Warp Knitting | Elastane Safety System (ESS device)

The ESS device prevents the rebounding (re-jumping) of yarn ends in case of yarn breakages
on warp knitting machines processing elastane yarns.

In keeping with its concept of "accurate feeding of delicate yarns", Karl Mayer Textilmaschinenfabrik GmbH has recently optimized its two-bar tricot machines by developing a special tension bar for processing fine-count elastane yarns more efficiently with the name Elastane-Security System (ESS).

The demand for super light as well as opaque and mouldable underwear fabrics, produced in finer machine gauges, is continuing to rise. The market share of fine-count elastane yarns in the 11 - 14 dtex range is also continuing to rise.

An easily accessible tubular guide, which is driven by the yarn, is currently used as standard for feeding the elastane yarn to the knitting point. This system guarantees a uniform yarn feed. A prerequisite for this is that the yarn tension between the warp beam and the guide causes the yarns to adhere at the tube. However, as the yarn count decreases, the maximum yarn tension that can be achieved also decreases. As a guideline, this should be roughly 1 gram per 10 dtex of yarn. For example, an elastane yarn of 44 dtex can be loaded with four grams, and a yarn of 11 dtex with just one gram.

In order to achieve these low yarn tension levels at fine counts during processing, a modified tubular guide belonging to the new ESS is actively controlled via its own EBA drive. The rubber-coated surface, the precision grinding of the tubular guide, and an additional pressure roller guarantee the non-slip transfer of the peripheral speed to the yarns (Fig. 1). The control functions are also carried out by the EBA computer, which is extended to three positions on the two-bar machines.

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Warp Knitting Pattern|Curtains,Roller Blind and Fabrics for Decoration

Curtains,roller blinds and fabrics for decoration,three products,one fabric.Karl Mayer Pattern No.28/2003 (lapping Lay-out No.S-3005975) from a high performance tricot with three guide bars. This fabric also offers protection against solar radiation,allowing to look outside,at the same time bringing colour around the window.The honeycombed structure with its high porosity ensure more transparency .But this fabric is also covered with aluminum coating,thus,offering the same protections against the sun.The incident sunlight is reflected the rays cannot fail directly into the room,cannot dazzle and cannot overheat the room . The utility properties of this fabric quality can be compared to those of example number one,so that this textile has the same applications.This fabric was printed by Transfertex GmbH & Co,Kleinostheim /Germany (design No.50840)

Pattern (finished fabric)
Stitch courses	:	27.2/cm (set:28 stitches/cm)
Weight	:	95 g/m2
Finished fabric	:	102% of the knitting width
Finishing	:	Washing,dying,setting,aluminum coating,transfer printing.
Machine
Machine	:	HKS 3-M
Machine gauge	:	E 28 (nd./25.4 mm=1")
Machine width	:	170" (431 cm)
No. of guide bars	:	3
Machine speed	:	2100 [min⁻¹]
Production (finish fabric)	:	37 running m/h
Material specification			Percentage of	Run-in per rack
			material
GB 1 (in front)		dtex 76 f 24 polyester CS,flat,dull,round	50.4%	1000 mm/rack
GB 2		dtex 50 40  polyester CS,flat,dull,round	28.4%	1500 mm/rack
GB 3		dtex 50 40  polyester CS,flat,dull,round	28.4%	1500 mm/rack
Lapping				Threading
GB 1 (in front)		(0 - 1 / 1 - 0 ) x 3 //		fully set
GB 2		4 -5 / 4 - 3 / 4 -5 / 1 - 0 / 1 - 2 / 1 - 0 //		1 in 1 out
GB 3		1 - 0 / 1 -2 / 1 - 0 / 4 - 5 / 4 - 3 / 4 - 5 //		1 in 1 out

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Warp Knitting | Repairing of SU Aggregate Pattern Drive

Repairing  and Mounting Instruction  for SU Aggregate.
(V-Gear ,P-Magnet)

In order to avoid too long stop of the machine when pattern aggregate is fails,you may put this pattern aggregate to operation again with the help of this mounting instructions:
The individual steps of mounting are subdivided as follows;

1. Demount of pattern aggregate.
2. Exchange and adjustment of  drive or intermediate wheel.
3. Mount guiding elements (guides and slides piece).
4. Mounting and adjustment of the switching and locking lever.
5. Mount distribution plate and piston rod.
6. Verify distribution plate and measure out magnetic attraction ability.

