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HOSE REINFORCEMENT - Knitting Machinery Corp

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KNITTING MACHINERY CORP.
mc
K N ITTIN G
M A C H IN ER Y
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C O R P . O F A M ER IC A
M A N U F A C T U R E R S O F H O S E R E IN F O R C E M E N T M A C H IN E R Y
F O R T H E P L A S T IC , R U B B E R A N D S IL IC O N E IN D U S T R IE S
PROVIDING A GLOBAL INDUSTRY
MACHINES FOR HOSE
REINFORCEMENT
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KMC HOSE REINFORCEMENT
• INTRODUCTION
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35 YEARS
11 PATENTS
HISTORY
CUSTOMER BASE
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KMC HOSE REINFORCEMENT
• Knitting Machinery Corporation was founded in
1963 by John Greczin. After 38 years of building
and improving, including 11 patents, the company
is proud to have a world-wide customer base.
• Now a Crawford Group Company, our
headquarters is located in Cleveland, Ohio. We
have manufacturing facilities in Cleveland and
Greenville, Ohio.
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OUR MISSION
• In-Line Hose Manufacturing
- Our mission was to produce a machine that
would provide reinforcing on a hose, without
distortion, as it was being extruded and then coextrude over the reinforcement. This would
result in a completed product at production line
speed.
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OUR MISSION
• We also wanted to produce a single machine
that would provide our customers a solution
to their varied reinforcement needs.
-Various needs include:
•Different size of hose
•Knitting
•Spiral Wrap
•Combinations of Knitting and Spiral
Wraps.
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PHILOSOPHY
• In producing a hose we want to minimize any
distortion from the manufacturing process. It is
necessary to keep the hose straight and to
minimize twists from yarn tension. Requiring
precise line control.
• KMC is minimizing those outside forces in
knitting head design, by allowing a relaxed knit
with tension applied as needed.
• KMC is minimizing those outside forces in spiral
head design, by using a low tension design.
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OUR ACCOMPLISHMENTS
• KMC has manufactured machines to do just
that.
• Our machines are able to provide
reinforcement to an extruded hose and then
co-extrude over the reinforcement; AND
one machine will allow the customer to
knit, spiral wrap, or run various sizes of
hose.
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OUR ACCOMPLISHMENTS
• Our machines are
currently being used to
produce reinforced hose
around the world.
• We have designed and
built the machines that
have allowed us to
encompass the world
with reinforced hose.
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TYPE OF HOSE
• There are 4 basic types of hose.
•Low Pressure - Non-Reinforced
•Low/Medium Pressure - Knit
•Medium Pressure - Spiral
•High Pressure - Braid
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LOW PRESSURE HOSE
Non-Reinforced
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LOW/MEDIUM PRESSURE
Knit
•Knit is produced by using a continuous line
process at a rate of 30-60 feet per minute.
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MEDIUM PRESSURE HOSE
Spiral
•Spiral is produced by using a continuous line
process at a rate of 60-200 feet per minute.
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TYPES OF REINFORCEMENT
• KMC provides four basic types of
reinforcement.
•Spiral Wrap
•Plain Stitch
•Lock Stitch
•Combination Radial/Plain Stitch
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SPIRAL WRAP
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PLAIN STITCH
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LOCK STITCH
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RADIAL/PLAIN STITCH
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MACHINE HEADS
• KMC uses two types of machine heads:
– Spiral Heads
– Knitting Heads
•Both the Spiral Head and the Knitting Head
can be exchanged with one another.
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SPIRAL HEAD
• Spiral wrap application is of a face-to-face
design with a tightly-controlled
environment. The Spiral process is
accomplished by wrapping a specified
number of yarns through the rotating yarn
guide; as the hose passes through at a
controlled rate. The heart of our Spiral
Head is the yarn guide and bushing.
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SPIRAL HEAD
– The yarn guide comes in incremental sizes.
Each one with the various feeds required.
– To provide a tight-wrap pattern, we use
bushings that enable precision control of the
hose.
– We also use tension plates in conjunction with
the yarn guide immediately around the hose.
– The type, size, and/or denier of yarn effects the
tension of the machine.
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SPIRAL HEAD
– Many times customers may have specific
requirements for tensioning; KMC will make
recommendations.
– Optional
• There is a three-part rotary tensioned head that
allows for an infinite tension adjustment.
