BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to yarn feeding mechanisms of flat knitting machines,
and specifically relates to how to prevent slack of yarn in a feeding path that supplies
a plurality of yarns to a yarn carrier.
2. Description of the Related Art
[0002] A technique has been known in which a top tension device or a side tension device
is provided in a feeding path through which a yarn fed out from a cone is supplied
to a yarn carrier so as to apply tension to the yarn in order to prevent slack of
yarn in the feeding path (for example, see Patent Literature 1).
[0003] Further, a technique also has been known in which a plurality of yarns are combined
into a folded yarn by a yarn combining device, and the folded yarn is supplied to
the yarn carrier via the feeding path.
[0005] When the folded yarn is supplied to the yarn carrier via the feeding path, the used
amounts of yarns are each different depending on the difference in resistance applied
to each of the yarns or the difference between the inner periphery and the outer periphery
of the stitch formed during knitting. In that case, it has been proposed to provide
a top tension device or a side tension device to increase a tension of the folded
yarn in the feeding path so as to eliminate slack yarn which occurs in the yarns with
a small amount of use.
[0006] However, if the tension of the folded yarn is excessively increased in accordance
with the slack yarn, an adverse effect in knitting may occur in that the yarn which
does not have a slack is easily broken or the stitches are narrowed.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide a yarn feeding mechanism
of a flat knitting machine that ensures prevention of slack of yarn in a feeding path
without excessively increasing tension of a folded yarn.
[0008] In order to achieve the above object, the present invention assumes a yarn feeding
mechanism of a flat knitting machine in which a plurality of yarns are formed into
a folded yarn by a yarn combining device and supplied to a yarn carrier. Further,
a V-groove guide roller having a substantially V-shaped groove is rotatably supported
in the feeding path from the yarn combining device to the yarn carrier. Moreover,
it is characterized in that a rotation shaft of the V-groove guide roller is inclined
relative to a direction perpendicular to the feeding path so that the folded yarn
can be easily rolled from one inclined surface of two inclined surfaces of the groove
to a valley.
[0009] Furthermore, a line tracing a valley of the groove of the V-groove guide roller in
a circumferential direction may form one cycle of a sine curve for one turn of the
V-groove guide roller in an expanded state.
[0010] Furthermore, an active yarn feeder may be disposed in the feeding path so as to actively
feed the folded yarn to the V-groove guide roller depending on the demand.
[0011] Furthermore, an inclined angle changing mechanism may be disposed to change the inclined
angle of the rotation shaft of the V-groove guide roller relative to the direction
perpendicular to the feeding path.
[0012] Further, a downstream-side V-groove guide roller having a substantially V-shaped
groove is rotatably supported in the feeding path at a position close to the yarn
carrier than to the V-groove guide roller. The rotation shaft of the downstream-side
V-groove guide roller may be inclined in the direction opposite to the inclined direction
of the V-groove guide roller with respect to the direction perpendicular to the feeding
path so that the folded yarn rolled by the V-groove guide roller is rolled in the
opposite direction.
[0013] Alternatively, a downstream-side recessed groove guide roller having a recess-shaped
flat groove that is in contact with the folded yarn at the bottom is rotatably supported
in the feeding path at a position close to the yarn carrier than to the V-groove guide
roller. A rotation shaft of the downstream-side recessed groove guide roller may be
perpendicular to the feeding path such that the folded yarn rolled by the V-groove
guide roller is fed out without being twisted while being in contact with the flat
groove.
[0014] Since the rotation shafts of the V-groove guide rollers are inclined in the direction
perpendicular to the feeding path so that the folded yarn from the yarn combining
device is easily rolled from one inclined surface of the groove of the V-groove guide
roller to the valley, the folded yarn is twisted in the feeding path and thus firmly
twisted. Accordingly, it is possible to ensure prevention of slack of yarn in the
feeding path without excessively increasing the tension of the folded yarn.
