed rolls and characterized by continuously rotating the sliver feed rolls 14, 16 at selectively variable rates of speed to advance sliver fibers to the doffer 10 at rates equal to any selected fabric patterning rate plus a rate approximating the rate of charge loss resulting from fly loss and the non-selection or the minimal selection of needles.
Descr'ipt'ion' of'th'e Views o'f the Drawing Fig. 1 is a schematic diagram illustrating an electronically controlled multi-feed sliver high pile fiber circular knitting machine incorporating a preferred embodi-ment of this invention.
Fig. 2 is a schematic block diagram illustrating functionally the data transfer electronic circuitry for con-trolling the rates of feed of the sliver feed rolls of each sliver feeding mechanism of the knitting machine.
Fig. 3 is a fragmentary, partially schematic view in perspective, showing one of the sliver feeding mechanisms or cards of the machine, utilizing a stepping motor to drive its sliver feed rolls.
Fig. 4 is a fragmentary, schematic block diagram showing the data transfer electronic circuitry of Fig. 2 incorporating-suppLemental-control-circuitry-for the-sliver feed rolls to Qperate the same continuously, at selected minimum rates of speed, to provide selected minimum rates of sliver feed to compensatF for charge loss.
.
-` 1081490 Detailed Description of the Invention The improvement of the present invention may be incorporated into any known type of sliver high pile fabric circular knitting machine such as, for example, the sliver knitters illustrated in the following United States patents:
Hill No. 3,010,297, Hill No. 3,014,355, Wiesinger ~o.
3,427,829, Schmidt No. 3,563,058, Brandt et al No. 3,709,002 and Christiansen et al No. 4,007,607. At the present time, the best mode contemplated for carrying out the invention is to incorporate it into the electronically controlled multi-feed sliver high pile fabric circular knitting machine dis-closed in Christiansen et al U.S. patent 4,007,607. The disclosure of that patent is incorporated herein by reference.
Referring to the drawing, in Fig. 1 there is shown schematically in top plan the knitting head of the machine M
of Christiansen et al patent 4,007,607 having a plurality of independent latch needles (not shown) mounted in a circle in a conventional needle cylinder (also not shown), with capacity for selected reciprocal movement. The cylinder is rotatable in the direction of the curved arrow.
-In the embodiment shown, the machine M is provided with 12 sliver feeding stations, Fl to F2 inclusive, spaced at uniform intervals around the needle cylinder. Each such station includes a card C (Fig. 3) having the usual wire-clothed .
.
.
r ~
rotatable doffer lO and main cylinder 12, and a pair of rotatable sliver feed rolls 14, 16. The latter trans~er a roving or sliver (not shown) from a source of supply via the main cylinder 12 to the doffer 10 for delivery to selected needles. The feed rolls are driven by a stepping motor 20 through a conventional timing belt drive 22 and conventional gearing 24. Disposed at each sliver feeding station Fl-Fl2, in advance of its card C, are needles selecting mechanisms Sl to S12, respectively, each of which is composed of a plurality of individual electromagnetic needle selecting actuators of the type illustrated in Christiansen ~.S. patent 3,896,639.
~he electronic control apparatus for selecting needles includes a main memory 30, a buffer memory 32 and needle control logic circuitry 34, the latter being connected electrically by conventional circuitry to each separate electromagnetic actuator of the needle selecting mechanisms Sl to S12 inclusive. A power amplifier 36 is interposed in the circuit connecting each needle selecting actuator to the needle control logic circuitry 34 In the interest of brevity, only one circuit is shown in Fig. 1 connecting the needle control logic 34 to an electromagnetic needle selecting actuator (at Sl).
Data is transferred from the main memory 30 to the electromagnetic actuators in response to signals generated by an absolute encoder 38 geared to the knitting machine M.
Encoder 38 generates a train of pulses, proportional to the speed of rotation of the needle cylinder, to enable sequentially the several actuators of the successive needle selecting mechanisms Sl-S12.
, _ _ . . . . ... . ...
-~08149~
The electronic control apparatus for the knitting machine M also includes control circuitry for regulating continuously the speed of rotation of the stepping m~tors 20 associated with each of the 12 cards C, to control selectively the rate of sliver feed at each station Fl-F12. The electronic control for the stepping motors includes card feed rate logic circuitry 40, connected electrically to each stepping motor 20 by separate circuitry which includes decoding logic circuitry 42 and a power amplifier 44. The decoding logic 42 decodes the pulse train from the card feed rate logic circuitry 40 to the input form required by the stepping motors 20.
For the purpose of illustration, only one circuit is shown in Fig. 1 connecting the card feed rate logic 40 to one of the stepping motors 20 at a sliver feeding station (Fl).
It is to be understood that a separate circuit, each provided with its own decoding logic 42 and power amplifier 44, connects each stepping motor 20 of each card C to the card feed rate logic circuitry. To ensure that the sliver feeding rates of the 12 cards C are at all times proportional to the speed of rotation of the needle cylinder, the card feed rate logic circuitry 40 is clocked by a signal directly proportional to the rotative speed of the needle cylinder. The pulse output of the absolute encoder 38 may be utilized to provide the needle clock input to' the card feed rate logic.