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SPIRAL (speed) OUTPUT
• The feed is determined by taking the
circumference of the hose divided by the
desired spacing between the yarns. The
linear coverage is determined by the
distance the hose moves through the spiral
head in one revolution divided by the feed.
The yarn angle is a determinant factor in the
burst strength of the hose. 90Вє = total
coverage.
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KNITTING HEAD
• Design of KMC knitting heads include
these features:
–Self contained unit
–Compact
–Removable
–Low tension yarn flow
–Precision cams
–Precision adjustments
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KNITTING HEAD
• The Knitting Head is designed for both ease
of setup and maintenance. All adjustments
of the Knitting Head are of special
micrometer threads to maintain parallelism
and concentricity. There is also an
alignment adjustment that gives the ability
to realign the head in the event it would be
damaged by mishandling.
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KNITTING HEAD
• The flow of the yarn and the design of the
cam provides excellent needle life while
also making possible the ability to knit at
increased speeds.
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ITEMS OF IMPORTANCE
• SIZE OF THE KNITTING HEAD SET-UP
– KMC has various sizes of knitting head set-ups:
• The knitting heads are available in sizes of 2 1/2”,
3 1/2”, and 5”.
– Size the knitting head as close as possible to the
hose inner tube outside diameter.
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BURST STRENGTH &
EXPANSION
• Knitting a tight sock on the hose reduces
expansion.
• Obviously, burst strength is directly effected
both by the amount of yarn applied and how
it is applied.
• Burst strength and expansion are two
separate issues.
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KNITTING (speed) OUTPUT
• The output of the knitting process is
determined by taking the feed or the number
of lobes on the cam, which gives the
number of stitches per revolution of the
yarn table, times the distance between the
stitches. The distance is determined by the
movement of the hose through the machine
per revolution of the yarn table.
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THE KNIT PROCESS: FEEDS
• Each Feed is the result of a Cam Lobe.
– Ex. An 8 Feed has 8 Lobes. In one rotation, an
8 Feed Cam will produce 8 courses of knit on
the hose.
N eedles
8 C ourses of K nit
produced by one revolution
of an 8 F eed C am
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PRODUCT STRUCTURE
• The total feed determines the number of
courses of knit on the diameter of the hose
per revolution. The needles determine the
lines of knit linearly with the hose.
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NEEDLES
• The needles are what produces the loops or
stitches. The number of needles around the
circumference of the hose determines the
number of loops.
5 Needles
7 Needles
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FEEDS
• You can then see, as the hose moves faster
through the Knitting Head the Courses will
be further apart. The slower the hose
moves, the closer the Courses will be.
Slower
Faster
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PLAIN STITCH
• Plain Stitch reinforcement is produced by a
single track cam with 4, 6, or 8 lobes.
• Plain Stitch allows for more expansion and
less separation than the lock stitch.
PLAIN STITCH
CAM
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PLAIN STITCH
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LOCK STITCH
• Lock Stitch, or Skip Stitch, is produced by
using a double track cam with 8 or 12 lobes.
Each track containing half of the feeds;
thus, allowing an alternating stitch to be
produced.
• Lock Stitch can run at a
LOCK
higher speed and has
STITCH
less expansion than the
CAM
plain stitch.
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LOCK STITCH
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RADIAL/PLAIN STITCH
• This reinforcement is produced by spiral
wrapping with one head and following it
with a knitting head in the same machine; at
the same time, in either direction.
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RADIAL/PLAIN STITCH
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MACHINES
• KMC offers a wide range of machines to fit
the customers needs.
–The two basic kinds are for:
•Batch Process
•Continuous Line Process
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BATCH PROCESS
•The batch-process method involves making
an inner tube then placing it in pans, reels or
in tubs. The tubs are then taken to the hose
reinforcement area, where the reinforcement
is applied. After reinforcement, it is placed
back in the tubs; requiring more labor and
subjects the tube to twisting, pulling, and/or
contamination. This can cause the tube size to
vary in shape and wall thickness.
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BATCH PROCESS
•The next step in the batch-process method
involves passing the tube through the extruder
cross-head. At this time, a vacuum can be
applied to help achieve adhesion between the
inner and outer cover. In every stage of the
batch-process the quality must be checked
carefully, since the finished product may not
be completed for several days or weeks. The
batch-process also requires much more floor
space than the continuous line process.
