MACHINES FOR HOSE REINFORCEMENT

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KNITTING MACHINERY CORP.
PROVIDING A GLOBAL INDUSTRY

• MACHINES FOR HOSE REINFORCEMENT

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KMC HOSE REINFORCEMENT

• INTRODUCTION
• 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
co-extrude 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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MACHINE HEAD
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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. 90º
  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.

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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 higher speed and has
  less expansion than the plain stitch.

LOCK STITCH CAM
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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
  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.

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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 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-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 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-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 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.

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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 [phone]
• Fax [phone]
• Visit website (knittingmachinerycorp.com)