NATIONAL TEXTILE UNIVERSITY

SCHOOL OF ENGINEERING & TECHNOLOGY

Department of Textile Engineering (Knitting)

Lab Manual

KN-4054
Knitting mechanism II

Spring 2022
http://www.ntu.edu.pk/
 List of Experiments
1. To study the parts and their function of Gloves knitting machine.
2. To study the drive and mechanism of automatic gloves knitting machine.
3. To study the mechanism of hand flat knitting machine
4. Study the mechanism of SVR123SP flat knitting machine
5. To study about the carriage parts and cam system of falt knitting machine
6. To study parts and working principle of warping machine
7. To Study the parts and functions of tricot warp knitting machine
8. Check and analyze the take-up & let-off mechanism of tricot Warp Knitting machine
9. To Study and identify different parts of single cylinder socks knitting machine.

10. To Study the working principle of different parts of socks knitting machine
11. Open Ended Lab
12. Open Ended Lab

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 EXPERIMENT-1

To study the parts and their function of Gloves knitting machine

OBJECTIVES:
 To learn about the part of gloves knitting machine.
 To know about the working principle of parts.
THEORY:
It has been estimated that almost 20% of all disabling accidents on the job involve the hands (OSHA).
Without your fingers or hands, your ability to work would be greatly reduced. Meeting caustic or toxic
chemicals, biological substances, electrical sources, or extremely cold or hot objects can irritate or burn
your hands. Toxic substances are poisonous substances that can be absorbed through your skin and enter
your body. common type of gloves is.

 Disposable: light-weight plastic; can help guard against mild irritants.

 Fabric: cotton or fabric blend; improve grip or insulate from heat or cold.
 Leather: guard against injuries from sparks or scraping against rough surfaces. Combine with an
insulated liner when working with electricity.
 Chemical Resistance: nitrile, neoprene, vinyl, etc; protect hands from chemical exposure
 Metal Mesh: protect hands from cuts and scratches; used commonly with sharp instruments.
 Aluminized Fabric: insulate hands from intense heat; commonly used with molten materials
Spring disc tensioner bar Spring wire tensioner assembly Close guide plate Needle bed

Manual handle Oil pump

Figure 1 Gloves knitting machine

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 Figure 2. Different type of gloves

WORKING PRINCIPLE:

The knitting of gloves on the is done as per sequence mention in figure 2.

Figure 3 knitting sequence of gloves

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PROCEDURE:

 Visit the Lab with the teacher

 Note down all parts of gloves machine
 Note the functions of parts
OBSERVATIONS:

Sr# Yarn passage part name Function of Part How it Works

1 Creel stand:

2 Close guide:

3 Spring disc tensioner:

4 Needle:

5 Cams:

6 Cam Box:

7 Solenoid magnetic valve:

8 Feeders:

9 Stitch length control unit:

10 Looper:

11 Cutter:

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 Question 1: What is the purpose of elastic yarn in gloves
 Question 2: Why looper is required in gloves knitting machine
 Question 3: Is platting is possible in gloves knitting and how?
 Question 4: What type of structure of gloves made in SFG-I
 Question 5: What is the purpose of Looper
 Question 6: Can we make different gloves design on SFG-I machine
 Question 7: what is purpose of cutter and how It works

EXPERIMENT-2

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 To study the drive and mechanism of automatic gloves knitting machine.

OBJECTIVES:
 To learn about drive mechanism of gloves machine
 To learn about cams and its drive of gloves knitting machine
 To learn about machine panel of gloves knitting machine
THEORY:
It has been estimated that almost 20% of all disabling accidents on the job involve the hands (OSHA).
Without your fingers or hands, your ability to work would be greatly reduced. Meeting caustic or toxic
chemicals, biological substances, electrical sources, or extremely cold or hot objects can irritate or burn
your hands. Toxic substances are poisonous substances that can be absorbed through your skin and enter
your body.

WORKING PRINCIPLE

When the needle selection solenoid is energized the drum advancing clutch lever is lifted and motion of
drum advancing is conveyed to the drum advancing wheel thus the both drums are advanced one tooth
pick. When the needle selection rotates needle selection pin on the drum pushes up the control jack and
control jack push the jack but upward out of the needle bed and allowing needle selection

Figure 1 Needle selection mechanism

DRIVES OF MACHINE PARTS:

