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KNITTING

Lubrication System
For avoiding needle breakage and
frictional problem oiling is
necessary.
The lubricator provides uniform
lubrication to needles, cam tracks
and other knitting m/c
components.
By air pressure, oil is supplied
from a can to cam, sinker and
needle as a lubricant.
Oiling amount depend on m/c rpm. When rpm is raised then oiling speed is increased.
The patented nozzle construction separates the air-oil mixture into air and droplets of oil.
This method considerably reduces oil mist in the knitting workshop and ensures that the oil
only goes to the components to be lubricated.
Oiling amount is adjusted by programs setting in the machine.
3.5.1 Important Units of the
UNIWAVE Lubricator:
1. Flusher flushes and cleans knitting
components.
2. Air-regulator unit regulate the air
supply to the cleaning system.
3. Low pressure sensor stops the knitting
machine when the compressed air
supply to the knitting machine is
interrupted.
4. Low oil level sensor stops the knitting
machine immediately the oil level
drops below the preset minimum.
3.4 Air Circulation System
For cleaning, fluff, dirt, dust, lint etc.
removing air circulations fans are used.
For oil spreading equally.
For keeping machines cool & smooth running
and healthy environment
For strength consistency of yarn
Less breakage of needle and sinkers
Air gun is used for Air Gun
- Yarn feeding through tube from creel
- Lint removing from needle
- Maintenance purposes

3.4.4 Cam
Cam is the second primary knitting element. The cams are the mechanical devices which convert
the rotary machine drive into a suitable reciprocating action for the needles. In circular m/c,
different type of cams is used:
Knit Cam
Tuck Cam
Miss Cam

Fig. 3.7 Different Cams

M/C Operating Device

Inching Button: Runs the m/c very slowly by giving inching motion.
Inching Rod : Runs the m/c very slowly by giving inching motion.
Stop Button : Stops the m/c.
Start Button : Starts the m/c at full speed.

3.4.14 Motor

3.4.15 Gearing System

3.4.16 Fabric Take Down System


3.4.17 Take-down Rollers
There are 2-3 take down rollers after the spreader. The flat
double layered fabric passes through take down-rollers at a
uniform tension. After this the fabric is wound on to the cloth
roller through a guide roller.

8.1 Maintenance:
Maintenance is the process by which equipment is looked after in such a way that increase
machine life and ensure specific product quality required by the customer. Maintenance can
ensure trouble free service.

Maintenance of machineries is must for a knit composite mill. All machines and machines parts
of knitting are maintained with extreme care. Because production quality and quantity depends
on the maintenance with regularity. Knit Concern Ltd. leads maintenance with a troop of
skilled mechanical fitters.

8.2 Type of Maintenance:

Preventive Preventive Maintenance is a predetermined routine actively to


Maintenance: ensure on time inspection or checking of facilities to uncover
conditions that may lead to production break downs.
Routine Maintenance of different machines is prepared by expert engineers
Maintenance: of the maintenance department. Every machine has a schedule of
maintenance of 10 or 15 days. According to date, schedule
maintenance is taken on the machines. Operators are informed
about the time of maintenance. After pre-estimated production,
they hand over the machine to the fitters. Thus, fitters assure all
machines are OK.
Break down When product quality hampered and to complete production in due
Maintenance: time break down maintenance is taken. There are many faults seen
in the fabric during production due to needle, sinker, take down
roller etc. Then operators inform the mechanical fitters and they
fix it.

Knit Concern LTD. has an expert team for maintenance. When problem occurs they actively
solve the problems.
8.3 Manpower for different machines maintenance:
There are three shifts in this mill. Three groups of mechanical fitters for four persons work shifts.
Each group having a leader, a needle man and two assistant fitters. Fitters work under the
technical in charge for knitting section only.
For single jersey machine : 3-4 persons / hrs
For double jersey machine : 4-5 persons / hrs
M/C Cleaning & maintenance at the time of shift running.

