Khulna University of Engineering & Technology

Sessional Report on TE 4226

Experiment No: 05
Name of the Experiment: Study and Maintenance of Single Jersey Circular
Knitting Machine.

Remark:

Date of Performance:- 06-06- Name:- Naimul Hasan

2021 Date of Submission:- 25-
Roll:-1621060
06-2021
Year:-
4th
1|Page Term:-
2nd
1.0 INTRODUCTION

Knitting is the process of manufacturing fabric by transforming continuous strands of yarn

into a series of interlocking loops, each row of such loops hanging from the one immediately
preceding it. The basic element of knit fabric structure is the loop intermeshed with the loop
adjacent to it on both sides and above and below it. A knitting machine is a device used to
create knitted fabrics in a semi or fully automated fashion. There are numerous types of
knitting machines, ranging from simple spool or board templates with no moving parts to
highly complex mechanisms controlled by electronics. All, however, produce various types
of knitted fabrics, usually either flat or tubular, and of varying degrees of complexity. Pattern
stitches can be selected by hand manipulation of the needles, or with push-buttons and dials,
mechanical punch cards, or electronic pattern reading devices and computers. A knitting
machine is composed of lots of parts. Every parts of a machine are important for run the
machine smoothly. Every part has a specific function during operation.

Figure 1: Single Jersey Circular Knitting Machine

Circular knitting or knitting in the round is a form of knitting that creates a seamless tube.
When knitting circularly, the knitting is cast on and the circle of stitches is joined. Knitting is
worked in rounds in a spiral. Originally, circular knitting was done using a set of four or five
double-pointed needles. Most single-jersey fabric is produced on circular machines whose
2latch
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ge cylinder
and sinker ring revolve through the stationary knitting cam systems that, together with their
yarn feeders, are situated at regular intervals around the circumference of the cylinder. The
yarns are supplied from cones, placed either on an integral overhead bobbin stand or on a
free-standing creel, through tensioners, stop motion sand guide eyes down to the yarn feeder
guides. The Single jersey machine has only one cylinder on which one set of needles and
sinkers are placed on. The diameter of this cylinder is generally around 30 inches.

2.0 OBJECTIVES

The following objectives we will learn from this experiment

 To know about different parts of Circular Knitting machine

 To keep the machine running continuously up to the maximum production level.
 To prevent the undesirable failure of the machine.
 To improve machine efficiency.
 To increase knitting machine longevity.
 To know the health and safety measures of Circular Knitting machine.

3.0 SPECIFICATION OF CIRCULAR KNITTING MACHINE

For doing this experiment, the specification of the machine is given below:

 Origin: Japan.
 Brand: Fukuhara.
 Model: EX-3SB.
 Diameter: 20 inches.
 Gauge: 24 GG.
 Feeder: 60.

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4.0 MAIN PARTS OF CIRCULAR KNITTING MACHINE

The names of the parts of the circular knitting machine are given below:

Figure 2: Schematic Diagram of S/J Circular Knitting Machine

 Creel.  Sinker Box.

 Cone Holder.  Sinker Ring.
 Aluminum Telescopic Tube.  Cylinder.
 MPF (Memminger Positive  Base Plate.
Feed)
 Automatic Needle Detector.
 Yarn Tensioner.
 Fabric Detector.
 Yarn Guide.
 Adjustable Fan.
 Feeder Guide.
 Lubricating Tube.
 Needle.
 Gate.
 Pulley Belt.
 Spreader.
 CAM.
 Take-Down Motion Rollers.
 CAM Box.
 Winding roller/Cloth roller.
 Sinker

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Creel:

Creel is a vertical aluminum stick where

creel is placed for holding the yarn cone. It
also known as side creel. Creel is a part of
a knitting machine. Here yarn package is
stored and ready to feed in the knitting
machine. There are two types of creel
namely side creel and overhead creel.
Creel holds yarn cone with cone holder.

Cone Holder:

Cone holder is an inclined metallic stick

where yarn cone is placed for feeding the
yarn to the feeder easily. It is also known as
cone carrier. Cone holder holds yarn cone in Figure 3: Creel and Cone Holder
creel.

Aluminum Telescopic Tube:

This is the tube through which yarn is

passed. It reaches the yarn to the
Memminger Positive Feeder (MPF). It
works as a yarn cover. It protects the yarn
from the excessive friction, dust and fly
fiber.

