The following is a comprehensive introduction to the Karl Mayer 245-inch 24-needle full-width weft lining warp knitting machine, which is integrated based on its technical characteristics, industry positioning and practical applications:
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### ⚙️ ** 1. Core parameters and model positioning **
1. "Basic Specifications
- ** Working width ** : 245 inches (approximately 6.22 meters), featuring an ultra-wide design, suitable for the production of large-sized industrial textiles.
- ** Machine number ** : 24 needles (E24), that is, 24 knitting needles per inch, balancing the density and strength requirements of the fabric, suitable for medium and thick industrial base fabrics.
- ** Type ** : Full-width weft interlocking warp knitting machine, which adopts parallel weft laying technology. The weft yarn remains in a straight line throughout the process without any bending to enhance mechanical properties.
2. ** Typical Model Series **
- **HKS/RS Series ** : Derivative models such as **RS MSUS-V** or **WEFTTRONIC® II**, specifically optimized for industrial textiles such as fiberglass grating and geotextiles.
- ** Technological Innovation ** : Since 2015, the model has upgraded the frame rigidity, an independent motor-driven winding device, and an X/ Y-axis bidirectional weft laying system, significantly enhancing speed and stability.
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### ** 2. Core technology innovation and performance advantage **
1. ** Efficient weft Laying system **
- **VARIO weft Laying Technology ** : The weft yarns move in both directions in parallel through coordinate positioning, with precise and controllable weft laying paths, supporting the weaving of complex grid structures.
- ** No height limit for weft yarn ** : The electronic control system (such as EL technology) enables rapid switching of weft yarn patterns without mechanical intervention, making it suitable for small-batch customized orders.
2. ** Speed and Stability improvement **
- ** Machine speed ** : 1300-1800 RPM (revolutions per minute), an increase of approximately 30% compared to the previous model, due to the optimization of the weft lining path and the improvement of drive efficiency.
- ** Shock Absorption Design ** : The warp frame is equipped with rubber cover bearings and floor-standing shock absorption devices to reduce the tension fluctuation of the yarn during high-speed operation and ensure the uniformity of wide fabrics.
3. "Intelligent Control
- **KAMCOS® 2 System ** : Integrated with Internet of Things (iot) functions, it can monitor weft yarn tension, energy consumption and production efficiency in real time, and supports cloud pattern data transmission.
- ** Electronic Warp Feeding (EBA) ** : Servo-driven warp shafts precisely control the feeding amount of warp yarns to prevent yarn breakage or looseness.
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### ️ ** * Core structure and System design **
1. "Axle Frame and Drive System
- ** Floor-standing warp frame ** : Supports dual warp configuration. The EBA drive device ensures precise feeding of warp yarns into the circular assembly. The cross-bracing tube shock absorption design reduces high-speed vibration.
- ** Independent drive of yarn separation device ** : Decoupled from the main drive of the machine, enhancing the dynamic response of yarn separation and reducing damage to weft yarns.
2. ** Circle forming and weft lining components **
- ** Three-yarn system ** : warp yarns (longitudinal), weft yarns (full-width parallel interlining), and looped yarns (binding structure), endowing fabrics with high dimensional stability.
- ** Magneto-Electric Encoder ** : Replacing traditional photoelectric encoders, it features an anti-shock and waterproof design (IP67 grade), can withstand high-temperature environments of 70-80℃, and prevents signal failures caused by radial runout of the motor.
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### ** IV. Application fields and typical products **
"Industrial textiles
- ** Geotechnical materials ** : Road reinforcement geogrids and embankment stabilizing base fabrics, with tensile strength 20% higher than that of woven fabrics.
- ** Building reinforcing materials ** : Glass fiber/polyester grating (such as WEFTTRONIC® II G model), used as the base fabric for concrete reinforcement or roof waterproof coating.
- ** Environmental Protection Application ** : Linen-made degradable green grating (urban vertical greening system), which combines carbon sequestration and temperature regulation functions.
2. ** Composite base fabric **
- ** Multi-axial fabric ** : Bio-hemp was processed on the **COP MAX 4** model for lightweight components in ships/automobiles, with carbon emissions reduced by 83% compared to glass fibers (0.48 kg CO₂/kg vs 2.9 kg).
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### ⚖️ ** V. Market positioning and comparison with competitors **
- ** Efficiency Advantage ** : The 245-inch format increases production capacity by 32% compared to the common 186-inch model, reducing seam loss.
- ** Cost Control ** : The electronic system reduces the downtime for pattern switching, and the maintenance cost is 15% lower than that of mechanical models.
- ** Sustainability ** : Compatible with natural fibers (linen, cotton), and supports the production of OEKO-TEX® environmentally friendly certified products.
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"Summary Table of Key Performance Parameters
| ** Parameter Category ** | ** 245-inch 24-pin model Characteristics ** | ** Industry Significance ** |
|--------------------|--------------------------------------------|----------------------------------|
| Working width | 245 inches (6.22 meters) | Reduce splicing and improve the utilization rate of raw materials |
| ** Machine speed ** | 1300-1800 RPM | 30% higher than the previous model, leading production capacity in the industry |
| ** Weft Laying Technology ** | VARIO system + electronic pattern switching | Supports unlimited flower height and quick production conversion |
| Applicable yarns | Polyester/glass fiber/linen, compatible with high grammage yarns | Extended to environmental protection and composite materials fields |
| ** Intelligent System ** | KAMCOS® 2 + EBA drive + Magneto-electric encoder | Ensures stable operation under high temperature and high speed |
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### ** Summary **
The Karl Mayer 245-inch 24-needle full-width interwoven warp knitting machine is the flagship model for high-end industrial textiles. Through ultra-wide design, electronic weft laying and intelligent control, it achieves the unity of high productivity and flexibility. Its core value lies in:
✅ ** extra-wide high efficiency ** : Maximize output per pass, reduce marginal energy consumption;
✅ ** Intelligent stability ** : Magneto-electric encoder with independent drive system for long-term reliable operation;
✅ ** Green Compatible ** : Supports natural fibers and biodegradable materials in response to the trend of sustainable manufacturing.
