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Loop length & its effects; Positive feeder; Dimensionally stable states of knitted fabric; Robbing back; Needle

bounce.

Loop length & its effects


Loop length is the fundamental unit of weft knitted

structure. Loop shape determines the dimensions of the fabric, and this shape depends upon the yarn used and the treatment that the fabric has received. is these that influence fabric dimensions and other properties, including weight. Variations in course length between one garment and another can produce size variations, whilst course length variations within structures (particularly when using continuous filament yarns) can produce horizontal barriness and impair the appearance of the fabric.

Loop lengths combine in the form of course lengths and it

But in modern knitting technology, the need to maintain a constant loop length at one feed for long periods of time between one feed and another on the same machine, and between different machines knitting the same structure has become of major importance in the control of fabric quality. This requirement has encouraged the development of yarn feed measuring and control devices.

Positive feeder
To maintain the uniform loop length & constant course

length Positive feed device have been introduced. The most advantage of using this device is positively supplying yarn at the correct rate under low yarn tension.
HATRA introduced the nip roller positive feed device

during the early 1960s. It consists of a lower roller driven by gearing , at a speed directly proportional to the machine speed, with an upper, freely running, weighted roller turning in contact with the yarn completing the nip.

Trip-tape positive feed.

The cheaper, simpler, more adaptable, tape positive feed system developed by Isaac Rosen proved to be more acceptable. A continuous tape driven from the machine drive by a single pulley encircles the machine above the feeders and provides identical and constant feed for any yarn threaded through the nip it forms with a free-running feed wheel at each feed position. On clockwise revolving machines, the yarn passes from its package into the right-hand side of the tape/wheel nip and on leaving the nip on the left it passes down through a detector to the feeder. The faster the tape speed relative to the machine speed, the faster the rate of yarn feed and the longer the resultant course length. The tape speed is altered by adjusting the scrolled segments of the drive pulley to produce a larger or smaller driving circumference. Punto di roma, milano rib and double pique require much longer course lengths at the feeders where most needles knit than at the other feeders. For structures of this type, up to four tiers of tapes, each driven at a different speed by a different diameter drive pulley, can be accommodated. Facilities for yarn disengagement are provided and sometimes the yarn is guided around the wheel in a coil to prevent slippage.

Positive storage feeder


Guide Driving unit

Knot detector

Indicator light Magnetic Tensioner Storage unit Sensor

Dimensionally stable states of knitted fabric


The yarns after knitting which were originally straight

& desire to return to the straight state were prevented from doing so by the frictional forces acting over the regions of loop interlacing. Changes in dimensions after knitting can create major problems in garments & in fabrics especially those produced from hydrophilic fibers such as wool & cotton. In order to avoid dimensional changes, the knitted fabric should attain a stable state of equilibrium.

The three important dimensionally stable states are:

Dry relaxed state: The fabric has been taken off the knitting m/c & allowed to lie freely for a sufficient length of time. Eventually the fabric attains a dimensionally stable condition, called the dry relaxed state. A plane fabric knitted from worsted yarn will recover from a 60-80% extension in length & a cotton fabric will recover 10-20% when subjected to dry relaxed state.

Wet relaxed state:

If the fabric is soaked in water & allowed to dry flat, the wet relaxed state is attained. The equilibrium is reached after static relaxation in water & subsequent drying. Wet Relaxation is carried out in water at 30 C containing 0.1% wetting agent, allowed to lay for 24hours. Then extracted & dried naturally for at least three days. Finished relaxed state: Here the fabric is subjected to agitation in water or steam at 80 c for 2 hours, tumbled dried in a domestic Top loading washing m/c & finally conditioned in the standard atmosphere for at least 24 hours.

Robbing back:

Model of weft-knitted loop formation indicating the mechanism of robbing-back and the build-up in yarn tensions acting on the needles.

As the needles descend the stitch cam, the tension required to pull yarn from the package increases rapidly and it becomes easier to rob back yarn in the opposite direction from the already-formed loops of needles further back that are then beginning to rise from their lowest (knock-over) position. With reference to above figure, it was suggested that, under the dynamic conditions of loop formation, yarn tension increases as it passes over the knitting elements from point A. Robbing back occurs from needles on the other side of the stitch cam. The lowest point of tension is reached at B. The tension on the yarn is determined by the yarn/metal friction. As robbing back reduces tension, at-bottom cams would obviously be undesirable and a cam angle shape of 60 degrees was preferable to one of 45 degrees because the number of yarn/metal contacts was reduced. It was further proposed that smoothly designed, non-linear camming with a pressure angle of greater than 50 degrees could provide smooth acceleration of needles for much higher knitting speeds. Camming of this type has been incorporated into some simple high-speed single-jersey machines but it requires adaptation for more complex and alterable cam arrangements.

Needle bounce
Needle bounce is a major problem in high speed knitting. This is caused by the needle butt being suddenly checked by the impact of hitting the upper surface of the up-throw cam after it has accelerated away from the lowest point of the stitch cam. At this moment, inertia at the needle head may cause it to vibrate so violently that it may fracture; also the up-throw cam becomes pitted in this section. Needles passing though in the miss section are particularly affected as their butts contact the lowest part of the cam only and at a sharp angle that accelerates them downwards very rapidly. To reduce this effect, a separate cam is often used to guide these butts at a more gradual angle. The smoother proles of non-linear camming help to reduce needle bounce and a braking effect is achieved on the butts by keeping the gap between the stitch and upthrow cams to a minimum.

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