Innovation in Servo-Controlled Trick Plate Adjustment

In the field of double needle bar warp knitting machines, precision and efficiency are critical factors that directly impact fabric quality and production performance. To address long-standing challenges in machine adjustment, A-ZEN has successfully developed an innovative solution: servo motor-controlled automatic adjustment of the trick plate distance (knock-over plate gap).

From Manual Adjustment to Intelligent Control

Traditionally, the adjustment of the trick plate distance relies on mechanical operation. Operators must rotate a handwheel to adjust the gap manually, then repeatedly measure and fine-tune the setting. This process is not only time-consuming but also prone to mechanical deviation and visual error, often requiring multiple corrections to achieve the desired result.

A-ZEN’s new system replaces this conventional method with a servo motor-driven automatic adjustment system.

How the System Works

The operation is simple and intuitive:

• The operator selects the required trick plate distance directly on the control screen.

• For example, if the current half-width is 1.8 mm and needs to be adjusted to 6 mm, the operator simply inputs “6” into the system.

• After confirming the input, the machine automatically completes the adjustment.

The entire process takes only a few seconds, eliminating the need for manual intervention and repeated calibration.

Key Advantages of Automatic Adjustment

This technological upgrade brings multiple practical benefits:

1. Higher Precision

Servo-controlled adjustment removes the inaccuracies caused by manual operation. The system ensures consistent and repeatable settings, which directly improves the spacer fabric thickness quality.

2. Significant Time Savings

Compared with traditional mechanical adjustment, which may take several minutes or longer, the new system completes the process in seconds, greatly improving production efficiency.

3. Easy Operation

The user-friendly interface reduces the complexity of machine setup. Operators no longer need extensive experience, which helps lower labor skill requirements and training costs.

4. Improved Production Stability

Accurate and stable settings reduce the risk of defects and machine inconsistencies, contributing to smoother and more reliable production.

Proven Performance in the Market

Since its introduction at the end of 2024, this technology has undergone more than one year of real-world application. It has been widely adopted in China and Turkey, receiving positive feedback from both customers and warp knitting machine operators.

The system has proven to be not only a technical improvement but also a practical solution that enhances daily production efficiency and user experience.

A-ZEN’s Continuous Innovation in Double Needle Bar Technology

A-ZEN has been continuously investing in the development of double needle bar warp knitting machines, building a comprehensive product portfolio that includes:

• AZ2885 / AZ2886

• RD5 / RD6EL / RD7EL

• RDJ5/1 / RDJ6/1 / RDJ7/1

• RDJ4/2 / RDJ6/2

Across these models, A-ZEN has achieved significant progress in machine stability, running speed, and overall performance, helping customers stay competitive in demanding textile markets.

Looking Ahead: Advancing Jacquard Technology

In addition to mechanical and control system innovations, A-ZEN is actively testing 3-Jacquard (triple jacquard) technology, aiming to further expand design possibilities and fabric complexity.

This 3-Jacquard machine (RDJ7/3) aims to develop brand new spacer with multi-colors and various designs in the shoe upper sectors. 

Looking forward, A-ZEN will continue to introduce new models and technologies to meet the rapidly evolving demands of the global textile industry.

Conclusion

The introduction of servo-controlled trick plate adjustment marks a meaningful step forward in the evolution of warp knitting technology. By combining precision, speed, and ease of use, A-ZEN delivers a solution that not only improves machine performance but also enhances the overall production experience.

At A-ZEN, innovation is not just about new features—it is about creating real value for our customers.

Automatic Trickplate Adjustment Video