Sunday, 18 July 2010

KARL MAYER shows its latest innovations in warp knitting machines at ITMA ASIA+CITME 2010

2010Lightweight components and a twin product line strategy – optimised concepts to suit every requirement - ITMA ASIA+CITME 2010, held 22 to 26 June 2010 in Shanghai

KARL MAYER’s successful policy for its warp knitting machines is based on lightweight constructions and a twin product line strategy – an arrangement that is specifically designed to meet the requirements of the market. The machines equipped with CFRP (carbon-fibre-reinforced plastic) components offer a unique performance profile, and the strategy of making both basic as well as high-tech machines available gives the company greater access to a broader client base.
The results of the company’s efforts to constantly optimise its products were on show at ITMA ASIA+CITME 2010, where KARL MAYER was displaying the first raschel machine equipped with CFRP components and a high-speed tricot machine, which is already benefiting from the advantages of 2nd generation of CFRP technology.
Other highlights on KARL MAYER’s stand at ASIA+CITME 2010 were a machine in the Seamless Smart range, a JL 59/1B, both in exceptionally high machine gauges, and the KAMCOS® Explorer for producing a basic MDE system.
The latest innovations in double-bar raschel machines were also on display at an in-house show held at KARL MAYER’s subsidiary in Wujin in the run-up to the fair and also during the exhibition itself. This event was held from 16 to 21 June and, as well as showing a new, basic HighDistance® machine, was also demonstrating the new RD 6/1-12.
The first raschel machine equipped with CFRP components
RSE 4-1 with CFRPThe new RSE 4-1 is the first machine in its series to feature lightweight technology. The package of optimised features includes the use of CFRP components in all the bars, and solutions for improving the stability to lateral distortion in the needle zone. The basic design as well as specific details of the machine were also adapted to suit the higher dynamics.
The result of changing over the RSE 4-1 to incorporate these lightweight, stable, fibre-reinforced plastic components is that the temperature window for reliable, trouble-free operation has been extended from +/- 2 °C to +/- 7 °C, and the weight of the bars has been reduced by as much as 25 % - and this has resulted in an exceptionally high productivity rate.
Throughout the exhibition, the RSE 4-1 (170", E 32) with its high speed of up to 2,600 min-1 caused quite a stir. The high-performance raschel machine is already one of the best-selling machines in KARL MAYER’s product range, and was in great demand during the fair.

High-speed tricot machines equipped with 2nd generation of CFRP technology                                                             
 By the end of last year, the HKS range of machines had largely been changed over to CFRP components. Subsequent optimisation work will focus on segmenting the shaft for controlling the bars. This component used to be produced from a single piece and had to be heated continuously to guarantee reliable operation even at high speeds. The high-precision segments are virtually dimensionally stable, without the need to apply heat externally. When arranged in a row for use as the shaft, they guarantee rapid start-up times and a high gauge accuracy, even at fluctuating ambient temperatures. This enables even fine fabrics to be produced in a high quality at wide working widths and high speeds – such as was demonstrated by a HKS 2-3 E in E 36 equipped with 2nd generation of CFRP technology and which extremely impressed the visitors. This high-tech machine was operating at speeds of up to 3,600 min-1, the basic machine has a working width of 180" but, as an option, this can be extended to 186" to cater for the growing trend for fabrics in wider widths. The final width of fabrics produced on the new HKS 2-3 E may be as much as 40 % higher.

Seamless, smart and extremely fine
In the Seamless Smart sector, the DJ 4/2 EL was producing complete, finished articles in a single piece in the new gauge of E 32, and the visitors were keen to learn as much as possible about this machine. The DJ 4/2 EL has a working width of just 44". With its high speed and exceptional flexibility, this compact machine has a list of performance features that makes it ideal for companies new to this sector, as well as those needing to produce a large number of patterns and sample. Small runs can be produced just as efficiently as large batches and intricate pattern samples.
Alongside the operating machine was a selection of new collections, which showed the type of clothing, lingerie and sportswear that can be produced.
The DJ 4/2 EL was producing a new type of shape leggings in a gauge of E 32 during the fair, and achieved a production rate of 750 courses/min.
As well as the new gauge of E 32, single tension fingers at the yarn guide elements are also a feature of the DJ 4/2 EL (DJ 6/2 EL). The single tension fingers are used to equalise any tension differences in the jacquard yarns when using non-stretch yarns. If single tension fingers are not used, expensive two-component yarns (e.g. core yarns) have to be used when producing many articles – a restriction which makes the product more expensive and limits the lapping and patterning possibilities.