The card feed rate logic circuitry 40 is illustrated schematically in Fig. 2 by the portion of the functional block diagram interposed between the buffer mem,ory 32 and the stepping motor decoding logic 42. As explained in Christiansen et al U.S. patent 4,007,607 aforesaid, the logic depicted in Fig. 2 . . .
-108~90 renders unnecessary incorporating into the main mem~ry 30 sliver feed control data, for controlling the rates at which sliver is fed at each sliver feeding station Fl-F12. The electronic control system depicted in Fig. 2 calculates continuously and accurately the necessary sliver feeding rates using the needle selection pattern data stored by the memory 30. The calculations are carried out by a data calculating and transfer circuit, which includes the buffer memory 32 for the temporary storage of needle selection pattern data, counter 50, multiplier 52, divider 54, rate mul~iplier 56 and buffer shift register 60.
In addition to using needle selection pattern data retrieved from the memory 30, the data calculating and transfer electronic circuit also incorporates into its calculations, from the input of clock pulses at the "ma" number, the selected speed of rotation of the needle cylinder. It also incorporates into its calculations the selected pile density of the fabric being knit, from a set of thumbwheel switches (not shown), the selected setting of which is applied to rate multiplier 58 interposed between rate multiplier 56 and buffer shift register 60.
The sliver feeding rate data obtained from the second rate multiplier 58 is stored in the buffer shift register 60, to which also are applied the "ma" clock pulses previously 25 referred to. The data stored in the buffer shift register 60, at the appropriate time, is transferred to one of the active shift registers Rl-R12 connected by suitable circuitry to one of the stepping motors for one of the twelve cards.
Fig. 2 illustrates an arrangement by which rate data .
. . . . .. _ . _ .. .. .. . ..
~081~90 is transferred from the buffer shift register 60 to the active shift register Rl, which controls the stepping motor 20 of the card C at sliver feeding station Fl. The active shift register Rl is clocked by the pulse output of the encoder 38, which is proportional to the speed of rotation of the needle cylinder. The data output of the active shift register Rl is combined with this clock, as indicated by the "and" function block 62. The resulting pulse train is decoded by the stepping motor decoding logic 42 and amplified by the power amplifier lQ 44, t~ drive the stepping motor 20 at the speed necessary for card C.to feed sliver at a selected rate in harmony with the fabric pattern selected. The result is to provide a card with continuously controlled sliver feed roll drive means, calculated to ensure that the sliver input to the machine harmonizes with the demand of selected needles for fibers, the speed of rotation of the circle of needles and the desired pile density of the fabric.
As explainea previously,--charge loss may arise and-create faults in multi-color patterned sliver knit fabrics where the feed of a sliver temporarily is stopped completely, due to non-selection of needles or is reduced to a very low rate because relatively few needles are selected to receive fibers. To compensate for this, and maintain constant the fiber charge in a sliver feeding system, the p esent invention provides for the continuous rotation of the sliver feed rolls 14, 16, at selectively adjustable minimum rates of rotation, calculated to feed sliver at minimum rates approximating the rate of fly loss, preferably at a rate equal to or slightly less than the rate of fly loss. Arranging for the sliver feed rolls 14, 16 to rotate continuously at selected minimum speeds of rotation to compensate for charge loss, ensures that a sufficient quantity or charge of fibers is maintained on the r ~081490 doffer 10 at all times during knitting to meet the demand of selected needles for fibers, and to avoid faults in the pile density of the fabric.
The additional logic or control circuitry required to obtain such selected minimum rates of sliver feed is illustrated in Fig. 4. It comprises a divider 70, rate multiplier 72, anti-coincidence circuit 74 and "or" gate 76.
The control logic to obtain the desired selected minimum rates of sliver feed is interposed in the basic data calcu-lating and transfer electronic circuit between rate multiplier58 and buffer shift register 60.
By way of illustration, it will be assumed that not more than 93 of each 100 data bits (i.e. discrete commands for needles to take sliver or to welt) transferred from rate multiplier 58 and stored in the buffer shift register 60, will be binary or logic "l's" (i.e. needle commands to take sliver).
The sliver therefore is advanced at its selected maximum feeding rate by the feed rolls 14, 16 when 93 of each 100 data bits entered on the shift register 60 are logic "l's". This arrange~ent provides for the possibility of increasing the speed of the stepping motor 20 by 973, or approximately 7.5%
beyond the selected maximum speed, resulting in a corresponding increase in the sliver feed rate.
~ - 12 -;~ 108149(1 The train of clock pulses "ma" applied to the buffer shift register 60 supplies one pulse for each data bit, i.e.
for each logic "1" or "0", entered in the register. As explained in Christiansen et al U.S. patent 4,007,607 afore-said, in the clock "ma" the designation "m" is a selectedconstant comprising a scaling factor and the designation "a"
denotes the data bits or commands for a selected number of needles "a". In the example given, "a" = 100 data bits.
Since the number of pulses of the buffer shift register clock 0 "ma" is proportional to the maximum sliver feed rate (i.e. 93 logic "l's" randomly evenly distributed for each 100 data bi~s), a pulse train which represents any fraction of the maximum sliver feed rate may be obtained by dividing the "ma" clock .,;
; pulses by any appropriate number "n". The divisor "n" is a ; 5 number which, when divided into "ma", produces a quotient ; preferably and normally, but not necessarily, equal to or less , .
than the difference between the data bits "a" of the clock ...
