Carding machine and carding element thereof

Abstract

A carding machine and a carding element thereof belong to the technical field of carding machines, the carding machine comprises a movable cover plate component and a needle cloth strip, and the needle cloth strip is connected to the bottom surface of the movable cover plate component through magnetic card clothing; the movable cover plate component comprises a beam body outer frame, a lower base body and a limiting strip, the beam body outer frame is connected with the lower base body, the limiting strip is connected with the beam body outer frame, and the limiting strip is made of a carbon fiber material and used for eliminating curvature deformation caused by thermal expansion of the lower base body; the carding element is designed to be a modular assembly, the carding element can adapt to various material manufacturing processes and is convenient to mount, dismount and maintain, expansion deformation of the lower base body is limited through joint cooperation of the beam body outer frame and the limiting strips, and deformation caused by heat can be counteracted in the working process without applying prestress before mounting.

Description

Technical Field

[0001] The present invention belongs to the technical field of carding machines, and in particular relates to a carding machine and a carding element thereof. Background Art

[0002] The main function of the carding machine's movable flats is to comb, clean, and blend the loose fibers during the carding process, removing most neps, impurities, and short lint. The distance between the movable flats and the card cylinder clothing is crucial to carding quality. Different raw materials and sliver specifications require different distances between the movable flats and the cylinders. Only the appropriate distance ensures that the fibers are combed as needed without excessive carding.

[0003] Nowadays, the covers of carding machines are mostly made of aluminum alloy. Although it is easy to process high-precision dimensions, the aluminum alloy movable covers are easily deformed by temperature during use. The amount of deformation directly affects the quality of carding, so the aluminum alloy movable covers generally have the problem of difficulty in adjusting the gauge.

[0004] Chinese patent publication number CN216107369U discloses a utility model patent for a lower-adjustable aluminum alloy movable cover plate for a carding machine, which addresses the aforementioned issues. The patent's disclosed technical solution addresses the problem of aluminum alloy movable covers deforming during use, causing gauge variations and impacting the carding quality and impurity removal and mixing performance of the carding machine. This patent allows for adjustable gauges and preset deformation amounts to compensate for deformation during use. This eliminates the curvature deformation in the cover plate ribs caused by prestressing due to heat-induced deformation during the carding process. This facilitates adjustment to the varying gauge requirements of different raw materials. However, while the screw adjustment method in the patent effectively presets deformation amounts to compensate for deformation during use, the changes in the cover plate itself vary depending on the climate and temperature rise. A disadvantage is that the prestressing must be applied before the cover plate ribs are installed in the carding machine, making it difficult to precisely adjust the operating conditions of the cover plate ribs and unsuitable for mass production. Furthermore, when installing the flat bar's adjustment rod, it's difficult to ensure completely consistent torque on the clamping nut. Different nut torques result in different preset deformations of the flat bar. Greater nut torque increases the deflection of the profile. Thermal expansion of the flat bar can also significantly vary the deformation of each bar. A typical carding machine's movable flat bar assembly consists of 70-120 bars. If the flatness of each bar varies significantly, the gauge difference between the bar and the cylinder clothing will also be significant, inevitably affecting the uniformity of the card's web.

[0005] Therefore, how to improve the performance of carding machine covers while reducing damage to fibers has become an urgent problem to be solved in the industry. Summary of the Invention

[0006] In view of the above situation, in order to overcome the defects of the prior art, an embodiment of the present invention provides a carding element for a carding machine, which at least partially solves the above technical problems.

[0007] The technical solution adopted by the embodiment of the present invention is as follows: a carding element for a carding machine, comprising a movable cover member and a card clothing strip, wherein the card clothing strip is connected to the bottom surface of the movable cover member via a magnetic card clothing;

[0008] The movable cover plate component includes a beam body outer frame, a lower base and a limiting strip. The beam body outer frame is connected to the lower base, and the limiting strip is connected to the beam body outer frame. The limiting strip is made of carbon fiber material to eliminate the curvature deformation caused by thermal expansion of the lower base.

[0009] Furthermore, the length of the limiting strip is the same as the length of the outer frame of the beam body, and the limiting strip is connected to the lower base through a plurality of fastening screws.

[0010] Furthermore, the number of the fastening screws is 2-15, and the fastening screws pass through the upper limiting bar and the outer frame of the beam in sequence from top to bottom and are fixed with glue.