[0015] Further, since the line tracing a valley of the groove of the V-groove guide roller
in the circumferential direction forms one cycle of a sine curve for one turn of the
V-groove guide roller in an expanded state, the valley of the groove meanderingly
moves between the inclined surfaces during one turn of the V-groove guide roller,
causing the inclined angles of the respective inclined surfaces to vary. Meanwhile,
since the folded yarn rolls only on one inclined surface, the folded yarn is rolled
on the one inclined surface and is twisted when the valley moves to the other inclined
surface with rotation of the V-groove guide rollers and the inclined angle of the
one inclined surface becomes gently inclined. When the valley moves to one inclined
surface and the inclined angle of one inclined surface become steeply inclined, the
folded yarn moves to one inclined surface. However, when the valley move back to the
other inclined surface and the inclined angle of one inclined surface become gently
inclined, the folded yarn is again rolled on the one inclined surface and twisted.
Accordingly, twisting of the folded yarn is facilitated by using only one inclined
surface of the groove of the V-groove guide roller so that the folded yarn can be
smoothly twisted in the feeding path to the yarn carrier.
[0016] Further, since the active yarn feeder is provided so as to actively feed the folded
yarn to the V-groove guide roller depending on the demand, the folded yarn actively
fed can also be rolled from the inclined surface of the groove of the V-groove guide
roller to the valley and can be smoothly twisted in the feeding path.
[0017] Further, since the inclined angle changing mechanism changes the inclined angle of
the rotation shaft of the V-groove guide roller relative to the direction perpendicular
to the feeding path, which of the inclined surfaces of the groove of the V-groove
guide roller is to be used or the degree of twisting of the folded yarn can be changed
depending on the types of the yarns. Accordingly, the degree of twisting of the folded
yarn can be increased or decreased depending on the thickness, the types or the knitting
conditions of the yarns.
[0018] Further, since the rotation shaft of the downstream-side V-groove guide roller located
at a position close to the yarn carrier than to the V-groove guide roller in the feeding
path is inclined in the direction opposite to the inclined direction of the V-groove
guide roller with respect to the direction perpendicular to the feeding path so that
the folded yarn which is rolled and twisted by the V-groove guide roller is rolled
in the opposite direction from one inclined surface to the valley of the groove of
the downstream-side V-groove guide roller, the folded yarn can be further twisted
between both guide rollers and thus firmly twisted, thereby ensuring prevention of
slack of the yarns in the feeding path.
[0019] Moreover, since the rotation shaft of the downstream-side V-groove guide roller is
inclined in the direction opposite to the inclined direction of the V-groove guide
roller with respect to the direction perpendicular to the feeding path, the folded
yarn from the downstream-side V-groove guide roller to the knitting needle can also
be twisted, and accordingly, knitting can be performed by the knitting needle while
the folded yarn is in a twisted state.
[0020] Alternatively, the rotation shaft of the downstream-side recessed groove guide roller
located at a position close to the yarn carrier than to the V-groove guide roller
in the feeding path is perpendicular to the feeding path so that the folded yarn twisted
by the V-groove guide roller is fed out without being twisted while being in contact
with the flat groove of the downstream-side recessed groove guide roller. Accordingly,
the folded yarn can be further twisted between both guide rollers and thus firmly
twisted, thereby ensuring prevention of slack of the yarns in the feeding path.
[0021] Moreover, when the folded yarn twisted by the V-groove guide roller is fed out without
being twisted while being in contact with the flat groove of the downstream-side recessed
groove guide roller, twist of the folded yarn after it is in contact with the flat
groove naturally returns. Accordingly, twist of the folded yarn between the rollers
can be released at a position from the downstream-side recessed groove guide roller
to the knitting needle so that knitting by the knitting needle can be performed in
the state in which twist of the folded yarn is released.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022]
Fig. 1 is a schematic configuration view which schematically shows a configuration
of a yarn feeding mechanism of a flat knitting machine according to an embodiment
of the present invention;
Fig. 2 is a configuration view which shows a detailed configuration of a feeding path;
Fig. 3 is a rear view of the upstream-side guide device seen from a position at which
the yarn carrier is not located;
Fig. 4 is a plan view of the downstream-side guide device seen from above;
Fig. 5 is a front view of the upstream-side and downstream-side V-groove guide rollers
seen in the direction perpendicular to the shafts;
Fig. 6 is a vertical cross sectional front view of the upstream-side and downstream-side
V-groove guide rollers;
Fig. 7 is an explanatory view which explains a twisting direction of the folded yarn
by the upstream-side and downstream-side V-groove guide rollers in the feeding path;
Fig. 8 is an explanatory view which explains the shape of grooves of the upstream-side
and downstream-side V-groove guide rollers in an expanded state; and
Fig. 9 is a schematic configuration view which schematically shows a configuration
of a yarn feeding mechanism of the flat knitting machine according to a modification
example of the present embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] With reference to the drawings, an embodiment of the present invention will be described.