"ma" and the maximum logic "l's" per "a" data bits (in the example given, the difference is 100 - 93 = 7).
.. ~ , ... .
.~ .
, .. .
., ' ~, i , ., ¢l ~' ~ , ,. .1 :
.
,;:'' `~ `
~ -12A-.,`"
.' '' ' '. . ~ :,, ,. '. , : '' :' ~08~490 In the modified electronic circuit of Fig. 4, the divider 70 and the rate multiplier 72 are utilized to divide by "n" the buffer shift register clock "ma", to provide the minimum sliver feed rate data. The divided clock is entered into the buffer shift register 60 as additional data by adding it via "or" gate 76 to the sliver feed rate data obtained from the data calculating and transfer circuit inter-posed between main memory 30 and buffer shift register 60.
The minimum sliver feed rate data, obtained from the divided buffer shift register clock, must be added to the register 60 when the data entered from the rate multiplier 58 is a logic "0". The anti-coincidence circuit 74, connected to the rate multiplier 58 and the "or" gate 76 ensures this, by detecting the presence of a logic "0" data bit entering the buffer shift register 60 from the rate multiplier 58.
The invention thus permits continuous feeding of sliver by the sliver feed rolls 14, 16 to the main-cylinder-12 and doffer 10, at selectively variable rates of sliver feed, such rates being proportionate to the number of needles selected, the speed of rotation of the circle of needles, the selected pile density of the fabric and the rate of fly loss, to maintain the charge of fibers in the sliver feeding system at a constant level at all times.
In practice, a minimum rate of sliver feed of 1%
of the maximum rate of sliver feed may be sufficient to compensate for any depletion of the charge. However, since fly loss will occur at various rates, under various knitting conditions, it is desirahle to provide means to adjust easily and selectively the compensating minimum rate of sliver feed.
For this purpose, a high-low divisor switch (not shown) pro-viding for two basic speed ranges, m or 2m, furnishes a selected input to the divider 70. Additionally, a second thumbwheel switch (not shown~, graduated from 0 through 9, with input to the rate multiplier 72, is provided for adjust-ing further the minimum sliver feeding rates through either of the two speed range settings provided by the divisor switch aforesaid.
The arrangement illustrated in Fig. 4 ensures that, at all times during knitting, when needles are selected to rake fibers from the doffer, the sliver is fed at a rate adequate to provide sufficient quantities of fibers on the doffer to meet the fiber demand of selected needles, as - required by the fabric pattern, and to compensate for charge loss resulting from fly loss and the non-selection or minimal selection of needles. Thus, there is provided a new and : 15 improved method of sliver knitting, whereby the rate of ;, sliver delivery to the doffer at all times is carefully con-^ trolled, so that it is proportionate to the number of needles .~, selected according to the design, the rotation of the needles, .,.: .
the pile density of the fabric and the rate of fly loss, to ~ 20 maintain the charge of fibers in a sliver feeding system at ,~ a constant level at all times. The method of the invention ensures operating the sliver feed rolls at selected minimum '~ speeds necessary to advance sliver to the doffer at rates ",'~'F sufficient to compensate for any depletion of the charge.
.~ 25 In the claims which follow, the terms (1) "selected fabric patterning rate"
t~ shall indicate a rate of sliver input to a . .
sliver feeding system in harmony with the demand of selected needles for fibers, accord-~' 30 ing to a selected fabric pattern, and ,~, ;, .
' ~
~.'t ., ~ . . .
;~ ' ,`' ' ',, , ' ' ' ' ~ ' ' . ' 108~490
Fly loss occurs because the slivers or rovings used in knitting high pile fabrics are composed of relatively fine, short, discrete fibers, which are especially susceptible to diffusion during handling. In sliver knitting, an unavoidable, relatively significant percentage of the fibers is lost as a sliver is transferred from its source of supply to the usual fiber carding and transfer mechanism, and thence to the needles of the knitting machine. Wheelock `~.S. patent 2,993,351 and ~ ~t U.S. patent 3,72~,872 illustrate apparatus designed for use with sliver knitters to recover fiber wasteage through fly loss.
The knitting of sliver high pile fabrics requires that a certain minimum quantity of fibers be in each sliver feeding system at all times, in order to produce fabrics of uniform pile density. This minimum quantity of fibers is defined as the "charge" of fibers in the feeding system necessary to meet the demand of the needles for fibers. The charge is composed of base fibers which tend to nestle within, and be retained by, the wire coverings of the main cylinder and doffer of a sliver feed system, plus the fibers in transit to the needles. The transit fibers of the charge ride upon the base fibers, as they travel to the needles.
To produce pile fabrics of uniform pile density, the charge of fibers in a sliver feeding system must be main-tained at a constant level. This presentæ no serious problemin the knitting of non-patterned work, since fly loss is . .