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 1. Drive of pattern drum
2. Looper drive
3. Different cams for cutter and Looper selection
4. Carriage selection and Looper selection mechanism
5. Types of sensors
6. Panel working
CAMS USED IN CARRIAGE
1. Bridge Cam(F)
2. Center Cam (F)
3. Stitch Cam(F,B)
4. Needle Raising Cam(F,B)
5. Set-up Cam
6. Needle Guide Cam(F,B)
7. Pressure Cam(F,B)
8. Elastic yarn Cam(F)
9. Cutter Cam (F)
10. Bridge Cam(B)
11. Center Cam (B)
12. Cutter Cam
Set-up Cam
The set up raising cam is set to working position only during finger tip knitting and finger crotch
knitting. Set up cam knits each one course of finger tip and finger crotch knitting
Stitch Cam
Determines the stitch value. Usually, the knitting stitches are adjusted by using the stitch adjustment
dials on the carriages
Pressure Cam
When knitting proceeds from a finger crotch to a next finger, the pressure cam is actuated to lower the
required needles so that the stitch holder can easily enter the working position. Thus , it sets up the
knitting position of next finger.
Elastic Yarn Cam
Elastic yarn cam is set to operating position during cuff knitting. Then, it work to make the high butt
needle knitted elastic yarn.
Cutter Cam
The Cutter Cam releases as elastic yarn or an X yarn at the second course after starting to insert. Then
this cam works for cutting and holding the elastic yarn after elastic yarn been inserted.

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 Figure 3 Cams of carriage
PROCEDURE:
Visit the Lab with the teacher
Note down all parts of gloves machine
 Note the functions of parts
OBSERVATIONS:
SR# OBSERVATIONS REMARKS
1 Drive of parts

2 Cams of machine

3 No of solenoid magnets

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4 Looper working

5 Cutter working

Draw Drive of machine

Question 1: How Looper get the drive
Question 2: How cutter works
Question 3: How needles selection drum take drive
Question 4: How carriage take drive
Question 5: What is the working principle of solenoid magnet

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 EXPERIMENT-3

To study the mechanism of hand flat knitting machine

OBJECTIVES:

 To know about the passage of yarn and fabric of the machine.

 To know about the different parts and their functions of the machine.
 To learn about the working of cams and type of cams in hand flat knitting machine
THEORY:
In the following figure shows a cross section of a simple hand powered and manipulated V-bed rib flat
machine. The trick walls are replaced at the needle bed verges by fixed, thinner, polished, and specially
shaped knock-over bit edges. In rib gating, a knock-over bit in one bed will be aligned opposite to a
needle trick in the other bed. During knitting, the edges of the knock-over bits restrain the sinker loops
as they pass between the needles and thus assist in the knocking over of the old loops and in the
formation of the new loops.

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Figure 1 Hand flat knitting machine

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WORKING PRINCIPLE:
The tops of the heads of the needles are level with the edge of the knock over bits. The butts of the
needles assume a straight line until contacting the raising cams R (R) because the leading stitch cams S
and AS (L) are lifted to an inactive position. The lifting action is an alternating action that always lowers
the trailing stitch cams and raises the leading stitch cams in each system as the traverse commences.
This action prevents needles from being unnecessarily lowered and strain being placed on the old.

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Figure 2 Needles working during knitting

PROCEDURE:
 Visit the Lab with the teacher
 Note down all parts through the yarn pass for knitting
 Note the functions of parts which involve
OBSERVATIONS:
Sr# Yarn passage Function of Part How it Works
part name

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 Question 1: Draw cams of hand flat knitting machine
 Question 2: What will happen if less weigh is place onto the fabric?
 Question 3: What is the working principle of flat knitted fabric?
 Question 4: What is the difference between needles of circular and flat machine?
 Question 5: what is the purpose of tension spring placed on machine?
 Question 6: How tension is control during the knitting?
 Question 7: How tubular fabric can be made on hand flat knitting machine?
 Question 8: Can we make jacquard designs on hand flat machine if yes then how?

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 EXPERIMENT-4
Study the mechanism of SVR123SP flat knitting machine

OBJECTIVES
 To study the working principle of flat knitting machine
 To study the working of parts of flat knitting machine
 To study the fabric formation process on flat knitting machine
THEORY:

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Spring-loaded movable full sinker system in SVR123SP provides a gentle hold-down movement and
yields ideal loop formation, thus improving fabric quality. The flat knitting machine manufacturer is
known for regularly bringing out improved and innovative version of technology and SVR series is one
of its latest offerings with innovative features. The machine comes with a single loop presser bed placed
above the rear needle bed, a feature which allows the machine to produce unprecedented designs in knit
fabrics, especially inlay patterns, which combine knit and weave characteristics to produce hybrid
textiles.
Inlay fabric is produced by inserting yarn into existing knit fabric in a weave fashion, yielding unique
fabrics that are neither typically knit nor woven. Inlay also suppresses typical stretch characteristics of
knitwear, and since new yarns and materials can be used for inlay structures, new applications in
addition to fashion apparel such as sports and medical as well as other industrial applications can be
anticipated. With fine 14 gauges, the machine can achieve knitting width of 122 cm with a knitting
speed of 1.4 meters per second. However, knitting speed can vary according to yarn and other knitting
conditions. Capable of a wide range of knitting from fashion to technical textiles, the machine offers
Wide Gauge capability whereby a variety of gauges – from finer-gauges using all-needle knitting, to
lower-gauges using half-gauge knitting – can be knit on a single machine. It benefits the user in handling
changing seasons and shifting trends without investing in a machine for every gauge or resorting to the
complex, time-consuming task of gauge conversion.