[0024] Fig. 1 is a schematic configuration view which schematically shows a configuration
of a yarn feeding mechanism of a flat knitting machine according to an embodiment
of the present invention; and Fig. 2 is a configuration view which shows a detailed
configuration of a feeding path.
[0025] In Figs. 1 and 2, a flat knitting machine 1 includes a yarn feeding mechanism 2 that
supplies yarns 12A, 12B fed out from two cones 11A, 11B, respectively, to a knitting
needle, which is not shown in the figure. The yarn feeding mechanism 2 includes a
yarn carrier 3 that slides relative to a rail which extends in a direction parallel
to a traveling direction of a carriage, which is not shown in the figure. The yarn
carrier 3 includes a base 31 and a single yarn feeding arm 32 which extends downward
from the base 31. A yarn feeding port 33 is provided on the lower end of the yarn
feeding arm 32.
[0026] Further, the yarn feeding mechanism 2 includes a yarn combining device 21 that combines
two yarns 12A, 12B fed out from the respective corns 11A, 11B into a folded yarn 12,
and upstream-side and downstream-side guide devices 22, 23 that guide the folded yarn
12 from the yarn combining device 21 to the yarn carrier 3. Further, an active yarn
feeder 4 is disposed in the feeding path 20 between the yarn combining device 21 and
the yarn carrier 3 so as to actively feed the folded yarn 12 from the yarn combining
device 21 to the upstream-side guide device 22 depending on the demand. The active
yarn feeder 4 includes a main roller 41 that is rotated by a servo motor 40, and a
driven roller 42 connected to the servo motor 40 via a driven mechanism (not shown
in the figure) to rotate synchronously with the main roller 41. The folded yarn 12
from the yarn combining device 21 is actively fed out while being nipped between the
rollers 41, 42.
[0027] Further, the active yarn feeder 4 includes a side tension device 44. The side tension
device 44 includes a pivotally movable buffer rod 45 biased in a direction which allows
the folded yarn 12 to be withdrawn out of the feeding path 20 (counterclockwise direction
in Fig. 1) so that the biasing force applies tension to the folded yarn 12.
[0028] Fig. 3 is a rear view of the upstream-side guide device seen from a position at which
the yarn carrier 3 is not located, and Fig. 4 is a plan view of the downstream-side
guide device seen from above. As shown in Fig. 3, the upstream-side guide device 22
is disposed between the active yarn feeder 4 and the yarn carrier 3 in the feeding
path 20. The upstream-side guide device 22 includes an L-shaped frame 221 which is
fixed to the housing 2a of the yarn feeding mechanism 2, and an upstream-side V-groove
guide roller 24 (V-groove guide roller) which has a substantially V-shaped groove
241 and is provided with a shaft 242 (rotation shaft) rotatably supported by a support
arm 222 which is supported by the L-shaped frame 221. Further, as shown in Fig. 4,
the downstream-side guide device 23 includes a guide support member 231 which is elongated
in the width direction and is mounted on the yarn feeding arm 32 of the yarn carrier
3, and a downstream-side V-groove guide roller 25 which has a substantially V-shaped
groove 251 and is provided with a shaft 252 (rotation shaft) rotatably supported at
one end of the guide support member 231 in the width direction (right end in Fig.
2).
