Innovation in Servo-Controlled Trick Plate Adjustment
Publish Time: 2026-04-10 Origin: Site
Quick Summary / Key Takeaways for Engineers & Textile Manufacturers:
Core Innovation: A-ZEN introduces a servo motor-controlled automatic trick plate (knock-over plate gap) adjustment system for double needle bar warp knitting machines, replacing slow and error-prone manual handwheel operation.
Key Benefits: Increases adjustment speed from minutes to seconds, ensures high precision for accurate 3D spacer fabric thickness, and lowers labor skill requirements.
Market Application: Field-tested for over a year in China and Turkey, integrated into A-ZEN double needle bar series including RD6EL, RD7EL, and RDJ5/1.
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.
Feature |
Traditional Manual Adjustment |
A-ZEN Servo-Controlled System |
|---|---|---|
Operation Method |
Manual handwheel turning + repeated measuring |
Digital touchscreen input (e.g., 1.8mm to 6mm) |
Adjustment Time |
15 minutes or longer |
Completed in seconds |
Accuracy & Consistency |
Subject to visual/operator error |
High precision, repeatable spacer thickness |
Labor Requirement |
Requires highly skilled technicians |
Easy operation, lowers training costs |
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:
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
Frequently Asked Questions (FAQ)
Q1: How does automatic trick plate adjustment work on A-ZEN double needle bar machines?
A: Operators simply input the target gap distance (e.g., changing from 1.8 mm to 6 mm) on the control touchscreen. The servo motor automatically drives the mechanism to complete the adjustment in seconds with high accuracy.
Q2: Why is precise trick plate gap adjustment critical for 3D spacer fabrics?
A: The trick plate distance directly determines the thickness and density of 3D spacer fabrics. Precise servo control ensures consistent fabric thickness across production lots and minimizes fabric defects.
Q3: Which A-ZEN warp knitting machine models support servo-controlled trick plate adjustment?
A: This technology is deployed across A-ZEN's double needle bar portfolio, including the RD6EL and RD7EL high-speed spacer fabric machines, and the RDJ series Jacquard machines.