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ON
Knitting Jacquard:
A Recent Invention in Circular Knitted Weft
Knitting Technology & Its Versatility
Project Paper
On
Knitting Jacquard:
A recent invention in circular knitted weft knitting technology & its versatility
Paper Submitted
To
Textile Talent Hunt 2015
Bangladesh Textile Today
Submitted By
Kh. Tahmidul Hasan Siam
TTH ID No: BUFT-24
TTH Merit Position: 35th
Department of Textile Engineering
BGMEA University of Fashion & Technology (BUFT)
Supervised by
Faisal Abedin
Lecturer
Department of Textile Engineering
BGMEA University of Fashion & Technology
Table of Content
ACKNOWLEDGEMENT
1. ABSTRACT
2. INTRODUCTION
3. OBJECTIVE
4. METHODOLOGY
7
7
9
10
12
12
14
15
15
15
16
17
18
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18
18
18
18
18
18
19
19
d)
e)
f)
g)
9.
19
19
19
19
20
20
20
21
21
22
9.1.
Pattern change
22
9.2.
Repeat of design
22
9.3.
Replace printing
23
9.4.
23
9.5.
24
9.6.
24
10.
CONCLUSION
25
11.
REFERENCES
26
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Acknowledgement
Foremost, I would like to express my sincere gratitude to my advisor Mr. Faisal Abedin,
Lecturer, Department of Textile Engineering, BUFT for the continuous support of my project,
for his patience, motivation, enthusiasm, and immense knowledge. His guidance helped me in all
the time of research and writing of this project paper. I could not have imagined having a better
advisor and mentor for my project.
Besides my advisor, I would like to thank the Pro.Vice-Chancellor of BUFT Prof. Dr. Engr.
Ayub Nabi Khan who provided me support to get permissions from the industries that I visited
to gather knowledge & complete my project paper.
Last but not the least; I would like to thank my family: my parents for giving birth to me at the
first place and supporting me spiritually throughout my life.
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1. Abstract
Knitting is a process of fabric manufacturing from a strand of yarn. In this process two types of
machines are used circular knitting machine & flat bed knitting machine. A knitting machine is
thus an apparatus for applying mechanical movement, either hand or power derived, to primary
knitting elements, in order to convert yarn into knitted loop structures. First hand operated
Circular knitting machine was produced in 1860. In the year 1870 first mechanical circular
knitting machine was produced. Machines may range from high-production, limited-capability
models to versatile, multi-purpose models having extensive patterning capabilities. The more
complex the structure being knitted, the lower the knitting speed and efficiency. The simplest of
the knitting machines would be hand-powered and manipulated whereas power driven machines
may be fully automatically-programmed and controlled from a computer system. Electronic
jacquard circular knitting machine is one of the powers driven fully automatic computerized
machines. This invention has opened up a vast area for knitting. Proper use of this invention may
lead to a knitted fabric of better physical properties & serviceability. This proposed thesis will
give a better idea to minimize the cost a knit fabric while increasing the properties,
serviceability, appearance etc. Also attempts to maximize the profit range with minimum
investment.
2. Introduction
During the 20s of the 20th century knitted upper garments for the first time entered the fashion.
Whenever knitwear entered the fashion, fashion was through its demand encouraged further
development of some kind of knitting machines. Consequently, the circular knitting machines
with latch needles developed the increasing possibilities of patterning. In Chemnitz, in 1921,
jacquard circular machine was constructed, which allows creation of different patterns in color,
and in 1927 steel tape for patterning was introduced [1]. Knitting technology continues to expand
the capabilities for conversion of fiber and yarns into knitted products. Obviously, there are
developments that have improved capabilities such as production speed and production
efficiency, patterning limitations etc. The present thesis relates to a jacquard circular knitting
machine, more especially to a jacquard circular knitting machine provided with a needle cylinder
driving mechanism capable of optionally and readily changing the rotary motion of the needle
cylinder of the circular knitting machine according to the pattern to be produced on the fabric
[5].