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 Figure 1 Shima Seiki SVR123SP

WORKING PRINCIPLE

The machine features a R2 CARRIAGE (R2 = Rapid Response) system that features an advanced
carriage mechanism combined with improved software programming that achieves quicker carriage
returns after each course. Field-tested and market-proven in the industry for 30 years, the company’s
patented Digital Stitch Control System (DSCS) continuously adjusts yarn feed and tension to yield loop
consistency with tolerance to within a remarkable (±) 1 per cent. Apart from loop consistency, it also
allows consistency among different batches and repeat orders. This results in quality control and thus,
higher productivity Another feature which aims to improve quality of the output is spring-loaded
movable full sinker system. While in the conventional forced-operation type sinkers, fabric is subjected
to unnecessary stress and cause compressed loops and even yarn breakage. However, spring-loaded
movable full sinker system in the machine provides a gentle hold-down movement and yields ideal loop
formation which in turn allows a significant improvement in fabric quality for complicated patterns

Figure 2 Knitting Mechanism

PROCEDURE:

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  Visit the lab with the teacher
 Note down all parts of flat knitting machine
 Check the working principle of all parts
 Develop a fabric and observe the working of all parts
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Abbreviation of SVR123SP

2 Process of take down

3 Lubrication system

4 No of cam systems in machine

5 All main parts of machine

Question 1: What are the benefits of comb take down and how it works

Question 2: What is the working of DSCS system and what are its benefits

Question 3: what is the purpose of stitch pressors

Question 4: What is the benefit of loop pressor and how it works

Question 5: What is the benefit of 3 cams system carriage over 2 cams system carriage

Question 6: Can we make intarsia design on SVR123SP machine

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 EXPERIMENT-5

To study about the carriage parts and cam system of falt knitting machine

OBJECTIVES:

 To learns about the cams of power flat knitting machines

 To learn about the working of cams
 To learn about the flat parts of flat knitting machine
THEORY:
The electronically-controlled power flat machine offers quick response to size, style and pattern changes
with versatile and infinitely variable adjustment of its electronically-controlled functions under the
guidance of the main computer soft ware programme and the back-up support of its memory.

Parts of carriage includes 1. Carrier Control Box: Carrier catching pins are come out of carrier control
box and attach the carrier thus carrier move with carriage. 2 Stitch presser: This presses fabric into
needle bed gap. 3. Needle selection Gauge/Needle Selection sensor: The needle selection sensor and
needle selection gauge installed on the carriage and detect the advancing direction of carriage , as well

20
as count the needles. 4 Needle Breakage switch:This detects the raising of fabric at needle bed gap. 5
Brushes: 6. Dust Cleaner: This can suck and accumulate dust from needle bed gap

Figure 1 Carraige parts

’
Figure 2 Flat parts of power flat knitting machine
WORKING PRINCIPLE:
1. Bridge Cam Move down the jack which was raised up to the knit position by the needle raising
cam

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2. Needle raising cam Rises the jack up to the knit position or the tuck position
3. Stitch Cam Moves up and down to stitch length
4. Transfer raising Cam Acts on the jack of needles during transfer
5. Transfer receiving cam Acts on the jack of needles that receives stitches during transfer
6. Transfer Guide Cam Along with the transfer raising cam, acts upon the jack of needles that
transfer stitches during transfer
7. Needle Guide Cam Moves the A position select jack down to H position
8. Select Jack Clear Cam Moves the select jack which was moved down to H position by the needle
guide cam even further down to B position.
9. Tuck Presser Acts on H position select jack, becoming a “Tuck”
10. Half Presser Acts on H position select jack , becoming a “receive during transfer” or tuck 2nd
stitch”
11. Fixed Welt presser Acts on B position select jack , becoming a “miss”
12. Actuator Activates the selector, which is selected A position or H position
13. Selector raising Cam Acts on the selector selected by the actuator to raise the select jack up to A
position
14. Selector guide Cam Acts on the selector selected by the actuator to raise the select jack up to H
position
15. Selector reset cam Returns the selector , which was pushed into the needle bed by the actuator ,
to its original position