Auxiliary means for disassemble or mounting respectively;
Tools,sliding caliper,thickness gauge, spring balance and magnet tester (setting gauge for drive wheels can b

Important : Its absolutely necessary to observe the following prescriptions.In order to avoid any damage of pattern aggregate during mounting and disassembling work,please use rubber or plastic mallet.
In order to avoid any difficulties when assembling the pattern aggregate after demounting ,please take care of each dismounted parts being deposited separately and assorted to its appropriate fixing elements,such as distance washer,bearing bush etc,according to demounting sequence.
e made available upon request).

Mechanical and Electrical Switching Elements of Pattern Aggregate with Permanent Magnets.

1 =  distribution plate.
2 =  carrying handle.
3 =  magnets.
4 =  hand grip
5 =  guide pieces.
6 =  slides pieces.
7 =  T-shaped guide ledge.
8 =  locking lever.
9 =  piston rods (switch units).
10= stroke.
11= switch lever.
12= right carrier wall.
13= left carrier wall.
14= drive unit ( drive and intermediate wheels).

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SU Aggregate Pattern Drive for Multibar Warp Knitting Machines

Warp Knitting Machine |Although new generation of multibars warp knitting machines has been released several year ago equipped  with electronic pattern drive used Servo motor such like JL 65/1 F, ML and FL series from Karl Mayer,however existence from old machine type such like
MRPJ 42/1,MRSEJ 73/1 SU and others types which is used SU (summary drive) for the pattern drive are still a lot  for used warp knitting machines.

SU drive (totalizing drive)

The SU drive is electronically driven and thus enables a pattern change in a very short time. The prerequisite is the elaboration of the pattern on a pattern computer. The pattern data is written on a floppy disk in a machine readable format and transferred to the working memory of the knitting machine by means of a loading station.
The SU drive controlled via the machine computer controls the shog movement of the guide bars as follows:
In the controlling unit 6 displacement rollers change the position of single sliding pieces with the pitch 1, 2,4, 8, 16 and 16 which – via combination – enable a total shog movement of up to 47 needles.
The individual displacement rollers are selected by the machine computer and put into operation, their sum
(SU drive) resulting in the shog movement. The maximum needle jump during an underlap is 16 needles.
2 guide bars can be controlled with one controlling unit. There are several kinds of units with 5, 6 or 7 displacement rollers, depending on the respective machine requirements.

Advantages:

•  fast pattern change

•  unlimited pattern repeats

•  fast pattern access

•  no storage system required as in case of chain links

 Disadvantages:

•  limited machine speed of 600 min-1

•  higher purchase costs

please see also :how to repairing SU Aggregate on the next posting.

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Warp Knitting Preparation for Technical Yarns

Warp Knitting Preparation Technology with Advantages for Yarn Guiding/Feeding

Technical modifications on creels and warping machines for processing technical yarns

Fig 1.:Horizontal balloon limiter

Out of all the textile materials, technical yarns are the most responsible for performance. They must match the end-use requirements exactly, can be processed into geogrids, tarpaulins, advertising substrates, 3D textiles, all kinds of nets, and reinforcement substrates for example, and, above all, they are extremely strong. Yams with counts of 1100 dtex and above provide maximum strength characteristics, but they also require special handling throughout all the processing stages. Yarn guiding forms the focus of steps taken to modify and adapt the warp  preparation technology developed by KARL MAYER.

In contrast to their large circumference, the thick yarns have a relatively small contact area on the package surface, and therefore do not adhere well to each other. The result is that individual yarn layers can slide between the back wall of the package and the package disc at the take-off points. They become entangled there, and can cause yarn breakages. This problem can be solved by having a foam rubber cover on the package disc and the spring-loaded contact points at the package (Fig. 2).

