Warp Knitting | Powernet Structure for Lingerie

Karl Mayer Pattern No. 148/09

(Design No .S-4002812)

From a high performance Raschel machine with four ground guide bars and CFRP bars.

Source : KWP 1/2010

This power-net structure for lingerie articles cuts a fine figure.In spite of its puristic appearance and cool touch,this is unsophisticated fabric unveil its true qualities when its comes to such functional features as e.g holding,supporting,shaping and moulding.This stretch textile with specific elastic smoothes out unflattering curves,without restricting or even constricting one’s movements.Not only can the body stylist breathe a sigh of relief but the body can also take deep breath.The filigree mesh openings ensure a sufficient heat and moisture balance.

Pattern (finished fabric)
Stitch courses :  Weight : Finished fabric:	84/cm (set: 50/cm) 119 g/m 86 % of the knitting width
Finishing :	Relaxation,washing,drying,setting,bleaching,optical brightening,stentering
Machine
Machine type : Machine gauge : Number of guide bars: Machine width : Number of pattern disks : Machine speed : Production (finished fabric) :	RSE 4-1 ,CFRP E 32 (needles / 25.4 mm=1”) 4 170” (431 cm) 4 ( 24 M ) 2.500  min-1   17.8 running m/h (7.9 kg/h)

Bars	Material specification	% of material	Run-in rack
GB 1	dtex 44 f 12 polyamide 6 (Nylstar ®),deep dull,flat,round	37.7 %	800 mm / rack
GB 2	dtex 44 f 12 polyamide 6 (Nylstar ®),deep dull,flat,round	37.7 %	800 mm / rack
GB 3	dtex 320 elastane (Dorlanstan ®),V 550,elongation 25 %	12.3 %	45 mm / rack
GB 4	dtex 320 elastane (Dorlanstan ®),V 550,elongation 25 %	12.3 %	45 mm / rack

Bars	Lapping	Threading
GB 1	1-0 / 1-2 / 2-1 / 2-3 / 2-1 / 1-2 //	1 out ,1 in
GB 2	2-3 / 2-1 / 1-2 / 1-0 / 1-2 / 2-1 //	1 out ,1 in
GB 3	( 0-0 / 1-1 ) x 3 //	1 out ,1 in
GB 4	( 1-1 / 0-0 ) x 3 //	1 out ,1 in

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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 2^nd 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
The 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.

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Warp Knitting | Calculation of Yarn run-in (mm/rack)

The relationships between fabric parameters and yarn run-in (yarn consumption) is an extremely important factor for production planning.This data allows the knitter to estimate his yarn requirements,predict  his production rate.
The values needed to determine the yarn run-in :
Lapping,Gauge  E (needles/inch) ,course per cm (CPC),needle thickness  (d).
Calculation :

Head of the loop = πd /2.2	d = needle thickness
Legs of the loop = 2 x S	S = 10 mm : course per cm (cpc)
a =  number of needle loops b =  number of needle gaps crossed by the sinker loop c =  number of sinker loops in the same wale	T = 25,4 mm : E (gauge)

Yarn run-in (mm/rack) *= 480 [a ( πd /2.2  + 2S) +bT + cT ]
notice : * The calculated values are as approximate values
Example 1 :

E = 28 CPC = 20

d = 0,5 mm Lapping =  1 0 / 1 2 //   | a = 1 | b = 1 | c = 0 (per course).

Yarn run-in (mm/rack) = 480 ( 0,7 mm + 1 mm +0,9 mm) = 1250 mm/rack

Example 2 :

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Warp Knitting | Warp Length Required to Knit a Certain Fabric Length

Following formula is to calculate the length of warp beam (yarn length) in order to produce certain fabric length.
To produce a length of fabric ( Lf-meters) ,the number of racks the warp knitting machine has to knit is:
rack =( Lf x CPC x 100) : 480
The length of warp in meters which required for each guide bars is :
meters = ( Lf x CPC x 100 x run-in) : 480     | run-in units are in meters/480 courses|

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