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					KNITTING MACHINERY CORP.
             mc           
                               KNITTING
                              MACHINERY
                              CORP. OF AMERICA
      MANUFACTURERS OF HOSE REINFORCEMENT MACHINERY
       FOR THE PLASTIC, RUBBER AND SILICONE INDUSTRIES




PROVIDING A GLOBAL INDUSTRY

                        MACHINES FOR HOSE
                         REINFORCEMENT
 


KMC HOSE REINFORCEMENT

• INTRODUCTION
     –   35 YEARS
     –   11 PATENTS
     –   HISTORY
     –   CUSTOMER BASE
 


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.
 


                               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 co-
     extrude over the reinforcement. This would
     result in a completed product at production line
     speed.
 


                             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.
  


                            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.
 


      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.
 


      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.
 


                          TYPE OF HOSE

• There are 4 basic types of hose.
     •Low Pressure - Non-Reinforced
     •Low/Medium Pressure - Knit
     •Medium Pressure - Spiral
     •High Pressure - Braid



    LOW PRESSURE HOSE




      Non-Reinforced
 


       LOW/MEDIUM PRESSURE




                     Knit
•Knit is produced by using a continuous line
process at a rate of 30-60 feet per minute.
 


     MEDIUM PRESSURE HOSE




                    Spiral
•Spiral is produced by using a continuous line
process at a rate of 60-200 feet per minute.
 


     TYPES OF REINFORCEMENT

• KMC provides four basic types of
  reinforcement.
     •Spiral Wrap
     •Plain Stitch
     •Lock Stitch
     •Combination Radial/Plain Stitch



    SPIRAL WRAP



    PLAIN STITCH



    LOCK STITCH



    RADIAL/PLAIN STITCH
 


                        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.
 


                          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.



                              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.



                                 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.
 


          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. 90º = total
  coverage.
 


                        KNITTING HEAD

• Design of KMC knitting heads include
  these features:
     –Self contained unit
     –Compact
     –Removable
     –Low tension yarn flow
     –Precision cams
     –Precision adjustments
 


                     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.
 


                     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.
 


             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.
 
              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.
 


     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.
 


     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.
                            8 Courses of Knit
                        produced by one revolution
                            of an 8 Feed Cam
              Needles
 


          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.
 


                              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
 


                                   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
 


                        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



    PLAIN STITCH
 


                         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.



    LOCK STITCH
 


           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.



    RADIAL/PLAIN STITCH
 


                                MACHINES

• KMC offers a wide range of machines to fit
  the customers needs.
   –The two basic kinds are for:
     •Batch Process
     •Continuous Line Process
 


                    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.
 


                    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.
 


                    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



                    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.



              KM-90-NV
    • This is a state of the art
      vertical machine for batch-
      process 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.
 


 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.
  


 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



    KM-89-SD
    


                                   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.
    


                                  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.
    


                                  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.



    KM-89-SS
    


                                   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 heavy-
                     duty construction.
•A standard machine is supplied with cat-pullers,
yarn interrupt detect, stitch interrupt detect, and
guiderolls.
    


                                  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.



    KM-89-SS-HS
    


                              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 heavy-
                     duty construction.
•A standard machine is supplied with cat-pullers,
yarn interrupt detect, stitch interrupt detect, and
guiderolls.
    


                             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.



       CAT/PULLER

    • KM-89 or KM-
      CAT/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.
  


                                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.





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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