The high weight of the technical yarns also makes it necessary to make further    

                   Fig.2 : Package  

 disk with foam rubber cover

design modifications. Projecting yarn balloons are produced during take-off at high speeds, and these can catch on each other. If the machine stops as a result of a yarn breakage, the yarn ends fall to the floor and pull the entire wound package along with them. This can be avoided by using balloon limiters. The horizontal limiters consist of intermediate plates arranged horizontally between the rows of packages for catching the yarn ends (Fig. 1). The vertical balloon limiters prevent the yams from jumping uncontrollably Into the yarn guide of the yarn tensioners. KARL MAYER's top balloon limiting devices have a cylindrical shape, completely surround each package, and ensure that the yams do not become entangled with each other or in the yam guides of the yam tensioner (Fig. 3),

 Consequently, as soon as the machine is switched on, it can be run at maximum speed and the yams are delivered in an orderly manner to the yam tensioner. The KFD-AIR is used in this case (Fig. 4). This yam tensioner is designed especially for processing filament 'yarns and technical yams from 50 to 3000 dtex or 167 to 1000 dtex, it can produce yam tension levels of 10 to 90, M or from 30 to 230 M when processing these types of yams, absorbs yam tension peaks by air damping of the compensating lever, and is resistant to contamination. When processing coarse monofilament yarns with diameters above 0.3 mm, the KFD-AIR should also be fitted with a special cover. This prevents the rigid yarns from jumping out of the guide devices during take-off. If the yarn is too heavy for overhead take-off, the use of a special take-off roller is recommended. This guarantees tangential unwinding and controls the yarn tension as well, and thus replaces the KFD yarn tensioner. The principle of tension compensation is based on the increase and decrease of the braking force during take-off, by the rise and fall of a metal ring moving in a magnetic field (Fig. 5). This system operates extremely accurately and permits take-off speeds of up to 400 m/min for a maximum package weight of 6 kg to be achieved.

In addition to ancillary equipment needed for guiding the technical yarns, the machine used for warping them also has to be equipped with special devices. These include a roller unit with a more efficient motor and larger roller diameters. The resulting larger contact area of the yarns on the roller surface, in combination with the higher motor efficiency, enables the high tension level needed between the roller unit and the warping machine to be established. A pressure roller also ensures that the warp beam produced has a smooth, uniform surface. KARL MAYER Textilmaschinen GmbH offers a variety of raschel and high-performance tricot machines with and without weft insertion facility for processing the beams into custom-made technical textiles. Table 1 gives an overview of the warp preparation technology recommended for the specific warp knitting machines.

All in all, this represents custom-made technical expertise from one and the same manufacturer!

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Warp Knitting Terminology | S |