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 Figure 3 Cams in a carriage

PROCEDURE:
 Visit the lab with the teacher
 Open the carriage of flat knitting machine
 Check the working of cams as described
 Check the working of flat parts
 Note down all observations
OBSERVATIONS:
SR# OBSERVATIONS REMARKS
1 Funcation of needles selection
sensor
2 Drive of carriage
3 Working of Loop presser bed

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4 Working of sinkers
5 Working of takedown mechanism
6 Working of DSCS

QUESTION 1: What is the working principle of actuators

QUESTION 2: What is the funcation of jacks & select jacks

QUESTION 3: What is the functaion of stitch cams and how it controls the stitch length of fabric

QUESTION 4: What is the functaion of pressor and how it helps in knitting

QUESTION 5: What is the funcation of selector raising cams

EXPERIMENT-6

To study parts and working principle of warping machine

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OBJECTIVES:

 Learn about purpose of warping

 Learn about Parts and their working
 Learn about calculation of warping
THEORY:

The parallel winding of warp ends from many winding packages (cone, cheese) on to a common
package (warp beam) is called warping. In sectional warping sections are made sequentially and because
of this the process is rather slow. It is the practice therefore to produce no more than is required to fill a
single weavers beam. the result is that the sectional warping is used mainly for short runs or for complex
colour patterns. Features of sectional warping. To produce Fancy fabric (stripe/Check) to produce
weavers beam from yarns which does not required any sizing material to be applied before weaving. To
produce weavers beam of small amount of warp yarn. At first wound section by selection and final
weavers beam produce immediately after sectional warping. Production is less, so costly process. A
tapered beam or drum is used. High speed warping denotes the transference of yarns from single-end
yarn packages, wound packages, directly to a beam in a one step process. This means that there are an
equal number of packages in the creel area as there are ends on the beam, except in the case of a
magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new
wound package for an easy package transfer. From the wound packages in the creel.

Figure 1 Warping machine

TYPES OF WARPING:

 Sectional or Pattern Warping (conical drum or dresser warping).

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  High speed/ Beam/ Direct Warping (preparatory beam warping).

SECTIONAL OR PATTERN WARPING:

In sectional warping sections are made sequentially and because of this the process is rather slow it is
the practice therefore to produce no more than is required to fill a single weavers beam. the result is that
the sectional warping is used mainly for short runs or for complex colour patterns. Features of sectional
warping. To produce Fancy fabric (stripe/Check) to produce weavers beam from yarns which does not
require any sizing material to be applied before weaving. To produce weavers, beam of small amount of
warp yarn. At first wound section by selection and final weavers beam produce immediately after
sectional warping. Production is less, so costly process. A tapered beam or drum is used.

HIGH SPEED/ BEAM/ DIRECT WARPING:

Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in
a one step process. This means that there are an equal number of packages in the creel area as there are
ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one
wound package to the beginning of a new wound package for an easy package transfer. From the wound
packages in the creel.

COMPONENTS OF A WARPING MACHINE

 Creel Stand:

Creel stand is the part of warping machine, on which all the cones are placed. It includes 200
cones on creel stand.

 Tensioner plate:

Tensioner plate consist of close guide plate, disc tensioner etc

 Side close guide assembly:

Yarn from the cones on the creel stand passes through the side close guide assembly, that gives
the path to the yarn.

 Close guide plate:

This is the plate, that includes all the close guides, through which yarn passes.

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  Needle guide plate 1:

Needle guide plate consist of needles. All the yarn passes through the needles and gets a way.

 Tensioner rollers:

These rollers give tension to the yarn. One is stationary roller, and one roller moves up and down
to increase or decrease the tension according to the requirement.

 Needle guide plate 2:

This plate works just like the first one. It gives tension and gives a separate path to the yarns.

 Oiler roller:

Oiler roller is used for some specific yarns. When yarn passes through this portion, roller rotates,
and transfers oil to the yarn equally.

 Yarn adjustable needle bar plate:

To adjust yarn tension, yarn adjustable needle bar plate is used, this bar uniformly provide
tension to the yarns.

 Yarn adjustable plate:

This plate adjusts yarn tension and provides uniformity. This uniformity helps to keep yarn in
their place.

 Main motor:

Main motor provides motion to the complete machine. All the parts, including beam and other
motors get motion from Main motor. It is located at the right side of the machine.

 Piston Portion:

Piston portion is located on the left side of the machine. It moves the oiler roller.

 Beam:

Beam is in the center of Main Motor, and Piston Portion. It is the part, on which yarn is wound.