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BATCH PROCESS
•The batch-process, however, is excellent for
short runs and just in time production.
• Batch Process Machines are:
– KM-72-S
– KM-90-NV
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KM-72
• This is an economical
machine that is used in the
batch-process method.
• The machine is available
in a variety of sizes: 2.5”
and 3.5” bore diameter.
• KM-72 is available with a
soft start or variable speed
drive.
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KM-90-NV
• This is a state of the art
vertical machine for batchprocess method.
• The machine is available
in a variety of sizes: 2.5”,
3.5”, and 5” bore diameter.
• KM-90-NV offers large
yarn capacity, variable
takeoff and machine drive.
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CONTINUOUS LINE PROCESS
• A line set-up and control must be precise in
every aspect. A precision line produces a
precision product.
• A precision line is also dependent on proper
puller placement. Keep the puller
immediately following the spiral/knitter for
precise reinforcement.
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CONTINUOUS LINE PROCESS
• Things to consider in a continuos line process.
– Type of cooling (if needed)
– Type of bonding of the inner and outer layers. Hot
bonding or solvent bonding.
– Is the heat or solvent compatible with the yarn.
• KMC has three machines that are used in a
Continuous Line Process. They are:
– KM-89-SD
– KM-89-SS
– KM-89-SS-HS
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KM-89-SD
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KM-89-SD
• This is a single deck machine
used only for knitting. It is a 56”
machine to allow for adequate
yarn clearance and is of a very
heavy-duty construction.
•A standard machine is supplied with cat-pullers,
yarn interrupt detect, stitch interrupt detect, and
guiderolls.
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KM-89-SD
•The bore size is 6” in diameter and
is supplied with a knitting head of
2.5”. The knitting head is available
in either a plain or lock stitch.
• Knitting heads come in sizes of 2.5”, 3.5” and 5”.
• The knitting heads can quickly be removed and
interchanged with other knitting heads of various
sizes and/or stitches.
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KM-89-SD
•The machine allows for a large
yarn capacity of approximately 15
pounds per yarn package.
• For special applications, send yarn specifications
to KMC.
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KM-89-SS
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KM-89-SS
• This is a two-deck machine that
can be used for knitting and/or
spiral wrap. It is a 56” machine
to allow for adequate yarn
clearance and is of a very heavyduty construction.
•A standard machine is supplied with cat-pullers,
yarn interrupt detect, stitch interrupt detect, and
guiderolls.
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KM-89-SS
•The bore size is 6” in diameter and
is supplied with a knitting head of
2.5”. The knitting head is available
in either a plain or lock stitch.
•KM-89-SS can be set-up as a 12 feed, 8” yarn
package or a 24 feed, 5” yarn package machine.
Other combinations are available.
•It runs at a speed of 800 RPM.
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KM-89-SS-HS
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KM-89-SS-HS
• This is a two-deck machine that
can be used for knitting and/or
spiral wrap. It is a 56” machine
to allow for adequate yarn
clearance and is of a very heavyduty construction.
•A standard machine is supplied with cat-pullers,
yarn interrupt detect, stitch interrupt detect, and
guiderolls.
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KM-89-SS-HS
•The maximum bore size is 3” in
diameter to allow for a 2 3/4” hose
inner core outside diameter.
•KM-89-SS-HS can be set-up as a 12 feed, 6” yarn
package machine. Other combinations are available.
•It runs at a speed of 1100 RPM.
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CAT/PULLER
• KM-89 or KMCAT/PULLER has a 5”
capacity. Provided with
a timing belt design and
an adjustable centerline.
It is fully guarded. It is
available with many
takeoff belt cover
options.
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DISCLAIMER
• To the best of our knowledge, the information
contained herein is accurate. However, all
information contained is subject to revision as needed
and Knitting Machinery Corporation of America does
not assume any liability whatsoever for the accuracy
or completeness of the information contained herein.
It is the sole responsibility of the customer to
determine suitability for any particular end use. Such
usage should comply with all appropriate health and
safety standards. This publication is not a license to
operate under, or intended to suggest infringement of
any existing patents.
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Knitting Machinery Corporation of America
15625 Saranac Avenue
Cleveland, Ohio 44110
Phone (216) 851-9900
Fax (216) 851-9909
Visit website (knittingmachinerycorp.com)
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