[0029] Fig. 5 is a front view of the upstream-side and downstream-side V-groove guide rollers
24, 25 seen in the direction perpendicular to the shafts 242, 252, and Fig. 6 is a
vertical cross sectional front view of the upstream-side and downstream-side V-groove
guide rollers 24, 25. As shown in Figs. 5 and 6, the upstream-side V-groove guide
roller 24 includes two inclined surfaces 243A, 243B on each side of the groove 241,
and the downstream-side V-groove guide roller 25 includes two inclined surfaces 253A,
253B on each side of the groove 251.
[0030] As shown in Fig. 3, the shaft 242 of the upstream-side V-groove guide roller 24 is
gently inclined (for example, inclined by approximately 10 degrees) relative to the
substantially horizontal direction (left-right direction in Fig. 3) which is perpendicular
to the folded yarn 12 supplied from the feeding path 20 which extends in the substantially
vertical direction (up-down direction in Fig. 3). Further, as shown in Fig. 4, the
shaft 252 of the downstream-side V-groove guide roller 25 is gently inclined (for
example, inclined by approximately 10 degrees) relative to the direction (up-down
direction in Fig. 4) which is perpendicular to the folded yarn 12 supplied from the
feeding path 20 which extends in the substantially horizontal direction (left-right
direction in Fig. 4). This facilitates rolling of the folded yarn 12 from the inclined
surfaces 243A, 253A, which are one of the inclined surfaces 243A and 243B, 253A and
253B of the grooves 241, 251 of the upstream-side and downstream-side V-groove guide
rollers 24, 25 to the respective valleys.
[0031] Fig. 7 is an explanatory view which explains a twisting direction of the folded yarn
12 by the upstream-side and downstream-side V-groove guide rollers 24, 25 in the feeding
path 20. In Fig. 7, inclination of the shaft 242 of the upstream-side V-groove guide
roller 24 facilitates rolling of the folded yarn 12 from one inclined surface 243A
of the groove 241 to the valley. Accordingly, the folded yarn 12 which is twisted
in clockwise direction (the arrow direction indicated by the one-dotted chain line
in Fig. 7) in the feeding path 20 to the yarn carrier 3 can be firmly twisted, thereby
ensuring prevention of slack of the yarns 12A, 12B in the feeding path 20 without
excessively increasing the tension of the folded yarn 12.
[0032] Further, the shaft 252 of the downstream-side V-groove guide roller 25 is inclined
in the direction opposite to the inclined direction of the upstream-side V-groove
guide roller 24 with respect to the direction perpendicular to the feeding path 20
so that the folded yarn 12 twisted by the upstream-side V-groove guide roller 24 is
rolled in the opposite direction. Accordingly, the folded yarn 12 twisted by the upstream-side
V-groove guide roller 24 is rolled from one inclined surface 253A of the groove 251
of the downstream-side V-groove guide roller 25 to the valley in the opposite direction
so as to be twisted in the counterclockwise direction (the arrow direction indicated
by the two-dotted chain line in Fig. 7) in the feeding path 20. As a result, the folded
yarn 12 can be further twisted between the upstream-side V-groove guide roller 24
and the downstream-side V-groove guide roller 25 so that the folded yarn 12 is firmly
twisted, thereby ensuring prevention of slack of the yarns 12A, 12B in the feeding
path 20.
[0033] Moreover, since the shaft 252 of the downstream-side V-groove guide roller 25 is
inclined in the direction opposite to the inclined direction of the shaft 242 of the
upstream-side V-groove guide roller 24 with respect to the direction perpendicular
to the feeding path 20, the folded yarn 12 from the downstream-side V-groove guide
roller 25 to the knitting needle can also be twisted. Accordingly, knitting can be
performed by the knitting needle while the folded yarn 12 is in a twisted state.
[0034] Fig. 8 is an explanatory view which explains the shape of the grooves 241, 251 of
the upstream-side and downstream-side V-groove guide rollers 24, 25 in an expanded
state. In Fig. 8, lines X, Y tracing the valleys of the grooves 241, 251 of the upstream-side
and downstream-side V-groove guide rollers 24, 25, respectively, in the circumferential
direction are shown in the expanded state in which one turn of the V-groove guide
rollers 24, 25 is one cycle of a sine curve. As the lines X, Y move meanderingly within
the range of W between the inclined surfaces 243A and 243B, 253A and 253B of the direction
of the shafts 242, 252, respectively, along the sine curve, the inclined angles of
the respective inclined surfaces 243A, 243B, 253A, 253B of the grooves 241, 251 vary.