 Panel:

27
 Panel of the warping machine includes the control buttons, to control all the functions of
machine. It basically helps to move motors, rollers and adjusts tension. In short, all the operations are
selected manually through control panel.

WORKING PRINCIPLE:

The required numbers of yarns are wound as parallel sheet of warp on a flanged beam under uniform
tension for supplying of yarn in the knitting zone at a 1constant rate and tension. The warp beams
knitting are similar to the beams used in weaving but the technique of preparation may differ. There is
no need of sizing but application of certain amount of oil/wax on warp may improve the knitting
performance. Both sectional warping and direct warping are applicable depending upon nature of warp
to be produced. Utmost care should be taken particularly for staple yarns so that variation of yarn
diameter and presence of defects such as slubs, knots etc. shall be minimum in the final beam. Content
of yarn in the beam depends on the fineness and density of yarn and flange diameter. The beam width
(flange to flange) is generally equal to the width of needle bar. However, for easy manipulation of the
beams, particularly in wider machines, two or more sections of beams are used instead of one wider
beam. The number of full width beams in the machine is equal to the number of guide bars. The beams
are situated at the top of the back side of the machine.

Figure 1 Warp beam used in the warp knitting

PROCEDURE:

 Visit the lab with the teacher

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  Check all the parts of the warping machine
 Parts included creel stand, Tensioner plate, Close guide, side close guide assembly, Close guide
plate, Needle guide plate, Tensioner rollers, Oil roller, Yarn adjustable needle bar plate, beam,
panel, etc
 Learn the purpose of warping
 Learn the yarn passage of machine
 Run the machine
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Creel Stand

2 Tensioner plate

3 Tensioner rollers

4 Yarn adjustable plate

5 Beam

QUESTION 1: What is the purpose of warping?

QUESTION 2: Is there any effect of beam size on the working if machine?

QUESTION 3: What is the purpose of tension plates on the creel?

QUESTION 4: How warping machine get the drive?

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QUESTION 5: How yarn length is monitor on the beam?

QUESTION 6: Major calculations of warping

EXPERIMENT-7

To Study the parts and functions of tricot warp knitting machine

OBJECTIVES:

 Study the different parts of tricots warp knitting machine

 Study the working of parts during fabric production
 Yarn passage through different parts
THEORY:

Warp knitting is defined as a loop forming process in which yarn is fed into knitting zone, parallel to
fabric selvedge. In warp knitting, fabric is made by forming loops from yarns coming in parallel sheet
form run in the direction of fabric formation. (Warp beams like in weaving) So that warping process is
essential for warp knitting. Every needle is fed by a separate yarn for loop formation. To connect the
loops into a fabric, the yarns are shifted between the needles. All the yarns will be knitted in course

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simultaneously. For the purpose of shifting yarn, guide will be used. Warp knitting machines are flat and
comparatively more complicated than weft knitting machines.

Types of Warp Knitting machines

1. Tricot machine
2. Raschel machine
Features of tricot warp knitting machine:

1. Initially only bearded needles were used

2. Fine filaments are knitted
3. Machine gauge up to 24 to 40 (here gauge is number of needles per inch)
4. Fabric is pulled at right angle to needle.
5. Sinker controlled fabric throughout the knitting cycle.
6. Low fabric takes down tension.
7. Number of guide bars usually not more than four.
8. Machines are wider and comparatively simple structures are produced
9. Warp beams are positioned at the back side of the machine
Knitting Mechanism of tricot warp knitting machine

Figure 1 Knitting Mechanism of tricot warp knitting machine

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Parts of Tricot Warp knitting machine

Beard needle:

In tricot warp knitting machine beard needle is used. To form loop and produce the fabric is the main
function of the needle.

Figure 2 Beard Needle

Needle bar:

A needle bar is used in this machine. The main function of it is to hold the needles together and helps the
needles to move unison while loop forming.

Figure 3 Needle bar

Guide bar:

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Guide bar is used in this machine to guide the yarn properly to the needle. It feeds the yarn around the
needle and controls the rate of warp feed from the warp beam by making lapping movement.

Figure 4 Yarn Guides

Sinker and Sinker bar:

In the tricot warp knitting machine tricot sinker is used to hold down the loops produced by the needles.
The sinker bar keeps the sinkers together to move unison while knitting. The main function of the sinker
is to hold down, knock over and supporting the fabric loops.

Figure 5 Sinkers

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Cloth roller:

The produced fabric is wound on the cloth roller.

Figure 6 Cloth roller

Let-off mechanism:

The process of releasing the warp yarns according to the requirement of the machine and speed of cloth
roller is the main function of let-off mechanism.