'` 1081490 rel~tively constant. The rate of sliver input by sliver feed rolls is easily adjusted to feed sliver at a rate sufficient to produce fabric of selected pile density, while compensating for fly loss. In the knitting of non-patterned sliver high pile fabrics, it is possible to ignore fly loss altogether, and produce satisfactory fabric of uniform density. The finished ~-fabric simply is of somewhat less pile density than would be the case if the fly loss either had been compensated for, or had not occurred.
However, in the knitting of multi-color patterned sliver high pile fabrics, which require selective feeding of various ~ ;
slivers either at variable rates or intermittently, a new problem arises. In knitting such fabrics, the sliver feed rolls cease feeding sliver altogther when needles are not selected. Where only relatively few needles are selected, thereby diminishing the demand of the needles for fibers, the rate at which sliver is fed by the sliver feed rolls to the main cylinder and doffer may fall below the rate of fly loss.
In such situations, the fly loss may create charge loss, i.e.
may cause depletion of the fiber charge on the doffer and main cylinder in the sliver feeding system, thereby creating faults in the fabric being knitted. Charge loss results from fly loss and either the non-selection of needles or the minimal selection of needles. Charge loss may be defined as fly loss extending over a period of time, when no additional fibers are added to the sliver feeding system, or insufficient fibers are added to compensate for fly loss.
In knitting multi-color sliver pile fabrics having intricate designs, it is essential, in order to obtain uniform pile density, to harmonize the rates at which selected slivers are fed by the doffer to selected needles with the demand of the needles for fibers, in accordance with the fabric pattern selected. When, during the knitting of multi-color patterned fabrics, feeding of a sliver is stopped completely, or is B ~ 3 ~ -- , .~ . . .
.
~ 1081~0 reduced to a very low feeding rate, fly loss may cause partial or even complete depletion of the charge fibers from the sliver feeding system and particularly from the rapidly rotating doffer.
Where no sliver fibers are fed to a card for a sus-tained period, the doffer and even the main cylinder might empty completely of charge fibers through fly loss. If this occurs, the first needles eventually selected to receive fibers at such doffer may take no fibers at all, causing a fault in the fabric.
If, due to reduced needle selection, sliver fibers are fed at a minimal rate to the doffer, the rate of feed may be less than the rate of fly loss, thereby reducing the fiber charge in the card. As a result, the few needles selected may draw an insufficient supply of fibers, causing a fault in the fabric.
Usually, fly loss presentsno problem when a large number of needles are selected to rake sliver fibers from a s~sfem B doffer, because the level of the charge in the sliver feeding~
remains constant. It is only when relatively.few needles are selected, or none are selected, and the rate of sliver feeding varies accordingly, that the problem arises.
Summary of the Invention The primary object of this invention is to provide a new and improved method of knitting multi-color~ patterned sliver high pile fabrics on circular knitting machines, which compensates for charge loss during knitting.
A further object of the invention is to provide a new and improved method for feeding sliver to a high pile fabric circular knitting machine in which the rate of sliver feed is proportioned automatically to harmonize with the demand of selected needles for sliver fibers, while compensating for charge loss resulting from fly loss and the non-selection or minimal selection of needles.
A further object is to provide a new and improved method for knitting a patterned multi-color sliver high pile fabric on a multi-feed circular knitting machine whereby a minimum quantity of sliver fibers are maintained on each doffer during knitting, to ensure that sufficient quantities of pile fibers are avail-able at all times to meet the demand of selected needles for fibers, to ensure the production of high quality fabric ofuniform pile density.
A further object is to provide a new and improved method for knitting sliver high pile fabrics having intricate designs on multi-feed circular knitting machines whereby the rate of feed of each sliver to the needles is proportionate to the number of needles selected according to the design, the speed of rotation of the circle of needles, the selected pile density of the fabric and the rate of fly loss, but not less than a rate sufficient to compensate for any depletion of the charge fibers in the sliver feeding system.
In accordance with an aspect of the invention there is provided a method for maintaining constant the fiber charge~in a sliver feeding system during knitting of multi-color patterned sliver high pile fabric on a multi-feed circular knitting machine, to provide patterned high pile fabric of substantially uniform pile density throughout the pattern, said sliver feeding system including a rotatable doffer for delivering fibers to the needles and, a pair of selectively rotatable sliver feed rolls and characterized by continuously rotating the sliver feed rolls 14, 16 at selectively variable rates of speed to advance sliver fibers to the doffer 10 at rates equal to any selected fabric patterning rate plus a rate approximating the rate of charge loss resulting from fly loss and the non-selection or the minimal selection of needles.
Descr'ipt'ion' of'th'e Views o'f the Drawing Fig. 1 is a schematic diagram illustrating an electronically controlled multi-feed sliver high pile fiber circular knitting machine incorporating a preferred embodi-ment of this invention.
Fig. 2 is a schematic block diagram illustrating functionally the data transfer electronic circuitry for con-trolling the rates of feed of the sliver feed rolls of each sliver feeding mechanism of the knitting machine.
Fig. 3 is a fragmentary, partially schematic view in perspective, showing one of the sliver feeding mechanisms or cards of the machine, utilizing a stepping motor to drive its sliver feed rolls.