S
Germany	English
Säumen	seam, edge, fell
säurefrei	non-acid, free of acid
Samt	velvet
Sarntlegung	four by one lap, four-needle lap
sanforisieren	sanforize
Satin	satin
Satinlegung	three by one lap, three-needle lap
Saugtrockner	suction drier, hydro extraction
Saum	seam, hem, edge, border, skirt
Schabracke	pelmet
Schiranlage	warping equipment
Schären	warping
Schärgatter	creel, warping creel
Schärgeschwindigkeit	warping speed
Schärmaschine	warping machine
Schärriet	warping reed
Schärtisch	warping table
Schärtrommel	warping drum, swift
Schärverhiltnis	warping ratio
Schärvorgang	warping process
Schaft einer Nadel	needle stem, stem, shank
Schafivolle	wool
Schal	scarf, shawl, muffler
schaltbare Musterpresse	selective cut presser
Schaltglied	control link
Schalthebel	switch lever
Schaltklinke	racking pawl, pawl
Schaltpresse	selective presser
Schaltrad	ratchet, rack wheel, feed wheel
Schaltstange	switch rod, feed rod
Schappeseide	floss-silk, floret silk, flirt, flurt
schaumstoffbeschichtet	foam backing
Scheibenbremse	disc tension device, disc break
Scheibenspule	flange bobbin
Schere	scissors, shears
Scheren	shearing
Schermaschine	shearing machine
Scheuerfestigkeit	abrasion resistance
Scheuertuch	scouring cloth
Schicht	shift
Schieber	pusher, slide
Schiebernadel	compound needle with open stem
Schirmbespannung	umbrella fabric
Schlafarizug	pyjama
SchlaMecke	blanket
Schlagbiech	siehe Faliblech
Schlauchkops	tube-less cop
Schlauchware	circular fabric, tubular fabric,
	tubular goods, tubular web
Schleier	scarf
schleifen	grind
Schlichte	size-dressing, sizing agent, starch
schlichten	sizing, slashing
Schlichtmaschine	sizing machine, slashing machine
Schlinge	loop
Schlingenplüsch	terry, loop plush
Schlingenteppich	pile carpet, loop pile, carpet
Schlingenware	terry fabric, loop pile
Schlüpfer	pant, parity
Schmeizpunkt	melting point
Schmeizspinnverfahren	melt spinning process
Schmiermittel	lubricant
Schmierbl	machine-oil, lubricant
Schmierstelle	lubrication point
Schmierung	lubrication oiling
schmirgein	emery
Schmutzempfindlichkeit	resistance to soiling, soil proof, dirt repellent
Schnecke	worm
Schneckengetriebe	worm gear
Schneckenrad	worm wheel
Schneckenradgehiuse	worm wheel housing
Schneckenwelle	worm shaft
Schneidapparat	cutting device
Schneidmaschine	cutting machine
Schneidplüsch	cut plush
Schneidware	cut goods
Schrigverzahnung	spiral gearing
Schraubenfeder	coil spring
schrumpfen	shrinkage, contraction
schrumpffest	shrink resistant
schrumpfecht	shrink proof
Schrumpffrei-Ausrüstung	anti-shrink treatment
Schuhstoff	shoe fabric
Schurplüsch	sheared plush
Schurwolle	sheared wool
Schuβ	weft-inlay, weft, woof, weft filling
Schuβeinleger	weft inserter
Schuβeinrichtung	weft insertion device
Schuβeinrichtung für Eirizelfadenvürlage	weft insertion device with a single end storage
Schuβeinrichtung für Teilbreiten	weft insertion device for a part width
Schuβeinrichtung mit Magazinvorlage	weft insertion device with magazin storage
Schuβfaden	weft, weft thread, inlay thread
Schuβfranseneinrichtung	weft fringing device
Schuggarn	weft yarn
Schuβkettenplüsch	inlay warp plush
Schuglegung	inlay lap
Schuβplüsch	weft plush, inlay plush
Schweiβechtheit	fastness to perspiration durability
Schwenkarm	movable arm
Schwung der Legebarren	swing of the guidebars, guidebar swing
S-Drehung	S-twist
Sechsecktüll	three stitch tulle
Sechskantschraube	hexagonal head screw
Seegerring	circlip
Seegerringzange	pair of circlip pliers
Segmentsteuerung für Mustergetriebe	segment control for pattern drive
Seide	silk
seidiger Griff	silk-like handle
Seitenwand (jugere)	side frame
seitlicher Versatz	lateral displacement, evasion, lateral shog
Sektionalschirmaschine	sectional warping machine, mill warper
selbstjustierend	self adjusting
Selbstöler	lubricator
selbstregeind	self-regulating
selbstschmierendes Lager	self-lubricating bearing
selbsttitig	self-acting, automatic
selbstätiger Warenabzug	automatic take-up
selbstätig geregelte Fadenablaufeinrichtung	self regulating warp let-off device
Sengen	gassing, singeing
Sicherheitsabstelivorrichtung	safety stop motion device
Sicherheitsvorrichtung	safety device
Signierfärbung	staining (fugitive dye)
Silikon-Ausrüstung	silicone finishing
Simmerring	oil seal
Simplex	Simplex
Sisalhanf	sisal hemp
Slip	pants, panties
Socke	sock
Sondereinrichtung	special attachment
Sortiermaschine	sorting machine
spannen	tension, tenter, stretch
Spannfeder	tension spring, spring
Spannrahmen	stenter, stretching frame,
	tentering machine, tenter frame
Spannring	tension ring
Spannrolle	idler, tension roller, take up roller
Spannung	tension, stress