Figure 4: Aluminum Telescopic Tube

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Yarn Guide:

Yarn guide receive yarn from the

Memminger Positive Feeder (MPF). It is
used to guide the yarn and sent yarn to the
feeder guide. It maintains the smooth
tension on the yarn.

Feeder Guide:

Feeder guide receive yarn from yarn guide

and feed yarn to the needle. It is the last
device which releases yarn to the knit Figure 5: Yarn Guide and Feeder Guide
fabric.

Memminger Positive Feeder (MPF)

Device:

MPF means Memminger Positive Feed. It

receives yarn from aluminum telescopic
tube. As this device gives a positive feed of
yarn to the needles, so it is called
Memminger Positive Feed device. MPF
provides uniform tension to yarn, reduces
Figure 6: Memminger Positive Feeder Device
machine stoppage, identify and remove
yarn knot and give a signal if yarn breaks.

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VDQ Pulley:

VDQ means Variable Diameter for

Quality. As this pulley controls the
quality of knitted fabric by adjusting
GSM & stitch length during the knitting
process, so it is called VDQ pulley. To
increase the fabric GSM the pulley is
moved towards the positive direction
and to decrease the fabric GSM the
pulley is moved towards the reverse
direction. This pulley also called quality
adjustment pulley (QAP) or Quality
adjustment Disk (QAD).

Pulley Belt:

Pulley belt gives the motion to pulley. Figure 7: VDQ Pulley & Pulley Belt

Needle:

It is a principal element and master part of the

knitting machine. Needle receive yarn from the
feeder, create a loop as well as release old loop
and finally produce the fabric. Prior to yarn
feeding the needle is raised to clear the old loop
from the hook, and received the new loop above
it on needle stem. The new loop is then
enclosed in the needle hook as the needle starts
to descend.
Figure 8: Knitting Needle

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Sinker:

Sinker is another master part of the knitting machine.

It supports yarn to form the desired loop. Sinker is
located at each and every gap of the needle. It is
most important element of the machine. Its help to
loop forming, knocking over and holding down the
loop.
Figure 9: Knitting Sinker

Cam:

Cam is the device which converts the rotary motion

into a definite reciprocating motion for the needles
and some other devices. It is the third primary
knitting element. There are three types of cams used
in single jersey knitting machine; they are knit cams,
tuck cams & miss cams. Figure 10: Knitting Machine Cams

Cam Box:

Cam box holds and supports cam and cams are set
horizontally. Knit, tuck and miss cams are
arranged horizontally according to fabric design
in the cam box.

Figure 11: Knitting machine Cam Box

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Cylinder:

Cylinder is another master part of the knitting

machine. Cylinder adjustment is one of the
most important technical work. The cylinder
holds and carries needle, cam box, sinker, etc.
Needle tracks are situated here. Needles are
attached in the trick portion of the cylinder.

Figure 12: Knitting Machine Cylinder

Adjustable Fan:

Generally, two sets of running fans are

continuously circulated from the center of
machine dia. These fans are faced with the
needle points that remove dust, hairy fiber
as well as keep needle cool. Adjustable fans
are rotated in the opposite motion of the
cylinder.
Figure 13: Adjustable Fans of Knitting
Machine

Lycra Attachment Device:

Lycra is placed here. And feeding to the

machine. Lycra yarn is feed by the
following device.

Figure 14: Lycra Attachment Device

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Air Blow Gun:

A device connected with high-velocity

pressurized air. It blows air to feed the yarn
through the aluminum tube. It also used for
cleaning purposes.

Figure 15: Air Blow Gun of Knitting m/c

Spreader:

Spreader is situated below the machine

body. It receives fabric from the needle,
spreads fabric and ensures uniform fabric
tension. The spreader is adjusted as the
fabric is open type or tube type.

Figure 16: Knitting Machine Spreader

Take Down Motion Rollers:

These rollers are situated just under the

spreader. They pull fabric from the
spreader, grip fabric firmly and take fabric
down. These rollers also called fabric
withdraw rollers.

Figure 17: Take Down Motion Rollers

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Cloth/Winding Roller:

This roller is situated just under the take-

down motion rollers. It rolled the fabric
itself. When this roller becomes bigger by the
fabric layer it also moves upward.