Fig. 4 is a fragmentary, schematic block diagram showing the data transfer electronic circuitry of Fig. 2 incorporating-suppLemental-control-circuitry-for the-sliver feed rolls to Qperate the same continuously, at selected minimum rates of speed, to provide selected minimum rates of sliver feed to compensatF for charge loss.
.
-` 1081490 Detailed Description of the Invention The improvement of the present invention may be incorporated into any known type of sliver high pile fabric circular knitting machine such as, for example, the sliver knitters illustrated in the following United States patents:
Hill No. 3,010,297, Hill No. 3,014,355, Wiesinger ~o.
3,427,829, Schmidt No. 3,563,058, Brandt et al No. 3,709,002 and Christiansen et al No. 4,007,607. At the present time, the best mode contemplated for carrying out the invention is to incorporate it into the electronically controlled multi-feed sliver high pile fabric circular knitting machine dis-closed in Christiansen et al U.S. patent 4,007,607. The disclosure of that patent is incorporated herein by reference.
Referring to the drawing, in Fig. 1 there is shown schematically in top plan the knitting head of the machine M
of Christiansen et al patent 4,007,607 having a plurality of independent latch needles (not shown) mounted in a circle in a conventional needle cylinder (also not shown), with capacity for selected reciprocal movement. The cylinder is rotatable in the direction of the curved arrow.
-In the embodiment shown, the machine M is provided with 12 sliver feeding stations, Fl to F2 inclusive, spaced at uniform intervals around the needle cylinder. Each such station includes a card C (Fig. 3) having the usual wire-clothed .
.
.
r ~
rotatable doffer lO and main cylinder 12, and a pair of rotatable sliver feed rolls 14, 16. The latter trans~er a roving or sliver (not shown) from a source of supply via the main cylinder 12 to the doffer 10 for delivery to selected needles. The feed rolls are driven by a stepping motor 20 through a conventional timing belt drive 22 and conventional gearing 24. Disposed at each sliver feeding station Fl-Fl2, in advance of its card C, are needles selecting mechanisms Sl to S12, respectively, each of which is composed of a plurality of individual electromagnetic needle selecting actuators of the type illustrated in Christiansen ~.S. patent 3,896,639.
~he electronic control apparatus for selecting needles includes a main memory 30, a buffer memory 32 and needle control logic circuitry 34, the latter being connected electrically by conventional circuitry to each separate electromagnetic actuator of the needle selecting mechanisms Sl to S12 inclusive. A power amplifier 36 is interposed in the circuit connecting each needle selecting actuator to the needle control logic circuitry 34 In the interest of brevity, only one circuit is shown in Fig. 1 connecting the needle control logic 34 to an electromagnetic needle selecting actuator (at Sl).
Data is transferred from the main memory 30 to the electromagnetic actuators in response to signals generated by an absolute encoder 38 geared to the knitting machine M.
Encoder 38 generates a train of pulses, proportional to the speed of rotation of the needle cylinder, to enable sequentially the several actuators of the successive needle selecting mechanisms Sl-S12.
, _ _ . . . . ... . ...
-~08149~
The electronic control apparatus for the knitting machine M also includes control circuitry for regulating continuously the speed of rotation of the stepping m~tors 20 associated with each of the 12 cards C, to control selectively the rate of sliver feed at each station Fl-F12. The electronic control for the stepping motors includes card feed rate logic circuitry 40, connected electrically to each stepping motor 20 by separate circuitry which includes decoding logic circuitry 42 and a power amplifier 44. The decoding logic 42 decodes the pulse train from the card feed rate logic circuitry 40 to the input form required by the stepping motors 20.
For the purpose of illustration, only one circuit is shown in Fig. 1 connecting the card feed rate logic 40 to one of the stepping motors 20 at a sliver feeding station (Fl).
It is to be understood that a separate circuit, each provided with its own decoding logic 42 and power amplifier 44, connects each stepping motor 20 of each card C to the card feed rate logic circuitry. To ensure that the sliver feeding rates of the 12 cards C are at all times proportional to the speed of rotation of the needle cylinder, the card feed rate logic circuitry 40 is clocked by a signal directly proportional to the rotative speed of the needle cylinder. The pulse output of the absolute encoder 38 may be utilized to provide the needle clock input to' the card feed rate logic.
The card feed rate logic circuitry 40 is illustrated schematically in Fig. 2 by the portion of the functional block diagram interposed between the buffer mem,ory 32 and the stepping motor decoding logic 42. As explained in Christiansen et al U.S. patent 4,007,607 aforesaid, the logic depicted in Fig. 2 . . .
-108~90 renders unnecessary incorporating into the main mem~ry 30 sliver feed control data, for controlling the rates at which sliver is fed at each sliver feeding station Fl-F12. The electronic control system depicted in Fig. 2 calculates continuously and accurately the necessary sliver feeding rates using the needle selection pattern data stored by the memory 30. The calculations are carried out by a data calculating and transfer circuit, which includes the buffer memory 32 for the temporary storage of needle selection pattern data, counter 50, multiplier 52, divider 54, rate mul~iplier 56 and buffer shift register 60.
In addition to using needle selection pattern data retrieved from the memory 30, the data calculating and transfer electronic circuit also incorporates into its calculations, from the input of clock pulses at the "ma" number, the selected speed of rotation of the needle cylinder. It also incorporates into its calculations the selected pile density of the fabric being knit, from a set of thumbwheel switches (not shown), the selected setting of which is applied to rate multiplier 58 interposed between rate multiplier 56 and buffer shift register 60.