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A jacquard circular knitting machine includes a cylindrical needle cylinder provided with a
plurality of knitting needles, a patterning mechanism for controlling the vertical sliding motion
of the knitting needles on the knitting cylinder to knit a jacquard knitted fabric, and a driving
mechanism for driving the needle cylinder. Usually, the patterning mechanism employs a pin
drum or pin drums for controlling the knitting needles [2].
In recent years, however, computers have been employed in the patterning mechanism. A
patterning mechanism employing a computer, namely, a computerized patterning mechanism,
has an infinite patterning capacity [3]. That is, by controlling all the individual knitting needles,
the computerized patterning mechanism is capable of changing stitches along the wale direction
and is capable of producing diversified patterns in the course direction, as compared with the pin
drum type patterning mechanism. Furthermore, the computerized patterning mechanism has the
advantage that it enables quick and very easy pattern changes without requiring a skilled worker
[2].
Mechanical & electronic circular jacquard machines are very much useful & versatile in nature
but to do maximum use of these machines it is important to have proper knowledge about their
driving & patterning mechanism. The changed property of the fabrics produced from circular
jacquard knitting machines from conventional circular knitting machines is also a purpose of the
study. To change the demand of the world knit industry the versatile use of this jacquard knit
machines are very important. In Bangladesh the use of these latest machines are not quite up to
the mark just because of lack of knowledge about these machines. The main purpose of the study
is to make the circular knit jacquard machines mechanism more familiar with knit industries &
find out its versatility.
3. Objective
In this study the main objective is to understand the mechanism of the circular jacquard machine.
Patterning system to produce a design knit fabrics.
Also try to find out the difference in mechanism between mechanical jacquard & electrical
jacquard machines.
Another object is to find out the difference in properties among the fabrics produced by
conventional knitting machine & jacquard knitting machine with different type of yarn used.
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4. Methodology
1. At first types of jacquard circular knitting machines were determined.
2. Detailed information about different parts of the machines one by one from the machine
with their mechanism of work.
3. Then comparative study about patterning various designs was done.
4. Different patterned fabrics were tested to compare with knit fabrics produced from
circular knitting machines.
20th century
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21st century
a)
b)
c)
d)
e)
f)
g)
h)
i)
Peg Box
Peg
Selector
Cam Box
Jack Cam, Needle Cam, Pin Cam, Sinker Cam
Jack
Needle
Pin
Sinker
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Peg Box
Peg
Selector
Cam Box
Jack
Needle
Pin
Sinker
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In the past, a variety of mechanical Jacquard selection systems were available on the market, but
today manufacturers privilege only two types of mechanical Jacquard systems, equipped
respectively with
- Needle sliders or
- Pattern wheels
The slider selection system is the most commonly used system. Under each needle there is a slider
with 3 butts: a lower butt for needle raising, an upper butt for loop knocking-over and an
intermediate selection butt that can be positioned at different levels. A selection lever acts on
the intermediate selection butt. When the lever is idle (i.e. in external position) the slider
maintains a vertical position and is pushed upward by the raising cams so that the corresponding
needle can assume a working position. When the selection lever is active (i.e. in internal position)
the slider is pushed into the guide groove and the corresponding needle assumes a non-knitting
position. The selection lever is controlled externally and each manufacturer has developed its own
solution to control the selection lever (e.g. fixed turrets with plug-in cartridges for pattern
selection, punched cards system, reeds etc.)
The most recent models of circular knitting machines incorporate 37 selection levels (mini-jack
machines). On double-bed machines, the selection levels are limited to the cylinder. In addition
to the pattern selection levels, these machines also feature two extra levels to facilitate the
selection change-over procedures
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With the slider butts arranged diagonally, the pattern design includes in its width a number of
wales equal to the number of selectors. In symmetrical arrangement, the width of the pattern
design is twice the number of selection levels. The sliders arrangement can remain unchanged
for each machine revolution (fixed arrangement), and in this case the height of the design pattern is
given by the number of feed systems of the machine divided by the number of pattern colors. If
the operator wishes to modify the height of the pattern, the arrangement of the sliders must be
changed after every machine revolution. This operation can be carried out by applying different
methods, i.e.:
- Using small cylinders provided with as many holes as the number of selectors; each hole can
have a peg to exclude the corresponding selector. These small cylinders can be rotated after each
machine revolution to modify the slider selection on a specific feed system.