Meanwhile, the folded yarn 12 rolls only on one inclined surfaces 243A, 253A of the
inclined surfaces of the grooves 241, 251 of the upstream-side and downstream-side
V-groove guide rollers 24, 25. Accordingly, when the valleys of the grooves 241, 251
move to the other inclined surfaces 243B, 253B and the inclined angles of the one
inclined surfaces 243A, 253A become gently inclined, the folded yarn 12 is rolled
on the one inclined surfaces 243A, 253A so as to be twisted. Furthermore, when the
valleys move to one inclined surfaces 243A, 253A with rotation of the V-groove guide
rollers 24, 25 and the inclined angles of one inclined surfaces 243A, 253A become
steeply inclined, the folded yarn 12 moves to one inclined surfaces 243A, 253A. However,
when the valleys move back to the other inclined surfaces 243B, 253B and the inclined
angles of one inclined surfaces 243A, 253A become gently inclined, the folded yarn
12 is again rolled on the one inclined surfaces 243A, 253A so as to be twisted. Accordingly,
twisting of the folded yarn 12 is facilitated by using only one inclined surfaces
243A, 253A of the grooves 241, 251 of the upstream-side and downstream-side V-groove
guide rollers 24, 25. As a result, the folded yarn 12 can be smoothly twisted in the
feeding path 20 to the yarn carrier 3.
[0035] Furthermore, an inclined angle changing mechanism 26 is disposed in the upstream-side
guide device 22 to change the inclined angle of the shaft 242 of the upstream-side
V-groove guide roller 24 relative to the direction perpendicular to the feeding path
20. The inclined angle changing mechanism 26 includes a screw member 261 that fasten
the support arm 222 to the L-shaped frame 221 and is configured to change inclined
angle of the shaft 242 of the upstream-side V-groove guide roller 24 relative to the
direction perpendicular to the feeding path 20 when the support arm 222 rotates about
the axis of the screw member 261. Accordingly, which of the inclined surfaces 243A,
243B of the groove 241 of the upstream-side V-groove guide roller 24 is to be used
or the degree of twisting can be decided depending on the types of yarns 12A, 12B.
Therefore, the degree of twisting of the folded yarn 12 can be increased or decreased
depending on the thickness, the types or the knitting conditions of the yarns 12A,
12B.
[0036] Furthermore, in order to enhance wear resistance, the inclined surfaces 243A, 243B,
253A, 253B of the upstream-side and downstream-side V-groove guide rollers 24, 25
are processed with a treatment (such as plating) for improving smooth sliding of the
folded yarn 12. Accordingly, as shown in Fig. 8, notches 244, 254 are formed on the
inclined surfaces 243A, 243B, 253A, 253B of the grooves 241, 251 of the upstream-side
and downstream-side V-groove guide rollers 24, 25 at positions separated by 180 degrees
from each other in the circumferential direction and close to the peak of the most
gently inclined surface, and the notches 244, 254 have substantially L-shaped cross
sections which are linearly notched in a direction perpendicular to the shafts 242,
252. As a result, even if the inclined surfaces 243A, 243B, 253A, 253B of the upstream-side
and downstream-side V-groove guide rollers 24, 25 are processed with a treatment for
smooth sliding, the folded yarn 12 can be easily latched in the notches 244, 254 so
that the folded yarn 12 can be efficiently rolled and twisted on gently inclined one
inclined surfaces 243A, 253A from a position close to the peak to the valley.
[0037] In the above embodiment of the present invention, the active yarn feeder 4 is provided
in the feeding path 20. However, as shown in Fig. 9, only the side tension device
44 may be provided in the feeding path 20 between the yarn combining device 21 and
the upstream-side guide device 22.