The sliver feeding rate data obtained from the second rate multiplier 58 is stored in the buffer shift register 60, to which also are applied the "ma" clock pulses previously 25 referred to. The data stored in the buffer shift register 60, at the appropriate time, is transferred to one of the active shift registers Rl-R12 connected by suitable circuitry to one of the stepping motors for one of the twelve cards.
Fig. 2 illustrates an arrangement by which rate data .
. . . . .. _ . _ .. .. .. . ..
~081~90 is transferred from the buffer shift register 60 to the active shift register Rl, which controls the stepping motor 20 of the card C at sliver feeding station Fl. The active shift register Rl is clocked by the pulse output of the encoder 38, which is proportional to the speed of rotation of the needle cylinder. The data output of the active shift register Rl is combined with this clock, as indicated by the "and" function block 62. The resulting pulse train is decoded by the stepping motor decoding logic 42 and amplified by the power amplifier lQ 44, t~ drive the stepping motor 20 at the speed necessary for card C.to feed sliver at a selected rate in harmony with the fabric pattern selected. The result is to provide a card with continuously controlled sliver feed roll drive means, calculated to ensure that the sliver input to the machine harmonizes with the demand of selected needles for fibers, the speed of rotation of the circle of needles and the desired pile density of the fabric.
As explainea previously,--charge loss may arise and-create faults in multi-color patterned sliver knit fabrics where the feed of a sliver temporarily is stopped completely, due to non-selection of needles or is reduced to a very low rate because relatively few needles are selected to receive fibers. To compensate for this, and maintain constant the fiber charge in a sliver feeding system, the p esent invention provides for the continuous rotation of the sliver feed rolls 14, 16, at selectively adjustable minimum rates of rotation, calculated to feed sliver at minimum rates approximating the rate of fly loss, preferably at a rate equal to or slightly less than the rate of fly loss. Arranging for the sliver feed rolls 14, 16 to rotate continuously at selected minimum speeds of rotation to compensate for charge loss, ensures that a sufficient quantity or charge of fibers is maintained on the r ~081490 doffer 10 at all times during knitting to meet the demand of selected needles for fibers, and to avoid faults in the pile density of the fabric.
The additional logic or control circuitry required to obtain such selected minimum rates of sliver feed is illustrated in Fig. 4. It comprises a divider 70, rate multiplier 72, anti-coincidence circuit 74 and "or" gate 76.
The control logic to obtain the desired selected minimum rates of sliver feed is interposed in the basic data calcu-lating and transfer electronic circuit between rate multiplier58 and buffer shift register 60.
By way of illustration, it will be assumed that not more than 93 of each 100 data bits (i.e. discrete commands for needles to take sliver or to welt) transferred from rate multiplier 58 and stored in the buffer shift register 60, will be binary or logic "l's" (i.e. needle commands to take sliver).
The sliver therefore is advanced at its selected maximum feeding rate by the feed rolls 14, 16 when 93 of each 100 data bits entered on the shift register 60 are logic "l's". This arrange~ent provides for the possibility of increasing the speed of the stepping motor 20 by 973, or approximately 7.5%
beyond the selected maximum speed, resulting in a corresponding increase in the sliver feed rate.
~ - 12 -;~ 108149(1 The train of clock pulses "ma" applied to the buffer shift register 60 supplies one pulse for each data bit, i.e.
for each logic "1" or "0", entered in the register. As explained in Christiansen et al U.S. patent 4,007,607 afore-said, in the clock "ma" the designation "m" is a selectedconstant comprising a scaling factor and the designation "a"
denotes the data bits or commands for a selected number of needles "a". In the example given, "a" = 100 data bits.
Since the number of pulses of the buffer shift register clock 0 "ma" is proportional to the maximum sliver feed rate (i.e. 93 logic "l's" randomly evenly distributed for each 100 data bi~s), a pulse train which represents any fraction of the maximum sliver feed rate may be obtained by dividing the "ma" clock .,;
; pulses by any appropriate number "n". The divisor "n" is a ; 5 number which, when divided into "ma", produces a quotient ; preferably and normally, but not necessarily, equal to or less , .
than the difference between the data bits "a" of the clock ...
"ma" and the maximum logic "l's" per "a" data bits (in the example given, the difference is 100 - 93 = 7).
.. ~ , ... .
.~ .
, .. .
., ' ~, i , ., ¢l ~' ~ , ,. .1 :
.
,;:'' `~ `
~ -12A-.,`"
.' '' ' '. . ~ :,, ,. '. , : '' :' ~08~490 In the modified electronic circuit of Fig. 4, the divider 70 and the rate multiplier 72 are utilized to divide by "n" the buffer shift register clock "ma", to provide the minimum sliver feed rate data. The divided clock is entered into the buffer shift register 60 as additional data by adding it via "or" gate 76 to the sliver feed rate data obtained from the data calculating and transfer circuit inter-posed between main memory 30 and buffer shift register 60.
