Circular knitting machine parts are key components that ensure stable machine operation, consistent fabric quality, and minimize production errors. However, due to continuous operation under high mechanical pressure, components such as needles, cams, bearings, and sinker plates are prone to wear, bending, or degradation over time. If not inspected and replaced promptly, these malfunctions will directly affect productivity and finished product quality.
The following article will help you recognize common signs indicating when to replace circular knitting machine parts, along with effective handling solutions.
1. Warning Signs That Circular Knitting Machine Parts Need Replacement
1.1. Worn or Broken Knitting Needles
Knitting needles are the components that directly bear force during the yarn looping process. In the system of circular knitting machine parts, these are the most easily worn components due to continuous friction. When needles become dull, bent, or have broken latches, skipped stitches, fabric defects, or yarn breakage will occur. A knitting machine can use thousands of needles, and even a small number of faulty ones can significantly affect the entire fabric surface and production output.
Solution: Operators need to schedule regular inspections of knitting needles using a specialized magnifying glass to detect early signs of worn tips, bending, or broken latches. Inspections should be performed after each specific operating cycle, depending on the fabric type and production speed. Additionally, it is necessary to follow the recommended needle unit replacement guidelines from the manufacturer – typically every 3 to 6 months – to avoid affecting fabric quality and minimize unexpected machine downtime due to needle damage.
1.2. Worn Cams and Sinker Plates
Cams are responsible for creating the lifting and lowering motion for needles during the yarn looping process. In the system of circular knitting machine parts, cams play a crucial role in ensuring the knitting cycle runs smoothly and synchronously. When cams are worn, movements become imprecise, easily leading to yarn looping issues, overlapping stitches, or fabric misalignment – directly affecting product quality.
Solution: Operators need to regularly check the clearance and friction between the cam, sinker plate, and needle using specialized equipment. If cams show signs such as deep scratches, rough surfaces, or significant timing discrepancies, they should be replaced immediately to avoid damaging new needle latches or affecting other components. Regular cam replacement is also an important part of the preventive maintenance plan for circular knitting machines.
1.3. Bearings, Rotating Shafts Making Noise or Vibrating Strongly
Bearings and rotating shafts are continuously moving components within the system of circular knitting machine parts. When bearings are worn, lack lubrication, or become loose due to prolonged use, the rotating shaft will emit strange noises or vibrate abnormally. This is a clear sign that problems could spread if not addressed promptly. These vibrations not only affect the accuracy of the yarn looping process but also cause rapid wear on other associated components.
Solution: Schedule regular lubrication for bearing positions and check for looseness using a dial indicator or specialized equipment. If the value exceeds the manufacturer’s allowable limit, the bearings must be replaced immediately to ensure the stability of the entire circular knitting machine operating system.
1.4. Abnormalities in Output Fabric
Signs such as fabric pulling, wrinkling, yarn looping issues, needle defects, or changes in stitch density all indicate that the machine is operating unevenly. In the system of circular knitting machine parts, these errors often stem from the degradation of components like needles, cams, or sinker plates. If not detected and addressed promptly, these errors will spread, reducing finished fabric quality and affecting production schedules.
Solution: Operators need to carefully observe fabric samples after each operating shift to detect early signs of abnormalities. If errors tend to recur, the machine should be immediately paused to simultaneously inspect related components and replace worn or out-of-spec spares. Proactive early intervention will help minimize damage and extend machine lifespan.
1.5. Abnormal Temperature Increase in Machine Units
When circular knitting machine spares wear out over time without proper maintenance, friction within the system will increase. This forces the motor to operate at a higher intensity to compensate for slippage or imbalance, causing a sudden temperature increase in mechanical units. The consequence is rapid heating of the machine unit, high risk of lubricating oil leakage, electric motor burnout, or even central control circuit damage – leading to severe damage to the entire production line.
Solution: Install temperature sensors and specialized gauges at critical locations such as bearings and cam units to continuously monitor temperature. If the temperature exceeds the safe allowable limit, quickly inspect, identify the worn spare, and replace it immediately. This helps prevent widespread issues and keeps the operating system stable.
2. Factors Affecting the Lifespan of Circular Knitting Machine Parts
2.1. Operating Intensity
Operating intensity directly affects the durability of circular knitting machine parts. Factories operating continuously 24/7 often need to replace parts more frequently due to rapid wear of components. Conversely, facilities operating in shifts may extend usage time but still require periodic inspections to ensure safety and quality.
2.2. Type of Yarn Used
The type of yarn used in production also determines the wear rate of circular knitting machine parts. For example, soft cotton yarn causes less friction than synthetic yarns like spandex or polyester – which often create significant pressure on needles and cams. Choosing the appropriate yarn type or adjusting operating parameters will help extend the lifespan of spares.
2.3. Maintenance Conditions and Work Environment
Environmental conditions such as dust, humidity, temperature, and ventilation levels in the workshop greatly affect the durability of circular knitting machine parts. If not regularly maintained and properly cleaned, components like bearings, cams, and needles are prone to rust or dirt accumulation, leading to inaccuracies and rapid wear. Investing in a periodic maintenance system and a clean working environment will significantly save on spare replacement costs.
3. Effective Handling & Maintenance Solutions
3.1. Documenting the Lifespan of Circular Knitting Machine Parts
Maintaining technical records for each knitting machine is a crucial step to control the condition of circular knitting machine parts. Each record should include usage history, maintenance dates, replacement times, and technical specifications related to each component. This allows businesses to proactively develop periodic maintenance plans, prevent malfunctions, and replace spares at the right time.
3.2. Equipping with Specialized Inspection Tools for Circular Knitting Machine Parts
To ensure quality and accuracy during inspection, production workshops should invest in specialized equipment to check cam wear, sinker plate clearance deviation, and knitting needle durability. Using specialized tools will help timely detect faults in circular knitting machine parts, thereby minimizing unnecessary machine downtime and extending machine lifespan.
3.3. Training Maintenance Staff in Identifying Circular Knitting Machine Parts Faults
Training maintenance staff in fault identification skills is a core factor for effectively protecting equipment and the circular knitting machine parts system. Personnel need to be trained to observe, listen for strange sounds, feel for abnormal vibrations, and analyze fabric samples to detect early signs of damage. Human proactivity will increase the efficiency of the entire system.
3.4. Stocking Replacement Circular Knitting Machine Parts in Inventory
Maintaining a ready inventory of spares is a smart contingency strategy for production units with high operating frequency. Stocking essential components such as needles, cams, bearings, thread cutters, etc., will help quickly handle unexpected situations, limiting delays due to waiting for imports. Additionally, this also helps optimize operating costs and minimize disruption risks related to circular knitting machine parts.
4. Where to Buy Reputable Circular Knitting Machine Parts?
VieTextile – Professional Textile Machine Parts Distributor
- Supplies a full range of parts for various circular knitting machine brands (Mayer, Fukuhara, Terrot, etc.)
- Genuine imported knitting needles, cams, cutters, yarn feeders, bearings, etc.
- On-site inspection and replacement services available by schedule.
- Experienced engineers provide on-site technical support and adhere to company privacy policies.
Contact Information:
- Hotline: 0901 809 309
- Website: https://vietextile.com
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