A Mechatronic

Design of a Circular
Warp Knitting
Machine 5.1 5.4
Markus Landwehr
Jan Deforth
Michael McCluskey

Mechatronic system (MS) investigated

A circular warp knitting machine.
A prototype industrial machine for producing warp knitted
fabrics.
Warp = type of knitting pattern
Differs from weft kitting, which is more common.
Hard to understand without background knowledge.
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a) Weft Knitted Fabric vs.

b) Warp Knitted Fabric
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Comparison of kitting machines

5
11

Example of modern circular

bed weft knitting machine

Example of modern flat bed

warp knitting machine

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Warp knitting process

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Warp Knitting Cycle

1. Threads are swung from
the back to the front of the
needles
2. Overlap stage: sideways
shog
3. Threads are swung to the
back of the needle
4. Needles start to move
downwards
5. Underlap stage (shogging)
6. Needles rise again

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Advantages of warp knitted fabrics over

weft knitted fabrics
Better and more customisable multi dimension performance
than weft knitting.
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They do not ravel (unravel) easily

Less prone to sagging and stretching
Wide variety of fabrics (knitting pattern and material type)

Low stress rate on the yarn can be used for glass, carbon
and aramide fibres.
Greater variety of applications
Faster, cheaper and more productive than weaving (which is
different to knitting)
10

10

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Source: Machine Kitting Advice, 2012.

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Problems
What was the state-of-the-art before mechatronic systems
described were used?
Flat-bed machines5

Mechanical solutions6,7

What was the problem solved?

Complex configuration of circular warp knitting machines
Swinging motion totally novel approach is required
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Problems solved
Solution: Mechatronic approach
Slotted truncated-cone needlebed
Servo motors to control the rings

Patterning ring and needles on

truncated-cone needle-bed1

How the MS improved the state-ofthe-art?

Increases speed at which a stitch
is produced
Simplifies the movement of the
yarns
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V-model Part 1
Requirements: Synchronized
motions of a number of different
machine functions
System design: swinging motion
of the ring; reciprocating motion
of the needles
Domain-specific design:
Drives, actuators, software and
controls

VDI 2206; Design methodology for mechatronic systems; June 2004

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V-model Part 2

System integration:
Synchronization of the whole system
Assurance of properties: Actual
properties = desired system
properties?
Modeling and model analysis:
investigating of the system properties
with the aid of models and computeraided tools for simulation
Product: Circular Warp Knitting
Machine

VDI 2206; Design methodology for mechatronic systems; June 2004

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What was the scientific challenge?

2

1. In Circular machines
swinging movement is not possible

slotted truncated-cone needle-bed

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What was the scientific challenge?

2

2. Motions of machine functions

Vertical reciprocating needle motion
cam and follower mechanism

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Shogging motion
rotation of rings
Synchronisation of both movements with pattern chain
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Application related
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13

17

14

18
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What was the industrial challenge?

The textbook did not adequately explain the need for a new system.
Faster more flexible knitting machines

How to realize different knitting patterns in one machine?

Direction and amplitude of the rotation
Overlap just over one needle
Underlap over any number of needles

Following Group will explain more about patterning

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Discussion
What do you think about MS investigated?

Mechatronic system that we hadnt previously considered

Maybe more a mechanical than mechatronic solution

(key innovation is the angled needle position)

What do you think about scientific article?

More in depth than the textbook, well written and very

understandable despite the technical vocabulary

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Discussion
What do you think about application?

The applications of warp knitting are in everyday use and life could not
be imagined without

What do you think about its disruptive influence?

Made the already existing process a lot faster and facilitates seamless
warp knitted garments

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Discussion
What do you think about usefulness of this exercise?
It helped us understand a mechatronic system we hadnt considered.
Where else could mechatronics approach be applied?

What do you think about usefulness of this course?

Its good that every student has to figure the function of a mechatronic
device out and get background knowledge on it
Students could benefit from more problem solving, analysis, creativity
etc.

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Reflection
Group:
Divided tasks and complement each others work
Get together to discuss the chapter and each others work
Excercise:
New topic: machines in the textile industry
A lot of new vocabulary
Excercise was insightful and detailed

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Thank you
for your attention!
Any Questions?

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References

1Bradley,

D.; Russell, D.W.: Mechatronics in Action, Case Studies in Mechatronics

Applications and Education, Springer, 2010
2Mermelstein, S.P.; Hale, D.; Acar, M.; Jackson, M.R.; Roberts, K.: Patterning servomechanism for a circular warp knitting machine, Mechatronics, Vol. 11, p. 617-630,
2001
3Mermelstein, S.P.; Acar, M.; Modelling the pattern creation process for the optimum
design of a circular warp-knitting machine using a conical needle-bed, Mechatronics,
Vol. 98, p. 397-407, 2007
4VDI 2206; Design methodology for mechatronic systems; June 2004
5http://www.jwgf.com/jingweiHTML/changde_En/Product/KnittingMachinery/TowelWarp
KnittingMachine/201011/t20101109_981.htm
6R.E. Merrit et al; Circular Warp Knitting Machine, Patent 1970
7W.A. Lawrence, Circular Warp Knitting Machine, Patent 1911
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References

8http://www.threadsmagazine.com/item/4160/know-your-knits/page/all
9https://www.youtube.com/watch?v=et7IWm8ITMA
10Machine

Knitting Advice. (2012) Weft and Warp Knitting Differences [Online]. Available
from: http://machineknittingadvice.com/weft-and-warp-knitting-differences/. [Accessed:
20th October 2015].
11http://de.slideshare.net/shawanroy/final1-32886699
12https://grabcad.com/library/cam-follower-mechanism-spring
13http://www.yasaka.se/products/tracksuit-orion/
14http://www.globalsources.com/gsol/I/Reflective-safety/p/sm/1051814864.htm
15http://www.catch22products.co.uk/Pyramid-compact-mosquito-net.htm
16http://shopping.indiatimes.com/
17http://www.bmfautoparts.com/Car-Seat-Covers/Accessories.aspx
18http://www.helmetboys.com/products/MGP-Motorcycle-Helmet-Glossy-Black.html

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Appendix

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More warp knitting patterns

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Comparison with weaving

Warp knitted stitches are linked

vertically (and sometimes
horizontally).

Weft knitted stitches are linked

horizontally only.

Both types of knitting differ from

weaving (shown on the right).

Weaving helps illustrate the

distinction between the words
warp and weft.
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Mechanical solution

Two patterning rings controlled by open face cams

Maximum pattern length of 12 machine cycles
Cam with cycloidal profiles for each segment
Mechanical system converts a translational motion
created by the patterning cam into a rotation of the
patterning ring by means of a number of pivots and
mechanical linkages.
-> a design that allowed for more patterning flexibility
and ultimately higher operational speeds was
required

MERM01_Pattering_servo-mechanism_for_a_circular_warp_knitting_machine

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Opponent work (questions)

GYROBO

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Opponent work (questions)

5.5 5.7

What are the advantages and disadvantages of using servo motors?

How was the yarn feed mechanism realised?
Why is the contruction of the machine like a cone and not like a cylinder? (question for us) -> the
patents I found used a cylindrical shape (see pictures) -> answer in 5.6.3?
Which servo-motor angular velocity profile (triangular or trapezoidal) is better for a circular
knitting machine and why?
The power used to perform the move must be minimised -> Which profile needs more power
and where can you see it?
Were you satisfied with the books explanation of the mechatronic design process. We werent.
Maybe they just made a machine then claimed to use a mechatronic design process.
How does the number of patterning rings influence the patterning variety? Why?
Did you think that this was actually innovative?
Was there a need?

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