Figure 7 Beams

Take up mechanism:

It helps the produced fabric to wound on the cloth roller in proper tension. There are 3 take-up r/r in this
machine. It also gives proper tension to the warp sheet and controls the speed of warp beam.

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 Figure 8 Take up rollers

Pattern chain:

The pattern chain is the chain of links joined with each other. The pattern chain helps the machine to
produce design.

Figure 9 Pattern chain

Pattern drum:

It is a drum, which gives motion to the pattern chain. There are groove on it and the pattern chain is
placed on it. It gets motion from the machine driving motor through gearing.

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 Figure 10 Pattern drum

Main shaft:

The main shaft of this machine gives the machine motion from the motor.

PROCEDURE:

 Firstly, all safety measures should be completed.

 Basic instructions received from tutor.
 Theoretical background and applications of warp knitted fabrics should be studied.
 Basic mechanism of warp knitting machines should be studies
 Do discussion
 Draw conclusion
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Drive of beams

2 Drive of Sinkers bar

3 Drive of needle bar

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4 Drive of guide bar

5 Drive of Pattern wheel

QUESTION 1: How pattern wheel works?

QUESTION 2: How to change design in the warp knitting machine?

QUESTION 3: What is the major difference between tricot and Rachel warp knitting machine?

QUESTION 4: What is difference between mechanical and electrically control tricot machine?

QUESTION 5: What is the difference between a, b, c and d link type?

EXPERIMENT-8

Check and analyze the take-up & let-off mechanism of tricot Warp Knitting machine

OBJECTIVES:

 To check the take up and let off mechanism of warp knitting machine
 To analyze the how to change the Run-in of machine
 To study the feed System of warp knitting machine
THEORY:

Plain warp knitted fabric is not symmetrical on both sides. This two-guide bar structure illustrates the
side of the fabric facing the knitter. This side shown is called the “technical back” and can be recognized
by the underlaps floating on the surface. When dealing with a fabric made of several sets of ends, fed
from different warps, there are several layers of underlaps. The length of the underlap also influences the

37
fabric weight. When knitting with a longer underlap, more yarn must be supplied to the knitting needles.
The underlap crosses and covers more Wales on its way, with the result that the fabric becomes heavier,
thicker, and denser.

The shog movements determine the type of fabric produced and they need to be changed each time the
fabric structure is modified. Crucially the shog movements must place the guides at the center of the gap
between adjacent needles with 100% accuracy every knitting cycle for the entire lifetime of the machine.
If there was a failure in the shog displacement and the needle bar moved by less than a full needle pitch,
then the yarn guides would collide with the needles during the swing movement causing serious damage
to the machine.

RUN-IN

The yarn consumption during 480 knitted courses is called Run-in.

A longer run-in produces bigger stitches and a generally slacker, looser fabric. A shorter run-in produces
smaller and tighter stitches. With more than one guide bar the ratio of the amount of yarn fed from each
warp is termed the run-in ratio

Loop length is equally as important in warp knitting as in weft knitting. In the form of run-in, it is
determined by the warp let-off which is either negative or positive.

NEGATIVE LET-OFF

In negative let-off tension on the warp causes it to be pulled from the warp beam as it turns against a
controlled friction. The mechanism is self-compensating, releasing warp on demand. An overall increase
of run-in is obtained by increasing the speed of the fabric take-up rollers, which increases the tension.

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 Figure 2 Negative let-off

POSITIVE LET-OFF

The warp beams are positively driven to deliver a predetermined run-in. The surface speed is monitored
so that, as the beam circumference decreases, the beam drive speed is increased to maintain a uniform
rate of let-off. The arrangement must also be capable of catering for fluctuating let-off requirements in
patterned fabrics.

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 Figure 3 Positive Let-off

PROCEDURE
 Firstly, all safety measures were completed.
 Basic instructions were received from tutor.
 Theoretical background and applications of warp knitted fabrics were studied.
 Basic mechanism of warp knitting machines was studies
 Pictures of different parts of machines were taken and collected.
 Other related observations were collected.
 Discussion was done.
 Conclusion was drawn.
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Machine Specs
2 Main shaft drive mechanism

40
3 Effect of guage of fabric
4 Effect of larger underlap on
fabric
QUESTION 1: How to increase GSM of fabric

QUESTION 2: How to change Stitch length of fabric

QUESTION 3: How to Change let off speed of machine

QUESTION 4: How to change take up speed of machine

QUESTION 5: What will happen if let off speed is more than take up speed

EXPERIMENT-09

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 To Study and identify different parts of single cylinder socks knitting machine.