[0038] Further, in the above embodiment, the upstream-side and downstream-side V-groove
guide rollers 24, 25 have the lines X, Y which trace the valleys of the grooves 241,
251, respectively, in the circumferential direction, and are shown in the expanded
state in which one turn of the V-groove guide rollers 24, 25 is one cycle of a sine
curve. However, the upstream-side and downstream-side V-groove guide rollers may also
be used in which the line tracing the valley of the substantially V-shaped groove
in the circumferential direction is provided on the same plane perpendicular to the
rotation center of the groove, and each of the peak-side ends of the inclined surfaces
are eccentric such that two points spaced from each other by the same distance in
the radially outward direction on the above plane from the rotation center of the
groove on the straight line passing through the rotation center of the groove are
provided as the respective centers. In this case, although the line tracing the valley
of the groove in the circumferential direction is in straight shape without meandering
in the rotation shaft direction, the inclined surfaces of the grooves alternately
provide a gently inclined surface that allows for easy rolling at positions separated
from each other by 180 degrees in the circumferential direction during one turn of
the V-groove guide roller.
[0039] Further, in the above embodiment, the notches 244, 254 are provided on the inclined
surfaces 243A, 243B, 253A, 253B of the grooves 241, 251 of the upstream-side and downstream-side
V-groove guide rollers 24, 25 at positions separated from each other by 180 degrees
in the circumferential direction and close to the peak of the most gently inclined
surface. However, instead of the notches, bump shaped projections that protrude outward
may also be provided so as to facilitate latching of the folded yarn.
[0040] Further, in the above embodiment, the inclined surfaces 243A, 243B, 253A, 253B of
the upstream-side and downstream-side V-groove guide rollers 24, 25 are processed
with a treatment that allows for smooth sliding of the folded yarn 12. However, the
inclined surfaces of the upstream-side and downstream-side V-groove guide rollers
may be processed with a treatment that is resistant to sliding. In this case, since
the folded yarn is facilitated to roll on the inclined surface to the valley, the
notches or the projections may not be provided at positions close to the peak of the
most gently inclined surface.
[0041] Further, in the above embodiment, the upstream-side and downstream-side V-groove
guide rollers 24, 25 having the same configuration are provided in the feeding path
20. However, only the upstream-side V-groove guide roller may be configured in which
a line tracing the valley of the groove in the circumferential direction have one
cycle of a sine curve for one turn of the V-groove guide roller in an expanded state,
and the downstream-side V-groove guide roller may be an ordinary roller in which a
line tracing the valley of the groove in the circumferential direction corresponds
to the direction perpendicular to the shaft of the roller.
[0042] Alternatively, instead of the downstream-side V-groove guide roller, the downstream-side
recessed groove guide roller may be used which has a recess-shaped flat groove that
is in contact with the folded yarn at the bottom, and the rotation shaft of the downstream-side
recessed groove guide roller is perpendicular to the feeding path such that the folded
yarn rolled by the upstream-side V-groove guide roller is fed out while being in contact
with the flat groove. In this case, the folded yarn twisted by the upstream-side V-groove
guide roller is fed out without being twisted while being in contact with the flat
groove of the downstream-side recessed groove guide roller. Accordingly, the folded
yarn between the upstream-side V-groove guide roller and the downstream-side recessed
groove guide roller can be further twisted and thus firmly twisted, thereby ensuring
prevention of slack of yarn in the feeding path. Moreover, since the rotation shaft
of the downstream-side recessed groove guide roller is perpendicular to the feeding
path, twist of the folded yarn after it is in contact with the flat groove naturally
returns when the folded yarn twisted by the upstream-side V-groove guide roller is
fed out without being twisted while being in contact with the flat groove of the downstream-side
recessed groove guide roller, and twist of the folded yarn between the rollers can
be released at a position from the downstream-side recessed groove guide roller to
the knitting needle so that knitting by the knitting needle can be performed in the
state in which twist of the folded yarn is released.
[0043] Further, in the above embodiment, two yarns 12A, 12B are folded by the yarn combining
device 21 into the folded yarn 12. However, three or more yarns may be used to provide
the folded yarn by the yarn combining device.