Dec 07, 2023
Circular knitting machines, commonly used for textile production, may encounter various issues during operation. Proper adjustment and maintenance are essential to ensure smooth and efficient knitting processes. Here is a comprehensive guide to troubleshooting and addressing common problems with circular knitting machines:
Horizontal Stripes:
Uneven horizontal stripes caused by inconsistent tension can be resolved by using a tension gauge to measure and adjust tension evenly.
If tension fluctuations are significant, inspect the needle cylinder, needle ring, and needle plate for horizontal and concentric alignment.
Check for damaged calibration dial blocks, aging rubber rings, correct yarn wheel placement, and ensure normal yarn passage through the yarn guide.
Verify the uniformity of yarn dryness, consistent yarn sizes, and avoid mixing waxed and non-waxed yarn or different layers of yarn.
Fabric Slippage:
Excessive tension leading to yarn breakage and fabric slippage can be resolved by adjusting tension to meet yarn requirements.
Address fabric slippage caused by incorrect yarn guide positioning or excessive height by adjusting the yarn guide.
High yarn twist causing knots and fabric slippage can be prevented by adjusting the copper tube in the foot area.
Machine malfunctions affecting fabric placement may require electrical repairs to the computerized system or cleaning of sensors.
Fabric slippage due to the inability to cut yarn should prompt repositioning of the yarn shovels and blade replacement.
Fabric Holes:
Fabric holes attributed to yarn tension may be mitigated by changing the yarn or advising production to wax, flip, or loosen the yarn.
Adjust tension to prevent fabric holes caused by excessive or insufficient tension.
Reduce fabric holes by minimizing the pulling force, especially for specialty fabrics. Adjust tension and needle positions accordingly.
Investigate and adjust the needle groove, yarn guide, and needle position to prevent fabric holes.
For unique fabric types, address fabric holes by notifying production to adjust yarn length.
If holes persist on a specific needle, replace the defective needle.
Consistent holes in the same pattern may indicate a faulty tensioner; repair or replace as necessary.
Misalignment of Patterns:
For manual pattern adjustments, ensure correct needle and yarn sequence, color, and yarn type.
In automatic pattern selection, misalignment may result from incorrect sensor positioning, malfunctioning selectors, or faulty electronics. Adjust or repair accordingly.
Automatic double-sided patterning issues can be caused by misaligned sensors or malfunctioning pattern selectors. Clean or adjust selectors to resolve misalignment.
Tension-related pattern misalignment can be corrected by notifying technicians to adjust tension.
Needle Issues:
For straight needle issues, check for misaligned needle tongues and needle bar collisions.
Verify the correct needle angle and adjust if necessary.
Adjust tension if fabric length is too long and needles fail to withdraw properly.
Fine-tune the position of needle tongues, needle cylinders, and needle plates.
Adjust the tightness of needle tongues.
Improve yarn surface smoothness through waxing to prevent needle issues.
Dropped Stitches:
Replace faulty needles causing dropped stitches.
Adjust the distance, height, and lateral position of the yarn guide relative to the needles.
Fine-tune yarn tension.
Adjust pulling force.
Oil and Grease Issues:
Adjust the machine's oil supply and clean waste oil pipes regularly.
Inspect and replace damaged cushioning pads under the calibration dial.
Clean needle cylinders and needle plates when dirt and rust are present.
In summary, maintaining and troubleshooting circular knitting machines requires a combination of mechanical adjustments, regular cleaning, and careful attention to yarn and tension details. By addressing these issues systematically, textile manufacturers can enhance the efficiency and quality of their knitting processes.
Horizontal Stripes:
Uneven horizontal stripes caused by inconsistent tension can be resolved by using a tension gauge to measure and adjust tension evenly.
If tension fluctuations are significant, inspect the needle cylinder, needle ring, and needle plate for horizontal and concentric alignment.
Check for damaged calibration dial blocks, aging rubber rings, correct yarn wheel placement, and ensure normal yarn passage through the yarn guide.
Verify the uniformity of yarn dryness, consistent yarn sizes, and avoid mixing waxed and non-waxed yarn or different layers of yarn.
Fabric Slippage:
Excessive tension leading to yarn breakage and fabric slippage can be resolved by adjusting tension to meet yarn requirements.
Address fabric slippage caused by incorrect yarn guide positioning or excessive height by adjusting the yarn guide.
High yarn twist causing knots and fabric slippage can be prevented by adjusting the copper tube in the foot area.
Machine malfunctions affecting fabric placement may require electrical repairs to the computerized system or cleaning of sensors.
Fabric slippage due to the inability to cut yarn should prompt repositioning of the yarn shovels and blade replacement.
Fabric Holes:
Fabric holes attributed to yarn tension may be mitigated by changing the yarn or advising production to wax, flip, or loosen the yarn.
Adjust tension to prevent fabric holes caused by excessive or insufficient tension.
Reduce fabric holes by minimizing the pulling force, especially for specialty fabrics. Adjust tension and needle positions accordingly.
Investigate and adjust the needle groove, yarn guide, and needle position to prevent fabric holes.
For unique fabric types, address fabric holes by notifying production to adjust yarn length.
If holes persist on a specific needle, replace the defective needle.
Consistent holes in the same pattern may indicate a faulty tensioner; repair or replace as necessary.
Misalignment of Patterns:
For manual pattern adjustments, ensure correct needle and yarn sequence, color, and yarn type.
In automatic pattern selection, misalignment may result from incorrect sensor positioning, malfunctioning selectors, or faulty electronics. Adjust or repair accordingly.
Automatic double-sided patterning issues can be caused by misaligned sensors or malfunctioning pattern selectors. Clean or adjust selectors to resolve misalignment.
Tension-related pattern misalignment can be corrected by notifying technicians to adjust tension.
Needle Issues:
For straight needle issues, check for misaligned needle tongues and needle bar collisions.
Verify the correct needle angle and adjust if necessary.
Adjust tension if fabric length is too long and needles fail to withdraw properly.
Fine-tune the position of needle tongues, needle cylinders, and needle plates.
Adjust the tightness of needle tongues.
Improve yarn surface smoothness through waxing to prevent needle issues.
Dropped Stitches:
Replace faulty needles causing dropped stitches.
Adjust the distance, height, and lateral position of the yarn guide relative to the needles.
Fine-tune yarn tension.
Adjust pulling force.
Oil and Grease Issues:
Adjust the machine's oil supply and clean waste oil pipes regularly.
Inspect and replace damaged cushioning pads under the calibration dial.
Clean needle cylinders and needle plates when dirt and rust are present.
In summary, maintaining and troubleshooting circular knitting machines requires a combination of mechanical adjustments, regular cleaning, and careful attention to yarn and tension details. By addressing these issues systematically, textile manufacturers can enhance the efficiency and quality of their knitting processes.
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