Guide for Needle Dial Adjustment of Double Jersey Knitting Machine

In the knitting industry, the performance and production quality of double jersey circular knitting machines are greatly affected by the accuracy of the dial clearance. Improper dial clearance will not only lead to machine failure, but also affect the quality and production efficiency of the fabric. Therefore, an in-depth understanding of how to properly adjust the dial clearance and avoid potential problems is the key to ensuring the smooth operation of the knitting machine. The following is a detailed discussion and best practice recommendations for the adjustment of the dial clearance of double-sided circular knitting machines.

The Impact of Inappropriate Dial Clearance on Production

The Consequences of Too Small a Gap

If the dial gap is less than 0.05 mm, significant friction will occur. When the knitting machine is running at high speed, this friction is further aggravated, resulting in rapid wear and heating of parts. Under long-term use, it may not only cause premature damage to parts, but also have a negative impact on the service life of the whole machine. In addition, too small a gap can also affect the flexibility of the needle and hook, increasing the risk of broken needles or stuck threads, resulting in uneven surfaces or weaving defects in the fabric.

The Problem of Too Much Gap

If the dial gap is greater than 0.3 mm, it will cause yarns, especially elastic yarns (such as spandex), to become less fixed in the needle groove. This loose state is easy to cause the yarn to jump out of the needle slot during the knitting process, and the phenomenon of broken needle hooks, especially when weaving the base cloth. This not only affects the strength and uniformity of the fabric, but may also cause holes, fuzz or other weaving defects in the fabric.

The Challenge of Uneven Clearance

If the dial gap is inconsistent in different areas of the same machine, it will lead to uneven contact between the needle and the needle plate during the knitting process, which directly affects the overall appearance and smoothness of the fabric. The fabric may have poor performance, uneven texture, different tensile strength and other problems, which will affect the quality and yield of the fabric. In addition, uneven clearance will cause some needles to bear greater stress, exacerbate local wear, increase maintenance and replacement frequency, and increase production costs.

The Adjustment Method and Structure Analysis of the Dial Gap

Ring Gasket Adjustment Method

Ring gasket adjustment is a common and accurate adjustment method. By adjusting the thickness of the gasket, the operator can achieve fine tuning of the dial clearance. The advantage of this method is that its adjustment accuracy is high, it can maintain the stability during long running, and reduce the weaving defects caused by gap changes. Especially suitable for high-end knitting machines and demanding production environments.

Integrated Structural Adjustment Method

Compared with the ring gasket adjustment method, the integrated structure adjustment method is easier to operate and suitable for rapid adjustment and mass production. However, this method has shortcomings in accuracy and is easily limited by the accuracy of the mechanical structure itself and the durability of the component material, which is easy to lead to uneven clearance after a long time of use. Therefore, in the production of high precision and high quality requirements, fabric defects and other undesirable phenomena may occur.

Suggestions on Dial Gap Adjustment

Regular Inspection and Maintenance

To ensure that the dial clearance remains within the ideal range, a regular inspection schedule should be developed. It is recommended to use a 0.15mm gauge for clearance measurement, which can accurately detect gaps that are too small or too large. Regular inspection can help operators find and solve problems in time to avoid long-term damage to the machine and the reduction of production quality.

Initial Inspection and Commissioning of New Machine

Before the new machine is put into use, it must undergo a thorough first inspection. This includes checking whether the dial clearance meets design standards and testing how it performs in practice. The initial inspection helps to detect deviations or defects that may occur during manufacturing or transportation, ensure optimal machine performance during use, and reduce failures or quality problems caused by improper initial commissioning.

Strengthen the Precision Control of Domestic Equipment

At present, there is still a certain gap in the precision control of domestic knitting machines compared with some imported high-end equipment. Therefore, domestic manufacturers should constantly improve the manufacturing process and material selection, and strive to control the accuracy error within 0.03 mm. This will help to enhance the market competitiveness of domestic equipment and significantly reduce various problems in the production process.

Use Advanced Testing Tools and Techniques

In addition to the traditional gauge detection, advanced tools such as laser rangefinders or optical measuring devices can also be used to detect and adjust the dial gap. These technologies can provide higher detection accuracy and faster detection speed, help operators quickly adjust equipment status, and ensure the stability and consistency of production.

Summary

The precise adjustment of dial clearance is the core factor of efficient operation and high quality production of double-sided knitting machines. By adopting best practices such as ring gasket adjustment, regular inspection and maintenance, initial inspection of new machines, strengthening precision control of domestic equipment and using advanced inspection tools, manufacturers can significantly reduce possible problems in the weaving process and improve production efficiency and product quality.

If you encounter any difficulties during the dial gap adjustment process, or need more technical support and professional advice, please feel free to contact us. Our team will provide you with targeted solutions to help you optimize the condition of your equipment and increase productivity.

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