Energy-saving fabric setting machine

Abstract

According to the energy-saving type fabric setting machine provided by the invention, the space utilization rate and the energy utilization efficiency of equipment are remarkably improved by combining the integrated layout of the elevated platform with a solar power supply system. The solar power supply assembly is used as a main power supply, so that the dependence on a traditional power grid and the operation cost are effectively reduced, and carbon emission is reduced; the drying room adopts a partitioned circulating air duct design, is combined with an electric heater and a top exhaust fan, and is assisted by a closed air door, so that the heat energy utilization efficiency is remarkably improved, and the loss is reduced; key process units such as the cloth tightening assembly, the centering device, the weft straightening device, the headstock assembly, the padder, the cooling assembly and the doffing and rolling assembly run orderly under the coordination of the control system and are matched with tension detection devices arranged at multiple positions, so that the stability of the setting process and the fabric quality are ensured. The device is compact in overall structure, remarkable in energy-saving effect, economical and environment-friendly in operation and convenient and safe to maintain.

Description

Technical Field

[0001] The present invention relates to the field of fabric setting, and in particular to an energy-saving fabric setting machine and an operating method thereof. Background Art

[0002] The fabric setting machine is a key equipment for post-printing and dyeing finishing. Its function is to eliminate the internal stress of the fabric through thermal and mechanical effects, stabilize the size and shape of the fabric, and give the fabric the required feel, gloss and other properties.

[0003] Traditional fabric setting machines are usually arranged on a horizontal ground and consist of units such as cloth feeding, liquid squeezing, weft straightening, needle loading, drying, cooling and cloth dropping connected in sequence. The power mainly relies on the industrial power grid, and the drying process generally uses electric heating or gas heating.

[0004] With increasingly stringent environmental protection requirements and rising energy costs, the printing and dyeing industry faces immense pressure to conserve energy and reduce emissions. Data shows that the finishing process can account for 25%-30% of a printing and dyeing plant's total energy consumption, making it a veritable "energy hog." While existing technologies offer localized energy-saving measures such as waste heat recovery and variable frequency control, overall energy consumption remains high. Significant shortcomings exist in the spatial layout and energy structure. Firstly, the flat-laying equipment occupies a large floor space, requiring maintenance personnel to frequently access the equipment's underside or in narrow spaces for inspection and cleaning, which is inconvenient and poses safety risks. Secondly, the high reliance on traditional power grids or fossil fuels for energy supply not only increases operating costs and creates significant carbon emissions, but also restricts deployment in remote areas or those without a stable power grid. Furthermore, the thermal energy utilization efficiency of existing finishing machine drying rooms still needs to be improved, with heat loss being common.

[0005] Therefore, how to achieve compact equipment layout, reduce comprehensive energy consumption, and improve operational safety and environmental adaptability through systematic structural optimization and clean energy integration while ensuring the effectiveness of the finalized process has become a key technical issue that needs to be urgently addressed in this field. Summary of the Invention

[0006] The object of the present invention is to provide an energy-saving fabric setting machine and an operating method thereof, so as to solve the problems existing in the above-mentioned prior art.

[0007] To achieve the above object, the present invention provides the following solutions:

[0008] The present invention provides an energy-saving fabric setting machine, comprising:

[0009] An elevated platform, with guardrails on both sides of the elevated platform and stairs at the head and tail ends of the elevated platform;

[0010] A cloth feeding rack, the cloth feeding rack being arranged at the head end of the elevated platform;

[0011] A cloth tightening assembly, the cloth tightening assembly being mounted on the cloth feeding rack;

[0012] A centering device, the centering device being arranged at the rear end of the cloth tightening assembly;

[0013] a rolling car, the rolling car being arranged at the rear end of the centering device;

[0014] a weft straightening device, the weft straightening device being arranged at the rear end of the padding vehicle;

[0015] A headstock assembly, the headstock assembly being arranged at the rear end of the weft straightening device;

[0016] A drying room, the drying room being arranged at the rear end of the head box assembly;

[0017] A cooling assembly, the cooling assembly being arranged at the rear end of the drying room;

[0018] A cloth dropping and rolling assembly, the cloth dropping and rolling assembly being arranged at the rear end of the cooling assembly;

[0019] A driving assembly, the driving assembly being arranged on both sides of the elevated platform;

[0020] A solar power supply component, which is used to supply power to the entire device;

[0021] A control system, wherein the control system establishes communication with the cloth tightening component, the centering device, the padding car, the weft straightening device, the head box component, the drying room, the cooling component, the cloth dropping and rolling component, the driving component and the solar power supply component for operation control.