The minimum sliver feed rate data, obtained from the divided buffer shift register clock, must be added to the register 60 when the data entered from the rate multiplier 58 is a logic "0". The anti-coincidence circuit 74, connected to the rate multiplier 58 and the "or" gate 76 ensures this, by detecting the presence of a logic "0" data bit entering the buffer shift register 60 from the rate multiplier 58.
The invention thus permits continuous feeding of sliver by the sliver feed rolls 14, 16 to the main-cylinder-12 and doffer 10, at selectively variable rates of sliver feed, such rates being proportionate to the number of needles selected, the speed of rotation of the circle of needles, the selected pile density of the fabric and the rate of fly loss, to maintain the charge of fibers in the sliver feeding system at a constant level at all times.
In practice, a minimum rate of sliver feed of 1%
of the maximum rate of sliver feed may be sufficient to compensate for any depletion of the charge. However, since fly loss will occur at various rates, under various knitting conditions, it is desirahle to provide means to adjust easily and selectively the compensating minimum rate of sliver feed.
For this purpose, a high-low divisor switch (not shown) pro-viding for two basic speed ranges, m or 2m, furnishes a selected input to the divider 70. Additionally, a second thumbwheel switch (not shown~, graduated from 0 through 9, with input to the rate multiplier 72, is provided for adjust-ing further the minimum sliver feeding rates through either of the two speed range settings provided by the divisor switch aforesaid.
The arrangement illustrated in Fig. 4 ensures that, at all times during knitting, when needles are selected to rake fibers from the doffer, the sliver is fed at a rate adequate to provide sufficient quantities of fibers on the doffer to meet the fiber demand of selected needles, as - required by the fabric pattern, and to compensate for charge loss resulting from fly loss and the non-selection or minimal selection of needles. Thus, there is provided a new and : 15 improved method of sliver knitting, whereby the rate of ;, sliver delivery to the doffer at all times is carefully con-^ trolled, so that it is proportionate to the number of needles .~, selected according to the design, the rotation of the needles, .,.: .
the pile density of the fabric and the rate of fly loss, to ~ 20 maintain the charge of fibers in a sliver feeding system at ,~ a constant level at all times. The method of the invention ensures operating the sliver feed rolls at selected minimum '~ speeds necessary to advance sliver to the doffer at rates ",'~'F sufficient to compensate for any depletion of the charge.
.~ 25 In the claims which follow, the terms (1) "selected fabric patterning rate"
t~ shall indicate a rate of sliver input to a . .
sliver feeding system in harmony with the demand of selected needles for fibers, accord-~' 30 ing to a selected fabric pattern, and ,~, ;, .
' ~
~.'t ., ~ . . .
;~ ' ,`' ' ',, , ' ' ' ' ~ ' ' . ' 108~490
(2) "minimal selection of needles"
shall indicate the selection of so few needles that the demand of the needles for fibers, according to a selected fabric pattern, is less than the rate of fly loss from the sliver feeding system.
:
, .
.,, --.!i t '. ' '' i' ,,~,,:~
,'',~
~..~', . r `:~
~ -15-
shall indicate the selection of so few needles that the demand of the needles for fibers, according to a selected fabric pattern, is less than the rate of fly loss from the sliver feeding system.
:
, .
.,, --.!i t '. ' '' i' ,,~,,:~
,'',~
~..~', . r `:~
~ -15-
Claims (8)
1. A method for maintaining constant the fiber charge in a sliver feeding system during knitting of multi-color patterned sliver high pile fabric on a multi-feed circular knitting machine, to provide patterned high pile fabric of substantially uniform pile density throughout the pattern, said sliver feeding system including a rotatable doffer for delivering fibers to the needles and a pair of selectively rotatable sliver feed rolls, characterized by continuously rotating the sliver feed rolls 14, 16 at selectively variable rates of speed to advance sliver fibers to the doffer 10 at rates equal to any selected fabric patterning rate plus a rate approximating the rate of charge loss resulting from fly loss and the non-selection or the minimal selection of needles.
2. The method of Claim 1, characterized by rotating the sliver feed rolls 14, 16 at selectively variable rates of speed to advance sliver to the doffer 10 at rates sufficient to compensate for any depletion of the fiber charge.
3. A method according to either of Claims 1 or 2, characterized by rotating the sliver feed rolls 14, 16 at selectively variable rates of speed to maintain a sufficient quantity of fibers on the doffer at all times to meet the demand of selected needles for fibers according to a selected pattern.
4. A method according to Claim 1 or 2 characterized by continuously rotating the sliver feed rolls to advance sliver fibers to the doffer at selected rates not less than a rate substantially equal to the rate of fly loss.
5. A method for maintaining constant the fiber charge in a sliver feeding system during knitting of multi-color patterned sliver high pile fabric on a multi-feed circular knitting machine, to provide patterned high pile fabric in which the density of the pile is substantially uniform through-out the pattern, said machine having a plurality of sliver feeding cards spaced about the circle of needles, each card including a rotatable doffer for delivering sliver to the needles, a pair of selectively rotatable sliver feed rolls and a rotatable main cylinder interposed between the doffer and the feed rolls, needle selecting mechanism associated with each card and a yarn feed disposed adjacent selected cards, comprising (a) feeding sliver fibers and yarns to the needles to knit multi-colored patterned high pile fabric, said sliver fibers being fed by each card to the needles at selected rates of feed, (b) continuously selecting needles, according to predetermined needle selection pattern data, to receive sliver fibers from the doffers of selected cards and (c) continuously rotating the sliver feed rolls at selected rates of speed to deliver sliver fibers to the main cylinder and doffer of each card at rates equal to any selected fabric patterning rate plus a rate calculated to compensate for the rate of charge loss resulting from fly loss and the non-selection or the minimal selection of needles.