59-28-850 – the perfect measurements of the JL 59/1B
Fine gauges are also a hot topic on the lace raschel machine market. In keeping with the trend towards finer fabrics, KARL MAYER presented at ITMA ASIA+CITME a JL 59/1B in a gauge of E 28. The Jacquardtronic® Lace machine was producing transverse lace, conventional ribbons and full-width fabrics, each featuring its own, unique filigree design. By operating in sequential mode, this versatile production machine was showing the range of fine, contrasting patterns that can be produced in this new fine gauge on transverse lace in particular. The lace fabrics that were being produced in succession during the exhibition were patterned in an attractive combination of a delicate mesh ground and dense floral designs. The machine was operating at 28 stitches/cm (56 stitches/cm in the finished fabric) to produce the fine net zones on the transverse lace, and at 24 stitches/cm (42 stitches/cm in the final fabric) to work the floral patterns. The yarn run-ins of ground guide bar GB 1 and jacquard bars JB 59-60 were adapted to the sequential take-off values. The stability of the mesh structure, which is an important quality aspect of the fabric and affects the resilience of the lace, is higher than with conventional fabrics because of the high stitch number in the net section.
The visitors to KARL MAYER’s stand were also impressed by the high operating speed and flexibility of the JL 59/1B.The Jacquardtronic® Lace has a working width of 132", which can be extended to 134", and can reach speeds of up to 850 min-1. The JL 59/1B has eight strings in the individual shog lines instead of six – like its counterpart the JL 42/1) – and can produce a wide range of different patterns using a variety of different yarns.

The essential HighDistance® machine – the HD 6/20-35
KARL MAYER has now extended its successful twin product line strategy to encompass its double-bar raschel machines, and developed a basic version of the HighDistance® machine to coincide with the opening of ITMA ASIA+CITME.
This new machine is known as the HD 6/20-35. It was unveiled for the first time at an in-house show held at KARL MAYER (China) Ltd. in the run-up to ITMA ASIA+CITME 2010, where it impressed everyone with its performance features which are perfectly suited to the market.
The HD 6/20-35 (110", E 12) can reach a maximum productivity of 600 courses/min, and the distance between the trick plates can be adjusted from 20 mm to 35 mm. The result is a new range of spacer textiles that is particularly suitable for use in mattresses and car seats.
The HD 6/20-35 also offers KARL MAYER’s tried-and-tested technology, such as the KAMCOS® computer system, Motion Control and Single Speed functions, Laserstop yarn monitoring system, and electronically controlled yarn feeding. With its specific technology for moving the guide bars, the HighDistance® is a practical and cost-effective machine. The patented systems, which have already been used on the high-end version of the HighDistance® machine, guarantee that the pile bars on this new machine also operate in counter notation mode over the entire distance between the trick plates without any problems. This enables an IXI lapping to be worked here as well, which gives the spacer textile the required stability.
The HD 6/20-35, with its high level of productivity, is geared up to what is needed rather than what is possible, and offers rapid amortisation times.
Under normal, i.e. average, production conditions, the investment in a new machine will be recouped in about two years, which is an important aspect, especially for manufacturers in search of new business opportunities.
RD 6/1-12 high-speed machine
Spacer textiles with a small gap between the cover faces are the best-sellers among the spacer textiles, which makes the market for these textiles particularly competitive. KARL MAYER has therefore developed a new production machine with an extremely competitive cost:performance ratio in order to give its customers the edge over their competitors. This new machine is known as the RD 6/1-12, and it was presented at the in-house show in Wujin where it also generated a great deal of interest.
Everyone was talking about the new machine’s unique speed, and all the visitors were keen to get a closer look at it. This high-speed machine can reach a maximum operating speed of 475 min-1 or 950 courses/min. This accurate, reliable double-bar raschel machine is also extremely flexible in terms of the range of designs it can produce.
The technical details of this new, double-bar raschel machine are as follows: a working width of 138", available gauges of E 18, E 22 and E 24, optimum yarn monitoring using the Laserstop system, KAMCOS® system with Motion Control/Single Speed functions, and the possibility of setting the space between the trick plates in a range of 1 to 12 mm. Packaged with all the latest design features of the KARL MAYER Group, this new machine can meet even the most stringent of manufacturers’ requirements and, with its exceptional performance, is setting the trend on the market.

KAMCOS® Explorer – from desk to production machine at the click of a mouse
Alongside its new warp knitting machines, KARL MAYER was also showing the features of its KAMCOS® system at ITMA ASIA+CITME 2010. The focal point of its presentation was the new KAMCOS® Explorer system – a clever software system for organising a basic MDE system easily.
KARL MAYER had networked the machines on its stand to each other and to the typical office hardware found at the foreman’s workstation in order to demonstrate how easy it is to process information using this system. The visitors were able to see directly into the machines from this point. By using the tried-and-tested Windows menu-driven system similar to the KAMCOS® Operator Interface, all the machine data were displayed on the laptop - from the machine set-up in the production hall, through detailed information relating to the shift and piece data, to memos that can be input using free text.
The operating data can be printed out either using a printer linked to a PC or a networked printer at the machine for documentation and recording purposes. The networked printers can also be used to produce a hard copy of the various relevant items of information, such as fault records or current beam data, directly from the operator’s console.
The Teleservice system was also being demonstrated on a laptop during the fair - and this demonstration was particularly well received by the visitors to the stand.