[0022] Preferably, the cloth tightening assembly comprises two parallel stainless steel pipes, and the stainless steel pipes are rotatably arranged on the cloth feeding rack.

[0023] Preferably, the centering device includes photoelectric tubes arranged on both sides, and a correction roller is provided between the photoelectric tubes.

[0024] Preferably, a coating machine is provided between the weft straightening device and the headstock assembly.

[0025] Preferably, the headstock assembly includes an overfeed roller, the rear end of the overfeed roller is provided with an active needle-up brush, and the rear end of the active needle-up brush is provided with a passive brush to prevent needles from falling off.

[0026] Preferably, the drying room includes circulating fans arranged on both sides, the air inlet of the circulating fan is connected to the inside of the drying room, and an electric heater is provided at the air inlet, the air outlet of the circulating fan on one side is connected to the upper air duct through the upper air chamber, and the air outlet of the circulating fan on the other side is connected to the lower air duct through the lower air chamber, the cloth runs between the upper air duct and the lower air duct, and an exhaust fan is provided on the top of the drying room.

[0027] Preferably, an air-locking damper is provided on the side of the drying room.

[0028] Preferably, the cooling assembly includes a cooling air chamber and a cooling water roller.

[0029] Preferably, the rear end of the rolling mill and the rear end of the cooling assembly are both provided with tension detection devices.

[0030] Preferably, the cloth dropping and rolling assembly comprises a swing-type cloth dropping rack, and the bottom of the swing-type cloth dropping rack is connected to a rolling cloth dropping rack via a rolling cylinder.

[0031] Compared with the prior art, the present invention has achieved the following beneficial technical effects:

[0032] The present invention provides an energy-saving fabric setting machine, which significantly improves the space utilization rate and energy efficiency of the equipment through the integrated layout of the elevated platform combined with the solar power supply system. The solar power supply component serves as the main power supply, effectively reducing the dependence on the traditional power grid and the operating cost, and reducing carbon emissions; the drying room adopts a partitioned circulation air duct design and combines electric heaters and top exhaust fans, supplemented by air-tight dampers, which significantly improves the efficiency of heat energy utilization and reduces losses; and the key process units such as the cloth tightening component, centering device, weft straightening device, head box component, rolling car, cooling component, cloth dropping and rolling component operate in an orderly manner under the coordination of the control system, and cooperate with the tension detection devices installed in multiple places to ensure the stability of the setting process and the quality of the fabric. The overall structure of the device is compact, the energy-saving effect is significant, the operation is economical and environmentally friendly, and the maintenance is convenient and safe. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0034] Figure 1 A schematic structural diagram of an energy-saving fabric setting machine provided by the present invention;

[0035] Figure 2 This is a schematic structural diagram of the drying room portion of an energy-saving fabric setting machine provided by the present invention. DETAILED DESCRIPTION

[0036] The serial numbers of the components herein, such as "first", "second", etc., are only used to distinguish the objects described and do not have any order or technical meaning. The "connection" and "coupling" mentioned in this application, unless otherwise specified, include direct and indirect connections (couplings). In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", etc. are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0037] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0038] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0039] The purpose of the present invention is to provide an energy-saving fabric setting machine to solve the problems existing in the prior art.

[0040] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0041] Example 1:

[0042] This embodiment provides an energy-saving fabric setting machine. Figure 1As shown, the system comprises an elevated platform 1, a cloth feed frame 2, a cloth tensioning assembly 3, a centering device 4, a padding machine 5, a weft straightening device 6, a headstock assembly 7, a drying chamber 8, a cooling assembly 9, a cloth doffing and winding assembly 10, a drive assembly 11, a solar power supply assembly, and a control system. Except for the elevated platform 1, all of the aforementioned components are mounted on top of it, creating reusable storage or equipment expansion space beneath the platform, significantly saving the user's factory floor space.