6. The method of Claim 5, wherein the sliver feed rolls are driven rotatably by a variable speed motor, com-prising continuously operating the motor to cause the sliver feed rolls to rotate at variable speeds of rotation, to deliver sliver fibers to the doffer at selected rates of feed to maintain a sufficient quantity of fibers on the doffer at all times to meet the demand of selected needles for fibers according to a selected pattern.
7. The method of Claim 5, wherein the rate of sliver delivery to the main cylinder and doffer of each card is continuously controlled, whereby the rate of sliver delivery is proportionate to (a) the demand of selected needles for sliver fibers in accordance with a predeter-mined needle selection pattern, (b) the speed of rotation of the circle of needles, (c) the selected density of the pile of the fabric being knit and (d) the rate of fly loss, (e) but not less than a rate sufficient to compensate for any depletion of the fiber charge in the sliver feeding system.
8. The method of Claim 5, wherein each pair of sliver feed rolls is driven rotatably by a variable speed motor, comprising continuously operating and controlling the motor to cause the sliver feed rolls to rotate at selected speeds of rotation, to deliver sliver fibers to the doffer at a rate of delivery proportionate to (a) the number of needles selected to receive sliver fibers from the doffer, (b) the speed of rotation of the circle of needles, (c) the desired pile density of the fabric, and (d) the rate of fly loss, (e) but not less than a rate sufficient to compensate for any depletion of the fiber charge in the sliver feeding system.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US76148677A | 1977-01-21 | 1977-01-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1081490A true CA1081490A (en) | 1980-07-15 |
Family
ID=25062348
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA294,128A Expired CA1081490A (en) | 1977-01-21 | 1977-12-30 | Method of compensating for charge loss during knitting of sliver multi-color patterned high pile fabric |
Country Status (7)
| Country | Link |
|---|---|
| JP (1) | JPS5394641A (en) |
| BE (1) | BE863157A (en) |
| CA (1) | CA1081490A (en) |
| DE (1) | DE2802527A1 (en) |
| FR (1) | FR2378113A1 (en) |
| GB (1) | GB1569644A (en) |
| IT (1) | IT1107026B (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3433642A1 (en) * | 1984-09-13 | 1986-03-20 | Sulzer Morat Gmbh, 7024 Filderstadt | METHOD AND CIRCULAR KNITTING MACHINE FOR PRODUCING KNITWEAR WITH COMBED FIBERS |
| JPH0191935A (en) * | 1987-10-02 | 1989-04-11 | Denki Kagaku Kogyo Kk | Casting mold |
| IT1312021B1 (en) * | 1999-03-19 | 2002-04-04 | Orizio Paola Spa | KNITTING MACHINE WITH SELECTION OF MULTIPLE NEEDLES. |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2993351A (en) * | 1959-11-12 | 1961-07-25 | Du Pont | Fiber recovery unit for knitting machine |
| BE795456A (en) * | 1971-05-03 | 1973-05-29 | Glenoit Mills | METHOD AND APPARATUS FOR KNITTING LONG-HAIR FABRICS FROM RIBBON |
| US3896637A (en) * | 1972-11-06 | 1975-07-29 | Glenoit Mills | Sliver feeding means for high pile fabric circular knitting machines |
| US3973414A (en) * | 1973-05-08 | 1976-08-10 | Bunker Ramo Corporation | Apparatus for producing patterned deep pile circular knitted fabrics |
| US4007607A (en) * | 1975-10-09 | 1977-02-15 | Hayes-Albion Corporation | Method and apparatus for knitting patterned sliver high pile fabric |
-
1977
- 1977-12-30 CA CA294,128A patent/CA1081490A/en not_active Expired
-
1978
- 1978-01-13 GB GB1333/78A patent/GB1569644A/en not_active Expired
- 1978-01-20 FR FR7802449A patent/FR2378113A1/en active Pending
- 1978-01-20 BE BE184519A patent/BE863157A/en unknown
- 1978-01-20 IT IT67102/78A patent/IT1107026B/en active
- 1978-01-20 DE DE19782802527 patent/DE2802527A1/en active Granted
- 1978-01-21 JP JP482378A patent/JPS5394641A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| IT7867102A0 (en) | 1978-01-20 |
| FR2378113A1 (en) | 1978-08-18 |
| DE2802527A1 (en) | 1978-07-27 |
| IT1107026B (en) | 1985-11-18 |
| DE2802527C2 (en) | 1988-04-21 |
| BE863157A (en) | 1978-05-16 |
| JPS5394641A (en) | 1978-08-18 |
| JPS6256248B2 (en) | 1987-11-25 |
| GB1569644A (en) | 1980-06-18 |
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