Circular knitting machine maintenance

 Technology/Machinery

Knitting, braiding and digital solutions at ITMA 2023

From circular knitting machines and braiders to upgrades and digital solutions, Mayer & Cie. presented a wide range of solutions at the ITMA 2023 that make circular knitting machines and braiding machines even more durable and thereby more valuable.

Knitting

As a specialist for circular knitting machinery, the company exhibited 3 machines with which it focuses on a wide range of demand. A newcomer to the portfolio is the SF4-3.2 III. It specializes in lightweight and elastic 3-thread fleece fabrics. The Relanit 3.2 HS, a popular single jersey machine with outstanding productivity and very good plating properties, was on show at ITMA with various improvements. Another established model is the OVJA 2.4 EM, currently the most productive machine in its area. It specializes in mattress cover fabrics and Mayer & Cie., Albstadt/Germany, has developed a spacer kit to add to its capabilities.

Customers interested in jacquard machines were able to take an off-site look at the MJ 3.2 E and the OVJA 1.6 EE not far from the exhibition venue at Mayer & Cie.'s Italian representative Savio Macchine Tessili SpA, Pordenone/Italy.

Relanit 3.2 HS with improved needles and sinkers

In its latest iteration the Relanit 3.2 HS comes with a new yarn guide that makes feeding elastic thread significantly easier. The mechanical single jersey model processes a wide range of yarns and qualities most reliably. It also scores points for energy efficiency. The machine’s energy consumption is up to 30% lower than that of a conventional circular knitting machine. Existing machines can be upgraded to incorporate the new yarn guide.

A further innovation consists of equipping the Relanit 3.2 HS with improved needles and sinkers. Developed jointly with Groz-Beckert KG, Albstadt/Germany, the needle's predetermined breaking point prevents it from breaking uncontrolled under high load or with a defective needle latch and in the worst case broken needle butts, requiring more complex intervention by the knitter. This reduces downtimes.

The new sinker was also developed jointly with Groz-Beckert. With the new sinker the Relanit 3.2 HS runs more smoothly, more quietly and with less wear and tear. At higher speeds the thread tension increases less sharply too, thereby reducing the likelihood of faults in the fabric even with exacting qualities like sustainable cotton. The new sinker also makes setting the lower swing curve unnecessary, which in turn makes gauge gauges simpler.

OVJA 2.4 EM now with spacer

Customers were able to inspect three Mayer & Cie. jacquard machines at or near ITMA. At the trade fair stand itself the textile machinery manufacturer exhibited an OVJA 2.4 EM. At Savio, interested ITMA visitors were able to see the MJ 3.2 E and the OVJA 1.6 EE in action.

The OVJA 2.4 EM is one of 5 machines in the Mayer & Cie. portfolio that are specially designed for knitting mattress cover fabric. In a 38-inch diameter the OVJA 2.4 EM knits up to 30 kg of sought-after 300 g/m² fabric per hour.

This double-layer machine’s portfolio has been extended. In a few simple steps it can be converted to knit spacer fabric in gauges of E18 to E20. Visitors were able to watch the machine on show at the ITMA knitting spacer fabric with a hole structure.

One feature that delivers even greater reliability is the thread fluctuation system, which is installed in every other system. It ensures a constant thread tension and prevents the formation of thread loops or dropped stitches. The cross-flow nozzle can be switched off manually.

The new horizontal yarn guide serves the same purpose: to improve the machine's reliability and user friendliness. The horizontal yarn guide has a larger bore, which is especially beneficial when using a thicker weft yarn. Adjustments for a change in height of the rib dial are not necessary. The improved hold-down function is particularly useful when long floats are involved.

MJ 3.2 E electronic single jersey jacquard machine

The MJ 3.2 E is a specialist in mesh and body mapping. It knits electronic jacquard using the 2 or 3-way technique as required. The OVJA 1.6 EE was the second off-site exhibit on show at Savio. A double jersey jacquard machine, it has gained a reputation for being the most reliable choice in its sector. It knits both double-face fabric with a lay-in yarn and spacer fabrics.

SF4-3.2 III for lightweight 3-thread fleece fabrics

Mayer & Cie.'s third knitting machine at its stand at the ITMA was the SF4-3.2 III, addresses a major trend in the clothing industry. Lightweight elastic 3-thread fleece fabrics in both pure cotton and cotton blends are very much in demand. This new machine combines the tried and trusted S4 3.2 II and components from the MBF 3.2 such as the stitch formation.

The machine is characterized by its plating performance. The plating is so good that double dying is not necessary unless polyester yarn shows through, and if the polyester is processed invisibly in the way the SF4-3.2 III does the job, single dying is sufficient, cutting costs and saving resources.
To make the SF4 3.2 III even more flexible Mayer & Cie. offers a conversion kit that transforms it into an S4-3.2 II in a few simple steps. It then knits single jersey structures with up to 4 needle tracks, such as piqué and double piqué, all in fine gauges of up to E44. There is also a kit to convert an S4-3.2 II into an SF4-3.2 III.

Braiding

Mayer & Cie. exhibited a braiding machine at ITMA for the first time. The company has integrated the braiding division at its Albstadt headquarters since 2019.

The company exhibited an MR-15/18C/Single Deck, at this year's ITMA. The braiding machine handled yarn, and hose with a textile sheath has a wide range of industrial uses. The exhibited machine had a capstan wheel, which is especially suitable for smaller-diameter textile braiding and hoses. The optional SpeedBooster increases the efficiency of a braiding machine by up to 11%.

Following their clear pattern almost noiselessly, the 18 carriers rotated, creating their maypole braid. In actual production it is a different matter entirely. A braiding machine like the MR-15/18C/Single Deck reaches a rotor speed of up to 245 rpm. Each of the machine’s 18 carriers rotates 82 times per minute (82 rpm), producing 2.5 m of textile hose per minute. Normally a braiding machine is housed in a soundproof cabin because of the noise it makes, therefore it was a novelty to be able to watch one at work, especially as the eye would be unable to follow it at its normal working speed.

SpeedBooster delivers better performance

To further increase the speed and productivity of its braiding machines Mayer & Cie. has developed the SpeedBooster. It took the machine on show at the ITMA to a top rotor speed of up to 270 rpm, and with the SpeedBooster the carriers rotate up to 90 times per minute.

Technically, the SpeedBooster is a sensor-controlled filling level gauge. The more the fill level of the pools decreases, the faster the speed can be. An increase of up to 20% is physically possible. The SpeedBooster is an option when purchasing a new machine. It can be retrofitted to existing machines by means of an upgrade kit.

CapstanWheel for smaller-diameter hoses

The MR-15/18C/SD exhibited at ITMA had a capstan wheel. This haul-off unit is suitable for smaller hose diameters and textile braiding. The braided hose is wound several times round the capstan wheel. Its rotation draws the hose out of the braiding unit and feeds it to a winding unit. Capstan wheel and braiding unit are synchronized to achieve a high quality of braiding and a constant pitch length.
Mayer & Cie. braiding machines are fitted out with a haul-off MC as standard that is suitable for hoses and pipes with a diameter of up to 160 mm. Jaws are activated to clamp the hoses. The haul-off MC can be supplied with either a caterpillar (PAD version) or a belt take-off. The take-off and braiding unit are synchronized to ensure a high quality of braiding and a constant pitch length.
 

♦ References

►www.textiletechnology.net/

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