[0043] Specifically, the elevated platform 1 is constructed from a hot-dip galvanized H-shaped steel main beam welded to a checkered steel plate platform. The platform is ≥2.8m above the ground, with 1.2m-high guardrails welded on both sides. Both the leading and trailing ends are equipped with 45° inclined ladders, each 0.8m wide and equipped with anti-slip strips and handrails, meeting the safety requirements of GB4053-2009 for fixed steel ladders and platforms. LED lighting and fire sprinklers can be installed on the underside of the platform to enhance the safety of the space below for secondary use.

[0044] Furthermore, the cloth feeding frame 2 is located at the head end of the elevated platform 1 and is made of 4mm thick Q235-A plate bent and welded into a "door" shaped frame. Two sets of Stainless steel guide rollers are covered with EPDM rubber to prevent scratches on the fabric. A forklift port is provided at the front of the fabric feeder for easy fabric loading.

[0045] Furthermore, the cloth tightening assembly 3 is installed below the cloth feeding rack and includes two Parallel stainless steel pipes with a wall thickness of 3mm can be made of SUs304. Both ends of each steel pipe are fixed to the cloth feed rack through bearings with seats and are driven by a 0.37kW reduction motor with a stepless adjustable speed of 0-20rpm. The control system controls the wrap angle of the pipe in contact with the cloth to change the friction with the cloth, thereby achieving the purpose of tightening or loosening the cloth.

[0046] Furthermore, the centering device 4 is located at the rear end of the cloth tightening component 3 and consists of two opposing photoelectric tubes (detection accuracy ±1mm) and a The device is composed of a rubber-coated deflection correction roller. A photoelectric tube detects the position of the fabric edge in real time, and the signal is fed back to the deflection correction roller servo motor. The deflection correction roller can swing within a range of ±15° to ensure that the deviation between the fabric centerline and the equipment centerline is ≤2mm.

[0047] Furthermore, padder 5 utilizes a two-roller vertical structure. The upper roller is a passive roller, coated with a Shore A hardness of 85°; the lower roller is an active roller, with a chrome-plated finish. The pressure between the two rollers is provided by a 0.6MPa double-acting cylinder, controlled by a proportional valve in a closed-loop manner, and can be linearly adjusted between 0 and 60kN. A residual liquid recovery tank is located at the outlet of padder 5, equipped with a low-speed agitator (20rpm) to prevent dye liquor sedimentation. The residual liquid rate is stably controlled at 60% ± 3%.

[0048] Furthermore, the weft straightening device 6 employs a four-bending roller structure made of aluminum alloy with an anodized surface. Each roller is driven by an independent servo motor, which can adjust the bending amount (0-25mm) in real time based on the weft skew detection data (with an accuracy of ±0.5°), while also stretching the fabric edge to prevent curling.

[0049] Furthermore, a coating machine interface is reserved between the weft straightening device 6 and the head box assembly 7 for installing the coating machine 12. The coating machine 12 is a three-roller reverse scraper type, and the gap between the blade and roller is 0-2mm electrically adjustable; the glue tank volume is 20L, with a constant temperature oil bath (20-80℃). When the user requires functional finishing (such as waterproofing and UV protection), it can be directly hoisted and embedded in the work station without taking up additional space.

[0050] Furthermore, the headstock assembly 7 includes:

[0051] The superfeed roller 71 is composed of two groups of upper and lower The rubber roller, the upper superfeed roller linear speed is 0-15% faster than the main chain, and the lower superfeed roller linear speed can be 0-10% slower. They are independently driven by a frequency conversion motor and are used to adjust the radial density of the fabric.

[0052] Active needle brush 72, which adopts The bristle brush roller, with a rotation speed of 50 rpm, presses the edge of the cloth evenly into the needle plate;

[0053] Anti-needle passive brush 73, which adopts Soft brush to prevent the cloth edge from falling off the needle during high-speed operation.

[0054] A 10-inch industrial touch screen is installed on the top of the head box, which displays parameters such as overfeed rate, needle plate position, tension, etc. in real time.