OBJECTIVES:

 To Study about the sensors placed on the socks knitting machine and their working principle
 To study about the needles and Sinker’s arrangement on the socks knitting machine
 To observe dial and its parts of socks knitting machine
THEORY:

Socks is type of cloth manufactured by the knitting technique, it covers the foot and leg complete or
partial. There are many types of socks used for casual, sports and medical purposes. Socks make your
foot comfortable and warm. Socks are available in various colors, sizes, and materials. Raw Material is
very important quality and performance factor in Socks. when choosing, buying, and manufacturing the
socks the two parameters are kept in mind 1. health conditions and 2. allergies problems of user because
e.g., some fibers are beneficent for patients (diabetic) and some may cause the allergy problem, some
fibers give benefit for a particular time periods and beyond that will cause health problems. One thing
should be kept in mind when selecting material and designing sock’s structure is that the blood
circulation does not affect or resisted. Weather and the season conditions are also under consideration
when buying or manufacturing socks. The socks outlook is also an important part of sock selection
because the overall appearance of socks makes comfortable to the user.

Figure 1 Socks knitting machine

WORKING PRINCIPLE:

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Sock knitting machines are highly specialized circular knitting machines specific to the products made
on them. These machines can use any type of yarn or fiber to produce hosiery and socks made to shape,
size, and performance criteria. The principles of circular knitting are the same whether the yarn supply,
or creel, is at the side or top. Fed from above the knitting elements, yarns move from the creel through
guides to stop-motion controls above the machine, then back down through tension controls and yarn-
feeding devices to the knitting elements. High-quality products can be produced only when stop-motion
and yarn-feeding functions are set properly. The intricate action of knitting where needles form loops
occur at the middle of the machine, between the take-up and the yarn-feeding mechanism. In circular
weft knitting, needles knit one after the other in sequence, and loops are formed horizontally by needles
knitting around the cylinder, forming a tube.

MACHINE PARTS:

 Dial head:
It is very important part of machine. Dial circulates only when tie down knitting is required. Its speed
mostly matches with the speed of cylinder. Dial has its own motor, which can be used to perform
different mechanical operations.

Dial head have following parts:

I. Cutter
II. Vacuum pipe
III. Transfer jack
IV. clean knife
V. elastic trap
 Needle:
It is the element used in the designing of fabric. Needle is a tiny hook element used for loop formation.
For knitting three types of needles are used i.e., small, medium and long butt needles

 Cams:
Most of design is controlled by the cams. Functions of cam are

 To produce motion to needles

 To drive the needles
 Formation of loop

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  Cam Box:
This box is used for arrangement of cams according to the design.

 Machine Stand:
The stand which is used to load yarn is called machine stand. Yarn cones are kept on this stand.

 Yarn Tension Assembly:

It makes the proper tension on yarn.

 BTSR Sensor:
Whenever yarn breaks during feeding BTSR indicates on the screen.

 Finger:
Yarn is feed to needles through fingers. When finger is down yarn is being fed and viceversa.

 Terry Lever:
These are used to make terry inside the sock.

 Latch Needle Stop:

It detects latch problem of the needle, and an error message is displayed in the screen.

 Needle Butt Stop:

Whenever butt of the needle is broken needle butt stop detects it and an error message is displayed on
the screen.

 Dial Head:
It contains many parts on it such as elastic trap, clean knife, suction hood, suction pipe, cutter etc and
inside dial jacks.

 Transfer jack:
This part is used for the welt formation.

 Pattern Jack:
These are used to make designs.

 Medium Jack:
These Exist on upper side of pattern jack and help needle to move up and down.

 Pattern Drum:
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Selection drum lifts pattern jacks, which lift medium jack and medium jack lift needles.

 Elastic Motor:
To feed elastic yarn.

 Cylinder:
Main body in which sock is knitted. width of sock is according to its cylinder dia.

 Ejection Box:
Socks comes out of the machine through ejection box.

 Pressure Gauge:
It measures pressure being fed to the machine. (6.5 Bar)

 Motor:
Used to provide drives to cylinder and dial.

 Cutter:
Cutter is used to cut extra thread.

 Air Compressor:
Its sucks the socks and avoid the accumulation of socks in the machine.

YARN PASSAGE:

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PROCEDURE:

 Visit the lab with the teacher

 Observed all parts of machine
 Manually check the working of machine
 Note down all details
 Run the machine and make a pair of socks and again check the working of machine
 Take photo and draw conclusion
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Machine specs

2 Working principle
of BTSR sensor

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3 Air pressure
required
4 Welt formation

5 Working of terry
lever
6 Working of sinker

QUESTION 1: How to change stitch length of socks?

QUESTION 2: what happened if air pressure is less than 6.5 bar”?