- Using selection turrets that can be reset and provided with a new selection scheme for each
machine revolution.
6.1.3. Circular mechanical jacquard machine knitting mechanism
a) There are 39 pegs in a peg box. Top 3 are fixed or common butts. Rest 36 for design
(means in a repeat of a course there may be 36 Wales maximum).
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Peg box:
inside view
outside view
e) If left (peg) is pressed, it press selector and disconnect corresponding needle and forms
miss loop.
f) If only right (peg) is pressed, it press selector and disconnect corresponding needle after
forming a half loop and it forms tuck loop.
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Spring Jack
Needle
Sinker
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The precise definition of this needle selection system for circular knitting machines is
electromechanical selection with electronic control, based on the use of piezoelectric actuators.
That act on the selectors or of a magnet which commands a striker placed under the needle.
If the selection is carried out with a single magnet, when the magnet is excited, the striker
assumes a vertical position thanks to the action of a control spring then reaches the rising cam and
forces the needle in the working position. When the magnet is not excited, the spring withdraws
the striker into the groove in the non-knitting position together with the corresponding needle.
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The needle-by-needle selection allows the knitting of design patterns of almost unlimited Size
since each needle can be independently set in the knit, tuck or miss position. The electronic
Selection is now widely used for the needles of the cylinder, while on several double-bed knitting
Machines, the selection of dial needles is still Carried out mechanically with cams and tracks.
However, many machine manufacturers also offer Electronic dial and cylinder needle selection
systems.
For every knitting heads the needles stands on the head of the jack and the needle has no raising
cam. So when the jack pushes the needle upwards only then the needle forms a knit loop. Every
jack cam box contains two raising cam side by side. The left raising cam leads a needle to the
clearing position with help of the needle cam because both raising jack cam are came height of
the yarn taking height. For the both raising cam there are two ENS one for each. The spring jack
constructed in the way that there is no interruption its butt always follows the raising cam. So
when the magnet remains neutral the raising cam push the jack and jack push the needle so form
the knit loop.
When we need to form a tuck loop no electricity passes through the first ENS so it remains
magnet and attract the jack and jack become detached from the raising cam and the needle keeps
it position in the down. So no clearing action is happened. But electricity passes through the
second ENS which makes the second ENS neutral and jack moves upward following the raising
needle and so needle. In here needles raises only to the yarn taking height not in the clearing
position so the old loop tucked in the latch and take the new yarn. Following the next knit loop a
tuck loop is formed.
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When miss loop is required no electricity passes through neither ENS nor the ENS keeps the jack
detached from the raising cam whole the time. So needle remains in the bottom most position. So
neither clearing nor the yarn taking takes place. In this way miss loop is happened.
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However, in order to make black and white representation of the colored effect the presence of
different colors on the surface of the knitted structures have been shown by the characters R, G,
B etc. where R, G, B etc. stands for different colors.
Two more simple motifs produced on two colors black and white are shown. The first one (a)
repeats on 24 24 courses and wales whereas the second one (b) repeats on 20 28 courses and
wales.
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a) Yarn selection: As the experiment has done only for identifying the changes between
the fabrics of circular knitting machine & circular jacquard knitting machine so all the
yarns used were same for both the machines. Only change was in their design.
b) Knitting machine: Knitting Machines (Mayer & Cie, Germany) with same diameter
of cylinder but difference was one was single jersey circular knitting machine &
another was single jersey circular electric jacquard machine.
8.1.2. Methods:
a) Dyeing: All the yarns were dyed with same average color in a same machine at the
same time. Dyeing process was carried out at 60C on PH 9-1.2 with M: L Ratio 1:10
for 60 minutes.