Figure 18: Winding Roller

Lubricating Tube:

This tube supplies lubricants to the cam box,

sinker box to remove excessive friction and
heat. Lubricants are sent through the tube
with the help of an air compressor.

Figure 19: Lubricating Tube

Manual Jig:

It is attached with the machine body. It used

to adjust needle, sinker, etc. manually.

Gate:

Gate is situated under the machine bed. It

keeps covered the knitted fabric, take-down
motion rollers, and winding rollers.
Figure 20: Gate & Manual Jig of Knitting
m/c
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Fabric Detector:

If fabric torn off or fall down from the machine,

fabric detector touches the cylinder and the
machine becomes stopped. It also called fabric
fault detector.

Figure 21: Fabric Detector in Knitting

m/c

Automatic Needle Detector:

A device placed very close to the needle sets. It

gives a signal if it found any broken o damaged
needle.

Figure 22: Automatic Needle Detector

Expander:

The expander is rotatably mounted on a central

rod arranged coaxially to a knitting machine axis.
A pivoting bearing is arranged on the central rod
to allow limited swivel movements of the
expander relative to the central rod.

Figure 23: Expander in Knitting m/c

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5.0 MAINTENANCE OF CIRCULAR KNITTING MACHINE

Some maintenance scheduled can be followed-

Daily Maintenance:

 The yarn fluff and dust on the machine and yarn creel should be cleaned away after
each production shift. Keep the knitting parts and winding parts clean.
 Check automatic stop device and safety device in every production shift. If there is
any abnormal situation, then repair or replace immediately.
 Check the positive yarn feeder and adjust if any abnormal situation arises.
 Check oil glass of base plate and level tube of oil lubricator.

Weekly Maintenance:

 Clear up the yarn fluff in the yarn and adjust wheel.

 Check the belt tension of driving system to make sure the smooth of machine driving.
 Check the fabric take down system to make sure working in good performance.

Monthly Maintenance /Full Maintenance:

 Disassemble the Needles, Sinkers and CAM boxes of machine and clean thoroughly
and check if there is any damage, then replace immediately.
 Clean the adjusting fan and check the wind direction of the fan.
 Clean the yarn fluff and dust from all electrical devices.
 Check the performance of all the electrical devices such as auto stop device, safety
alarm system and detector system.
 Clean and inspect the positive-type yarn feed mechanism is flexible.
 Check all the oil is smooth and clean injection equipment.
 Greasing bearing points.
 Replace bearing points (if required).
 Check all circuit breaker, magnetic conductors and relays.

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Six-Monthly Maintenance:

 Clean complete the cylinder including needles and sinkers. If there is any
broken of needles and sinkers, then replace with new one instantly.
 Clean oil lubricator and check vitta (Oil tube).
 Check and clean the positive yarn storage feeders.
 Clean the yarn fluff, dust and oil in the motor and driving system.
 Check the vitta of used oil collection to make sure it is unblocked.

6.0 HEALTH AND SAFETY

Some health and safety measures should be taken-

 Use and maintain personal protective equipment such as Hand Gloves, head cap, Ear
plug etc., as specified.
 Never handle chemicals with bare hands
 Report to the supervisor any service malfunctions in the machine that cannot be
rectified.
 Store materials and equipment at their designated places
 Minimize health and safety risks to self and others due to own actions.
 Monitor the workplace and work processes for potential risks.
 Do not carry any metallic parts during machine running as there are chances of fire
and damage to machine parts.
 Act based on instructions in the event of fire, emergencies or accidents and participate
in mock drills/ evacuation procedures organized at the workplace as per the
organization procedures.

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7.0 CONCLUSION

The Single Jersey Circular Knitting Machine is designed with the central adjustment system
to adjust fabrics in different levels of density easily and conveniently, normally equipped
with different gauges of cylinders which is easy to alter and can meet the varying
requirements in the knitting market. So in this experiment we have learned about the single
jersey knitting machine including its parts & their functions and later we have learned about
how the machine is functioned properly. Then we were taught about the maintenance
procedure and safety management of this knitting machine. The knowledge of single jersey
knitting machine is pivotal for the increasing demand of quality garments. Therefore, the aim
to achieve such quality can become possible by careful planning, scheduled maintenance and
safety. We have fulfilled all of our mentioned objectives from this experiment, it will enhance
our knowledge and helpful to our future working area and do the related work with Single
Jersey Circular Knitting Machine.

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