[0055] Furthermore, if Figure 2 As shown, the drying room 8 has a total length of 15m and is divided into 5 sections, each 3m long, with an openable manual heat-insulating door. Each section is equipped with 4 1.5kW high-temperature resistant circulation fans 81 (maximum temperature resistance 220℃), and the fan inlet is equipped with a stainless steel fin electric heater 82, with a heating power of 0-30kW steplessly adjustable. After the hot air passes through the upper air chamber 83 and the lower air chamber 84, it is blown vertically to the cloth surface by the wind knife type upper spray pipe 85 and the lower spray pipe 86 respectively. There is a filter 89 under the two, and the wind speed is adjustable from 5-15m / s. A 2.2kW variable frequency exhaust fan 87 is installed on the top of the drying room, and the exhaust volume is 0-5000m 3 / h, used to exhaust hot and humid exhaust gases. Each drying room section is equipped with air-tight dampers 88 on the side walls. In the event of an emergency stop, the dampers close within 2 seconds, cutting off the heat source and preventing overheating and yellowing of the fabric. The drying room track spacing is adjusted by a servo motor and ball screw, with an adjustment range of 600-3200mm to accommodate changes in door width.

[0056] Furthermore, the cooling assembly 9 is divided into two sections:

[0057] The cooling air chamber 91 uses a 3kW centrifugal fan to supply air, with an air temperature of 20-25°C and a wind speed of 10m / s;

[0058] Cold water roller 92, using Double-layer rollers, with 15℃ chilled water flowing inside, roller surface temperature ≤25℃ to prevent the fabric from getting damp again.

[0059] Furthermore, the drive assembly 11, located on either side of the elevated platform, is driven by two 11kW AC variable-frequency motors, each driven by a helical gear reducer (reduction ratio 1:40). The chains have a 50.8mm pitch, self-lubricating bearings, and a continuously adjustable speed of 5-60m / min. Encoder + PLC closed-loop synchronization ensures a speed differential of ≤0.1% between the left and right chains.

[0060] Furthermore, the solar power supply assembly includes:

[0061] Photovoltaic array: Peak power 150kW, composed of 600 250W monocrystalline silicon panels, installed on the roof of the plant with a tilt angle of 30°;

[0062] Grid-connected inverter: 150kW three-phase string type, efficiency ≥98.5%;

[0063] Energy storage system: 200kWh lithium iron phosphate battery, used for rainy days or night shift production;

[0064] The EMs energy management system monitors power generation, load, and energy storage in real time, prioritizing photovoltaic power and automatically switching to mains power if power is insufficient, ensuring zero power outages. The entire system reduces CO2 emissions by approximately 120 tons annually.

[0065] Furthermore, the cloth rolling assembly 10 is located at the rear end of the cooling assembly 9 and includes:

[0066] The swing-type cloth drop frame 101 uses a 1.5kW servo motor to drive a crank swing arm, and the swing frequency is adjustable from 10 to 30 times / min;

[0067] Rolling and dropping cloth rack 102, which adopts The pneumatic shaft has a maximum winding diameter of 1200mm; the winding cylinder (cylinder diameter 80mm, stroke 300mm) enables fast switching between swinging and winding.

[0068] Furthermore, it also includes a tension detection device 13, which can be used The tension roller is integrated with a strain gauge sensor to control the winding tension in a closed loop of 20-200N. The detection data is transmitted to the PLC in real time via the Profibus-DP bus and used for the tension closed loop of the entire machine to ensure constant tension operation of the fabric throughout the entire process.

[0069] Furthermore, the control system, centered around a Siemens S7-1500 PLC, communicates with all inverters, servo drives, temperature control modules, and tension modules via Profinet. The human-machine interface features a 15-inch color touchscreen, and recipe management can store 100 sets of process parameters, allowing for one-click access. The system also includes an Ethernet interface for connecting to user MEs and ERP systems, enabling order management, energy consumption statistics, and remote diagnostics.

[0070] The present invention provides an operating method of an energy-saving fabric setting machine, comprising:

[0071] s1: Start the solar power supply component, and the EMs self-check the photovoltaic, energy storage, and load status to confirm that the power supply is normal.

[0072] s2: According to the fabric width and weight, the corresponding process formula is called on the touch screen, and the system automatically adjusts the track spacing, overfeed rate, and drying room temperature.

[0073] S3: Manually place the cloth roll on the cloth feed rack, start the cloth feed drive, and the cloth enters the headstock after passing through the cloth tightening assembly, centering device, padding machine, and weft straightening device.

[0074] S4: After the cloth edge is automatically aligned by the edge detector, the upper needle brush presses the cloth edge into the needle plate; the chain starts and the cloth enters the drying room.