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b) Finishing: Finishing has a strong impact on fabric properties. The finishing operation
had done in several steps. Firstly Slitting had done immediately after the dyeing to
make the tube fabric open by cutting the fabric through a preset needle line. Secondly
Drying was carried out by monforts dryer which had been used to dry the wet fabric
for the further smooth operation. Silicone softener (60g/l) was used at 30% overfeed
at 130C. At last stentering and compacting operation had done.
c) Relaxation: Knitted fabrics are very much prone to extend and shrink. So proper
relaxation before any kind of test is very much essential, especially for dimensional
properties. The fabrics had been kept at standard atmosphere of 27C and 65%
Relative Humidity for 24 hours at Physical Lab.
d) Determination of fabric weight (GSM): After relaxation & conditioning of knit fabric
samples, GSM of samples were tested by taking test samples with the help of GSM
cutter & weighting balance (electronic) [11].
Then by the over lock sewing m/c the 4 ends of the cut fabric were sewn. After
sewing, again by a scale mark (35cm35cm) on the fabric & then sample washed
with a standard soap solution (1g/l). After washing the sample was tumble dried at
65C 15C for 60 minutes. Then after cooling the sample tested with the shrinkage
tester scale also the spirality was tested. Shrinkage was tested length wise & width
wise along the mark of (35cm35cm). And spirality was tested along sewing line
alignment. (Distortion of the formation of loops) [12].
f)
an automatic bursting strength tester. Samples are gradually set on the diagram, the
automatic bursting strength tester, measures time, distortion, pressure & the flow rate
to burst the fabric. For different samples we recovered there parameters. [13]
g) Determination of fabric shrinkage: Shrinkage is an inherent property of knit fabrics
which cant be prohibited, but for better quality, it must be controlled in a systematic
way. After tumble drying & cooling of the fabric, shrinkage of this samples are in
widthwise. It was calculated from the difference in fabric length before and after
washed garment according to AATCC test methods 135 and 150 [14].
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Fabric GSM
250
200
GSM
150
100
Series 1
50
0
Plain Knit Fabric
Fabric Type
8.2.2. Effect on fabric shrinkage: From the experiment it is seen that the shrinkage of fabrics
made from jacquard knit machine is variable according the design. Whereas there is no
such differences in the fabrics of circular knit machine.
Shrinkage %
Fabric Shrinkage
9
8
7
6
5
4
3
2
1
0
Length wise
Width wise
Plain Knit
Jacquard Knit
(Design)
Fabric Type
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Jacquard Knit
(Compact)
8.2.3. Effect on fabric bursting strength: From the experiment it is seen that the normal knit
fabric show comparatively low bursting strength than jacquard knit fabric. The reason
behind that is jacquard fabric has more floated yarn in a square meter than a normal knit
fabric.
Bursting Strength
350
300
KPa
250
200
150
Bursting Strength
100
50
0
Plain Knit
Jacquard Knit
(Design)
Jacquard Knit
(Compact)
Fabric Type
8.2.4. Effect of fabric spirality: Though no of feeder plays an important role with spirality but
it is seen from the experiment that jacquard knit fabric shows less spirality than knit
fabric with same no of feeder.
Spirality
Percentage (%)
2.5
2
1.5
1
Spirality
0.5
0
Plain Knit
Jacquard Knit
(Design)
Fabric Type
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Jacquard Knit
(Compact)
9.
9.1.
Pattern change: Fast pattern change helps reduce downtimes and improves the efficiency
of the machine. Pattern change can be carried out quickly and easily with all types in the
electronic ranges [2]. All necessary pattern data are transferred onto a floppy disk, which can be
created quickly and easily using the pattern preparation system. The floppy disk becomes the
master and is read into the machine controller. This converts the pattern information into knitting
information and passes it on to the PIEZO selection unit. But new pattern ideas can also be
implemented quickly and easily on the Jacquard machines by direct means and, if necessary, via
the Internet [3]. Patterns that have once been read in can be modified retrospectively using easily
understood functions. All pattern data remain stored in the event of a supply failure or when the
machine is switched off. This means no loss of quality in the knit due to pattern offset when
restarting.
9.2.
Repeat of design: In jacquard circular knitting machine each and every needles can be
controlled using peg or jack. It is very easy to produce a design of very long repeat [8].
Whereas auto stripping machine has only 100 course for repeat & normal knit machines
has its limitations according to the number of feeder. Some examples of circular jacquard
knitted fabric with long repeat are given below:
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9.3.
