VASANT R KOTHARI has done Masters in Textiles Technology from DKTEs Textile and Engineering Institute, Ichalkaranji (Shivaji

University, Kolhapur), Maharashtra. He has also done Diploma in Export Management (Apparel Export) from the Indian Institute of Export Management, and Garment Export and Merchandising Management from NIFT, Bangalore. Presently, hes working as an Assistant Professor in Department of Fashion Technology, NIFT, Bangalore. (This is his eleventh input from the series of articles in Knitting Views)

lat knitting machines, also referred to as Flatbeds or V-beds, have two rib gated, diagonally-approaching needle beds, set at between 90 and 104 degrees to each other and are positioned so that the upper ends form an inverted V. The interactions between the yarn and the knitting elements that create the fabric occur at the apex of the V and the fabric moves away downward between the two beds, drawn down by the takedown system.

This knitting machine stitch potential includes needle selection on one or both beds, racked stitches, needle-out designs, striping, tubular knitting, changes of knitting width, and loop transfer. Further, a wide range of yarn counts may be knitted for each machine gauge, including a number of ends of yarn at each knitting system; the stitch length range is also wide; and there is the possibility of changing the machine gauge. The modern V-bed knitting machine is a highly engineered, fully automated,

electronically controlled, precision knitting system. The operation and supervision of the machines of the simpler type are also less arduous than for other weft knitting machines. The number of garments or panels knitted across the machine depends upon the knitting width, yarn carrier arrangement, yarn path and yarn package accommodation. (The machine shown in fig. 11.2 is a member of the Stoll CMS family of machines. The knitting needles, beds and other active elements are enclosed within sliding covers to reduce noise and fibre contamination and to enhance safety.)

V-bed knitting machine

A solidly built machine frame supports the two rigid needle beds. Needles slide up and down the beds in slots known as tricks, cut into rigid needle beds, which maintain the orientation and spacing of the needles and support them when they impact with the CAM system. The tricks in the opposing beds are arranged so that the needles can pass between each other

Fig 11.1: Needles in V-bed

The flat knit machines are the most versatile of the weft knitting machines.

Fig 11.2: V-bed machine

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Yarn take-back spring Yarn guides

Equally, production statistics can be collected centrally.

Yarn feeder Bow

Yarn

Knitting action of flat knitting machine

Carriage

Brushes

Fig 11.6: Carriage movement and its influence on knitting needle

Needle bed Fabric take-down roller Control unit

The needle then tracks through the CAM system as shown by the blue line in the following diagram
Lowering cam (Stitch cam)

Yarn carrier

Fig 11.3: Line diagram of V-bed knitting machine

during loop formation. This arrangement of the beds is called rib gaiting.

Guiding cam High butt needle Low butt needle

The raising CAM is in half position

Fig 11.7: CAM plate and knitting carriage

Fig 11.4: Rib gaiting

The front edge of the needle bed also acts as a knock-over support by helping to maintain the position of the fabric during knock-over.

The yarn supply is situated above the machine and the yarn is fed to the needles via yarn feeders that culminates in a tube or bore to precisely position the yarn. The feeder is fixed to a feeder block that slides along a feeder rail located above the needle bed. Modern machines typically have four feeder rails with 4/6 knitting feeders/rail. The feeder precedes the needle movement across the bed in such a way that the yarn is placed across the open latch of the needle during the clearing displacement so that when the needle retracts and the latch closes the yarn is trapped in the hook. On the most basic V-bed machines a roller traction system pulls the fabric down between the needle beds to provide the take-down tension necessary to maintain the position of the old loop against the verge of the needle bed during the clearing displacement. The modern flat knit machine also has its own on-board control and programming computer and the LCD monitor display built into the sliding machine covers. Normally, in a production environment these machines can be networked and knitting programmes can be downloaded from the CAD/programming stations directly to the machine's computer.

Fig 11.8: Knitting action of flat knitting machines

Fig 11.5: Needles in tricks

The two CAM systems are contained within the carriage. The carriage or CAM box traverses across the needle beds and selects needles to be knitted as it reciprocates side to side. The carriage effectively raises and lowers the needles on both beds simultaneously as it passes over them, depending on the desired pattern. Needle bed lengths can vary from 1.0 m to 2.2 m width and each is designed for a specific task or purpose.

1 The rest position: The tops of the heads of the needles are level with the edge of the knock-over bits. 2 Clearing: The needle butts are lifted as to raise the needles to tucking in the hook height. 3 Yarn feeding: The yarn is fed as the needles descend under the control of guard cam. The required loop length is drawn by each needle as it descends the stitch CAM. 4 Knocking-over: To produce synchronised knocking-over of both needle beds simultaneously, the stitch CAM in the front system is set lower than the auxiliary stitch CAM, so that the latter is rendered ineffective. 5 Delayed timing: If, however, delayed timing of the knock-over is employed, knock-over in the front bed will occur after knock-over in the back bed. Delayed timing is only normally used ongauges finer than 8 NPI and cannot be used for broad ribs
(In the next session, we would be discussing about circular knitting machines.)
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