8.4 Routine for servicing of machines


M/C dia Servicing time ( After production )
Less than 30" 3.5-4 hrs
34"-38" 4-5 hrs
More than 40" 7 hrs
46"-48" 8-9 hrs
52" or more 8 hrs
8.5 Maintenance tools and their functions:

Sl. No Name of tool Functions of maintenance tool


01 L- Key Loosen and tighten the screws
02 T- Key To open and fix the cam box
03 Air Suctioner Cleans machine by suctioning
04 Screw driver To loosen and tighten the screws
Spanner Loosen and tighten nut and bolt etc.
05 Tester To test electric circuit
06 Star driver Screw unlocking
07 Pliers Tighten screws and nuts
To grip anything & cut anything
08 Cutting pliers Cutting thin wire
09 Pulley key To loosen pulleys
10 Dial gauge meter Used to set the cylinder perfectly
11 Adjustable Wrench Used for setting nut & bolts
12 Socket Spanner Handle system for nut & bolt fitting
13 Hammer To apply load where required
14 Punch Used to fit any worn out shaft
15 Lock Opener To open the clip of bearing
16 Hack Saw To cut any metallic thing
17 Outside Calipers To measure outside dia
18 Inside Calipers To measure inside dia
19 Chain Ton To lift heavy load
20 Welding machine To join metallic parts
21 File To smooth any rough surface
22 Chisel To cut any metal
23 Steel Tape To measure length, width & height
24 Leveler To level the cylinder or dial accurately
25 Transfer Needle To transfer loop from one needle to another
To withdraw needle from needle bed

8.6 Maintenance Procedure:


For any mechanical fault of m/c, that hampers production, operator informs fitterman in
duty.
Fitterman observes the problem and begin to fix it.
If fittermans are unable to fix it, they inform technical in-charge, who comes in and fixes it.
For any electrical problem of m/c or serious mechanical problem, electrical department is
informed, they come and fix the problem.
They commence at work after informing of Deputy Manager.
There are two mechanical engineers in the department. For restorative maintenance, Sr. PO
orders fitterman to fit required m/c for cam and needle arrangement
In case of new design development other necessary requirements are adjusted.

8.7 Maintenance sequence of circular knitting machine


Power on/off

MPF/Positive feeder current line off

MPF belt out/loss

Yarn cut

Fabric out by handle

Cleaning and Oiling


Cam box out

Needle & sinker out

Needle & sinker cleaning by oil

Cam box cleaning by air

After opening & cleaning, m/c is leveled by using leveling meter and follows the reverse process
to ready the m/c.

8.8 Knitting Machine Lubrication


Check the oil level every day, if the oil level is below the two-thirds mark, refuel.
During maintenance, if oil is found in sediments, then all should be replaced with new oil.
If the transmission gear is oil-like stains, to increase once the oil in 180 days or so
Grease lubrication needs about 15 to 30 days plus a month at the time of maintenance,
lubrication checks throughout the drive bearing grease.
All components must use unleaded knitting oil.

8.8.1 Lubrication of circular knitting machine:

Lubrication location Lubrication time Lubricant name Brand


Cylinder bed , gear box Change after every 6 Tonna Oil S68 SHELL
months
Take- Down device Once a year Mobilux Grease #2 MOBIL
(wheel, gear, bearing)
Needle, Sinker & Cams During running time Klber Madol 934 Klber

8.9 Routine Maintenance of the Circular Knitting Machine


Sl Maintenance Works Schedule
1 Clean yarn fluff on the machine and yarn creel. DAILY
Check the automatic stop device and safety device
Check the positive yarn feeders, adjust if any abnormal situation.
Check safety gear shields, immediately repair/ replace.
Clean the m/c, yarn feeding to all needles, knot catcher of positive
feeder, sensor.
Before cutting a roll from cloth roller, clean needles, cam box etc.
Check oil level and inject enough oil.

2 Check belt tension of driving system to make sure the smooth of WEEKLY
machine driving.
Check the fabric taken down system to make sure working in good
performance.
Cleaning yarn feeding speed disk, the inner disk accumulated fly
cleaned.
Check transmission belt tension is normal and drive smoothly.
Carefully check the functioning of winding mechanism.
Check whether the needles and sinkers have damaged or not, in
case damaged, should replace new needles and sinkers
immediately.
If fabric is in bad condition, should consider to replace all.

3 Dismantle cam boxes and clear away yarn fluff. MONTHLY


Clean the fan and check the wind direction of fan.
Clear up the yarn fluff from all electrical devices
Check the performance of all electrical devices (auto stop device,
detectors)
Check dust removal devices are correct and clear above the dust.
Check the needle groove wall damage, if problems are detected,
repair/ replace.
Check all needles and sinkers, if used for too long, affecting the
quality of the fabric, replace.
Cleaning needle grooves to stop dirt coming into the fabric with
needles.

4 Clean completely the dial and cylinder include needles and sinkers. HALF
If there's any broken of needles and sinkers, should replace new YEARLY
ones immediately.
Clean oil lubricator
Clear away the yarn fluff and oil in the motor and driving system.
Check all the oil is smooth and clean injection equipment.
Clean and inspect the positive-type yarn feed mechanism is
flexible.