9.4.
Multiple yarns in one repeat: Any number of yarns of different colors or different
count or different specifications can be used for one repeat which gives the fabric versatile
design.
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9.5.
Design like woven fabric: Some stripes or designs which were only possible in
woven fabric can now very easily developed in knit fabric using electrical jacquard
circular knitting machine.
9.6.
Fabric with picture pattern: Introduction of CAD system in jacquard machine [8] allows
vast space for design single jersey knit fabric. Picture of any people or any scenario or any logo
can be developed in the fabric without any problem.
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10. Conclusion
This study has reveled full mechanism of circular jacquard knitting machine with the properties
of fabric that differs from circular knitting machine. If jacquard machine is used according to its
merit, than it can be a great profit for the world growing knitting industry. Only drawback of
jacquard machine is its RPM. Jacquard machine gives only 20-30 kg design fabric per 8 hour
shift whereas circular knitting machine gives 300 kg plain fabric per 8 hour shift. This problem is
increasing the cost of the jacquard fabric production. To produce a single jersey knit fabric
production cost is approximately 7-10 tk/kg but for single jersey jacquard fabric the cost is about
250-300 tk/kg. Further research is recommended to reduce the price of jacquard fabric
production. If do so then a vast area will be open for knitting industry. Paper can be replaced
with jacquard fabric. That will be better for the environment as fewer trees will be cut to prepare
paper.
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11. References
1. International, T., & Journal, I. (2011). Technological reasons for entering knits in the
fashion of the 20s, 1(7), 1622.
2. Jacquard circular knitting machine. (1985, July 3). Retrieved from
https://www.google.com/patents/EP0147139A2?cl=en&dq=knitting&hl=en&sa=X&ved
=0ahUKEwjP8Ijagc7JAhUIBY4KHYjqAdcQ6AEIRjAG
3. Ray, S. C. (2012). Fundamentals and Advances in Knitting Technology. Fundamentals
and Advances in Knitting Technology. Woodhead Publishing Limited. Retrieved from
http://www.sciencedirect.com/science/article/pii/B9780857091086500181
4. http://sewjazzy.angelfire.com/timeline.htm
5. Jacquard-Rundstrickmaschine. (1985, July 3). Retrieved from
http://www.google.com/patents/EP0147139A2?cl=de
6. Mechanical jacquard of computerized glove knitting machine. (2006, October 25).
Retrieved from
https://www.google.com/patents/CN2830442Y?cl=en&dq=mechanical+jacquard&hl=en
&sa=X&ved=0ahUKEwip_4fV7NHJAhUmeaYKHdmRB34Q6AEIIDAA
7. Knitting : Fundamentals, Machines, Structures and Developments, N.Anbumani
8. Beyn, E. J. (1976). United States Patent 1191.
9. http://docslide.us/documents/textile-reference-book-for-knitting.html
10. Banerjee, P. K. (2014). Principles of Fabric Formation. CRC Press. Retrieved from
https://books.google.com/books?id=ymVYBQAAQBAJ&pgis=1
11. ASTM D3776 / (2013), Standard Test Methods for Mass per Unit Area (Weight) of
12.
13.
14.
Fabric, American Society for Testing and Materials, West Conshohocken, PA, USA.
AATCC Test Method 187-2013, Dimensional Changes of Fabrics: Accelerated,
American Association of Textile Chemists and Colorists, Research Triangle Park, N.C.,
USA, Developed in 2000.
ASTM D3786 / 2013, Standard Test Method for Bursting Strength of Textile Fabrics,
Diaphragm Bursting Strength Tester Method. American Society for Testing and
Materials, West Conshohocken, PA, USA.
AATCC Test Method 135-2012, Dimensional Changes of Fabrics after Home
Laundering, American Association of Textile Chemists and Colorists, Research
Triangle Park, N.C., USA, Developed in 2000.
15. George, M., & Ferrin, W. (1984). United States Patent [4841748].
16. Spencer, D. (1996). Knitting technology. Knitting International.
http://doi.org/10.1533/9781855737556
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