Spannungsausgleichsvorrichtung	tension compensating device
spannungsgeregelt	regulated on yarn tension,
	regulated by tension
Spanpresse	finishing press
Speicherung	storage
Sperrklinge	pawl
Sperrstift	stop pin
spezifisches Gewicht	specific gravity
Spiegelscheibe	siehe Musterscheibe
Spindel	spindle, reel
Spinnerel	spinning mill, spinners
spinngefärbt	spun dyed, solution dyed
Spiralfeder	spiral spring
Spitzenband	banded lace, lace stripe, lace edging, lace band
Spitzenband	nipped edging
Spitzengrund	tulle ground
Spitzerimuster	lace pattern
Spitzennadel	bearded needle
Spitzenplain	all-over lace
Spitzen-Raschelmaschine	lace Raschel machine
Spitzenstoff	all-over lace, lace fabric
Spitzentrennung	lace separation
Spitzfeile	taper file
Spitzkaro	diamond
Splint	split dom, securing pin
Sportbekleidung	sports wear
Sportgürtel	sports girdle
Sporthernd	sports shirt
Sportschuh	sports shoe
Spreizdorn	spreading bolt
Sprengring	spring clip
Spule	cone, spool, bobbin, cheese
Spule mit Kreuzwicklung	cross-wound bobbin
spulen	winding
Spulengatter	creel
Spulengestell	creel, spool stand
Spulenhalter	cone holder, adaptor
Spulenständer	bobbin stand
Spulenwagen	bobbin carriage
Spulerei	winding department, winding room
Spulmaschine	winder, winding machine, spooling machine,
	bobbin winder
Spulvorgang	winding process
stabilisieren	stabilizing, stabilize
Ständer	stand
Stahifeder	steel spring
Standard-Raschelmaschine	standard Raschel machine
Standreihe	stopping line, stop mark
Stapelfaser	staple fibre
Stapellinge	staple length
Start	start
statische Elektrizität	static electricity
staubdicht	dustproof
Staubtuch	duster
Stauchkammerverfahren	stuffer box process
Stechkamm	stitch comb
Stechkammbarre	stitch comb bar
Stechkammblei	stitch comb lead
Stechkammhebel	stitch comb lever
Stechkarrimplatine	locking sinker, stitch comb sinker
Stechkammsteuerhebel	control lever of stitch comb
Stechkammwelle	stitch comb shaft
Steckstift	cone lifting bolt
Stehfaden	filler thread, warp in-lay thread
Stehfadenlegung	filler lap, warp in-lay lap
Stellring	adjusting collar, adjusting ring
Stellschraube	set screw, adjusting screw
Steppnaht                                                                saddle stitch seam, closing seam, quilting seam
Steppstich	lock stitch, back stitch
Steppstichnaht	saddle stitch seam
Sterriffirbeapparat	star dyeing apparatus
Steuereinrichtung	control mechanism, control device
Steuerelement	operating element
Steuerexzenter	control cam, control eccentric
Steuerkette	control chain
steuern	control
Steuerscheibe	control disc
Steuertrommel	control drum
Steuerung	drive, control
Steuervorrichtung	control mechanism
Stickeffekt	embroidery effect
Stickerei	embroidery
Stift	pin
Stiftbarre	peg bar, peg fontur, pin bar, point bar
Stiftnadelbarre	pin needle bar
Stiftnadelriet	pin needle reed
Stillstand	stoppage
Stimrad	spur gear, spur wheel
Störung	interference
störungsfrei	trouble-free
Stöβel	pushrod
Stöβeleinsatz	push-rod insert
Stöβelpfanne	push rod pan
Stoff	fabric, cloth, web
Stoffabschnitt	cutting
Stoff (bedruckter)	printed fabric
Stoffbezeichnung	fabric designation
Stoffbreite	bredth of the texture, fabric width, panel
Stoffdichte	fabric density
Stofflegemaschine	cloth spreader
Stoffrnuster	fabric sample, swatch
Stola	stole, shawl
Stoppzihiwerk	stop counter mechanism
Storchenschnabel	pantograph
Stoβkante	hem
Stoβklinke	push pawl, rocking shaft
Strahlentrockner	infra-red drier
Strand bekleidung	beach wear
Strandhose	beach slacks
Strandjacke	beach jacket
Strang	hank, skein
Strangfarbemaschine	hank dyeing machine
Strangfarbung	hank dyeing
Strangöffner	rope opener
Streckkops	Nylon tube
Streichgarn	woollen yarn
Streichgarnspinnerei	woollen spinning
Streiferimusterung	striped design
Stretchgarn	stretch yarn
stricken	knit
Strickereiindustrie	knitting industry
Strickfixierverfahren	knit-deknit method
Strickgarn	knitting yarn
Strick- und Wirkware	knitted goods
Struktureffekt	textured effect, structured effect
strukturiert	structured
Strumpf	stocking, hose
Strumpfhaltergürtel	parity girdle, suspender keitgirdle
Strumpfhose	tights, parity hose
Strumpfwaren	hosiery
Stückbreite	piece width
stückgefärbt	piece dyed, dyed in the piece
Stücklänge	piece length, length per piece
Stützhebel	prop lever
Stütziager	step bearing
Stützrohr	supporting pipe
Stufenlos-Getriebe	steppless drive
stufenlos regelbar	steppless-adjustable, infinitely variable
Stufenschalter	step switch
stufenweise	gradually
synchronisieren	synchronise
Synthetiks	synthetics
synthetische Chemiefaser	synthetic fibre

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