[0075] s5: After the drying room temperature reaches the set value, the circulation fan and exhaust fan will automatically start PID adjustment; in case of temporary shutdown, the air-locking damper will be closed immediately.

[0076] s6: After the fabric leaves the drying room, it is first cooled by the cooling air chamber and then cooled by the cold water roller to ensure that the fabric surface temperature is ≤30℃.

[0077] s7: After the fabric tension is tested, the fabric is evenly piled by the swing-type fabric drop frame or the winding cylinder switches to the winding state to complete the fabric drop / winding.

[0078] s8: During the production process, the control system records the speed, tension, temperature, energy consumption and other data in real time, and automatically generates batch reports for quality traceability and energy efficiency analysis. When processing the sidewall, electrodes with better surface quality and higher material removal rate can be obtained.

[0079] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0080] It should be noted that the components mentioned in the above embodiments are all universal standard parts or components known to those skilled in the art, and their structures and principles can be known to those skilled in the art through technical manuals or conventional experimental methods.

[0081] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be understood as limiting the present invention.

Claims

1. An energy-saving fabric setting machine, characterized by: include: An elevated platform, with guardrails on both sides of the elevated platform and stairs at the head and tail ends of the elevated platform; A cloth feeding rack, the cloth feeding rack being arranged at the head end of the elevated platform; a cloth tightening assembly, the cloth tightening assembly being mounted on the cloth feeding rack; A centering device, the centering device being arranged at the rear end of the cloth tightening assembly; a rolling car, the rolling car being arranged at the rear end of the centering device; a weft straightening device, the weft straightening device being arranged at the rear end of the padding vehicle; A headstock assembly, the headstock assembly being arranged at the rear end of the weft straightening device; A drying room, the drying room being arranged at the rear end of the head box assembly; A cooling assembly, the cooling assembly being arranged at the rear end of the drying room; A cloth dropping and rolling assembly, the cloth dropping and rolling assembly being arranged at the rear end of the cooling assembly; A driving assembly, the driving assembly being arranged on both sides of the elevated platform; A solar power supply component, which is used to supply power to the entire device; A control system, wherein the control system establishes communication with the cloth tightening component, the centering device, the padding car, the weft straightening device, the head box component, the drying room, the cooling component, the cloth dropping and rolling component, the driving component and the solar power supply component for operation control.

2. The energy-saving fabric setting machine according to claim 1, characterized in that: The cloth tightening assembly comprises two parallel stainless steel pipes, and the stainless steel pipes are rotatably arranged on the cloth feeding rack.

3. The energy-saving fabric setting machine according to claim 1, characterized in that: The centering device includes photoelectric tubes arranged on both sides, and a correction roller is arranged between the photoelectric tubes.

4. The energy-saving fabric setting machine according to claim 1, characterized in that: A coating machine is provided between the weft straightening device and the headstock assembly.

5. The energy-saving fabric setting machine according to claim 1, characterized in that: The headstock assembly includes an overfeed roller, the rear end of the overfeed roller is provided with an active needle-up brush, and the rear end of the active needle-up brush is provided with a passive brush for preventing needles from falling off.

6. The energy-saving fabric setting machine according to claim 1, characterized in that: The drying room includes circulating fans arranged on both sides, the air inlet of the circulating fan is connected to the inside of the drying room, and an electric heater is provided at the air inlet, the air outlet of the circulating fan on one side is connected to the upper air duct through the upper air chamber, and the air outlet of the circulating fan on the other side is connected to the lower air duct through the lower air chamber, the cloth runs between the upper air duct and the lower air duct, and an exhaust fan is provided on the top of the drying room.

7. The energy-saving fabric setting machine according to claim 6, characterized in that: An air-blocking damper is provided on the side of the drying room.

8. The energy-saving fabric setting machine according to claim 1, characterized in that: The cooling assembly includes a cooling air chamber and a cooling water roller.

9. The energy-saving fabric setting machine according to claim 1, characterized in that: The rear end of the rolling car and the rear end of the cooling assembly are both provided with tension detection devices.

10. The energy-saving fabric setting machine according to claim 1, characterized in that: The cloth dropping and rolling assembly comprises a swing-type cloth dropping frame, and the lower side of the swing-type cloth dropping frame is connected to a rolling cloth dropping frame via a rolling cylinder.

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