QUESTION 3: What is the purpose of Elastic trapper and cutter?

QUESTION 4: How elastic yarn fed to the machine?

QUESTION 5: Type of needles butt used and why different type of but used in the machine?

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 EXPERIMENT-10

To Study the working principle of different parts of socks knitting machine

OBJECTIVES:

 To study the working and picker and dropper

 To know about the Cylinder/Main drive mechanism from main motor
 To study about the main motor and drive to different parts from main motor
 To study about the elastane yarn tensioning control motor and its principal
THEORY:

Sock knitting machines are highly specialized circular knitting machines specific to the products made
on them. These machines can use any type of yarn or fiber to produce hosiery and socks made to shape,
size, and performance criteria Socks knitting machine is fully computerized. Design was feed into the
machine, and it work automatically. Heel and Toe Makeup Assembly: This part works when during
formation of Real or Y heel. It contains heel and toe take up wires which move during heel formation.
Reciprocal movement of cylinder is observed during heel formation.

Figure 1 Heel and toe makeup assembly

GENERAL PRODUCTION CAPACITY OF SOCKS MACHINE:

 Single or double welt with 1 or 2 feeds with possibility of having elastic on each course or on
alternate courses.
 Socks and pantyhose produced on 4 feeds with reciprocated heel and toe or pouch heel or tubular
in plain fabric normal or sandwich terry (half terry or all terry cloth).
 Possibility of plating on all feeds 2 color striping + ground color on the two feeds.

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  Socks produced with alternate course elastic.
 4 color patterns plus ground yarn on the same course. Possibility of 1 2 color + 3 ground color
patterning.
 3 color patterns on a single feed mesh and on background with elastic.
 Normal and sandwich terry cloth produced with the same sinker cap.
 Pattern facility with tucked stitch fabric on four feeds.
 Possibility of variable increase of the elastic motor on each course.
 Possibility upon request Sole reinforcement on the 4 feeds.
 180° reversed toe, right and left socks, 2-color heel, and toe.

CAMS USED IN SOCKS MACHINE:

 Tucking cam:
Socks knitting machine have four tucking cams. This cams is used to take the needle at tucking height
position to ensure that the level of yarn is to equal to needle latch.

This cam is also used for joining purpose.

 Clearing cams:
There are four clearing cams. These cams are used to take needle at knitting height. In this case yarn
runs under the latch.

 Stitch cam:
There are four stitch cams and one heel and toe cam in socks knitting machine. This cam is used for
stitching purpose. Stitch cam for heel and toe works at two positions (half and full) while other four
stitch cams work at three positions i.e., half+ full.

 Fixed cams:
This cam takes full needle at full/inactive position which are formerly picked by picker.

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 Figure 4 fixed cams with picker and droper

 Combination cams 1:
There are more than one cams in cam profile and perform multifunction, called combination cams which
can be lowering needle exit heel and toe: This cam brings large butt needles at inactive position which
were in active position during making of heel. In short, this cam is used to exit heel and toe knitting
positions.

Figure 5 lowering needle heel and toe

 Raiser needles inter heel:

This cam is used to take large butt needles at inactive position during knitting of real and y heel.

 Central cam:
This cam helps to clear needle of stitch cam feed #1so that they can pass through profile.

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 Figure 6 center cam

 Combination cam 2
Lowering needle color cam 1, 2,3: This cam is being used to bring design needle at lowering position so
that they can’t take any yarn of any other type & Raising medium jack- color 1and 2: It picks the
medium jack for design purpose and works to clear the needles.

PROCEDURE:

 Visit the lab with the teacher

 Observe the working of all parts of socks machine
 Develop a sock on machine and check the working of parts
 Note down all details
OBSERVATIONS:

SR# OBSERVATIONS REMARKS

1 Working of picker and droper

2 Making of heel

3 Making of welt

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4 Making of toe

5 Drive of machine

6 Working of sensors on placed

on machine

Draw the drive diagram of socks machine

QUESTION 1: What is the working principle of picker and dropper?

QUESTION 2: How welt is made on the machine?

QUESTION 3: Why elastic yarn is used as in inlay in socks?

QUESTION 4: What is difference between 4 feed and single feed machines?

QUESTION 5: What is the working principle of elastic motor?

QUESTION 6: Why reciprocating motion is necessary during heel and toe formation?

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 -EXPERIMENT-11

Open Ended Lab

OBJECTIVES:

THEORY:

WORKING PRINCIPLE:

OBSERVATIONS:

QUESTIONS?

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 EXPERIMENT-12

Open Ended Lab

OBJECTIVES:

THEORY:

WORKING PRINCIPLE:

OBSERVATIONS:

QUESTIONS?

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