[0011] Furthermore, the height of the outer frame of the beam body is 48-75 mm, and a stress relief hole is provided on the top of the outer frame of the beam body.

[0012] Furthermore, the material of the beam body outer frame is one of carbon fiber material, steel and aluminum alloy.

[0013] Furthermore, the outer frame of the beam body is a closed structure, and the interior of the outer frame of the beam body is a hollow cavity;

[0014] The lower base is made of one of aluminum profiles, steel and carbon fiber materials.

[0015] Furthermore, it also includes end caps, which are respectively installed at both ends of the outer frame of the beam body, and the end cap plugs are inserted into the inner cavities at both ends of the outer frame of the beam body. The top of the end cap plug is connected to the outer frame of the beam body by screws, and the connection method between the outer frame of the beam body and the lower base is one of screw connection, rivet connection, strong glue connection or structural snap connection.

[0016] Furthermore, the end plug part is provided with circular reinforcing ribs in the middle, and vertical reinforcing ribs at the upper and lower parts; a steel plate is provided inside the end, and the steel plate is completely wrapped inside through the injection molding process, which has a better reinforcing effect on the structure.

[0017] Furthermore, the end plug part is provided with a circular reinforcement rib in the middle, a heat dissipation hole is formed in the middle of the circular reinforcement rib, and vertical reinforcement ribs are provided at the upper and lower parts to stabilize the temperature change of the movable cover; a steel plate is provided inside the end, and the steel plate is completely wrapped into the interior through an injection molding process.

[0018] On the other hand, the present invention also provides a carding element for a carding machine, comprising a movable cover member and a card clothing strip, wherein the card clothing strip is connected to the bottom surface of the movable cover member;

[0019] The movable cover component includes a beam body outer frame and a lower base. The lower base is made of carbon fiber material. A plurality of elastic mushroom nails are provided in the length direction of the lower base and are integrally formed through an injection molding process. The elastic mushroom nails automatically pop open and clamp with the corresponding holes at the bottom of the beam body outer frame.

[0020] A carding machine comprises the carding element.

[0021] The beneficial effects achieved by the present invention using the above structure are as follows:

[0022] The present invention designs the combing elements as modular components, which can adapt to various material manufacturing processes and are easy to install, disassemble and maintain. The expansion deformation of the lower base is mutually restricted by the cooperation of different thermal deformation materials such as the beam body outer frame and the limiting strip, so that the deformation caused by heat can be offset during operation without applying prestress before installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A schematic diagram of the three-dimensional structure of an embodiment of the present invention;

[0024] Figure 2 Schematic diagram of the coordination between the outer frame of the beam body and the card clothing according to an embodiment of the present invention;

[0025] Figure 3 Schematic diagram of the cooperation between the end cap and the beam body frame according to an embodiment of the present invention;

[0026] Figure 4 Schematic diagram of the cooperation between the lower base and the beam body frame according to an embodiment of the present invention;

[0027] Figure 5 This is a schematic diagram of the cooperation between the lower base and the outer frame of the beam body according to one embodiment of the present invention;

[0028] Figure 6 This is a front view of the outer frame structure of the beam according to an embodiment of the present invention.

[0029] In the figure: 3 - conveyor belt mounting hole; 4 - end; 5 - cylinder card clothing; 6 - curved rail; 7 - card clothing strip; 8 - magnetic strip; 11 - beam body frame; 12 - lower base; 13 - fastening screw; 14 - stress relief hole; 16 - bending part; 21 - elastic mushroom nail; 41 - steel plate; 42 - plug; 43 - reinforcement rib; 44 - heat dissipation hole; 71 - magnetic card clothing;

[0030] 131-Restriction Article.

[0031] The accompanying drawings are used to provide further understanding of the embodiments of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0033] In the description of the embodiments of the present invention, it should be understood that terms such as "up", "down", "front", "back", "left", "right", "top", "bottom", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they should not be understood as limiting the present invention.

[0034] like Figure 1 、 Figure 3 and Figure 5 As shown, the present invention provides a carding element for a carding machine, comprising a movable cover member and a card clothing strip 7, wherein the card clothing strip 7 is connected to the bottom surface of the movable cover member through a magnetic card clothing 71;

[0035] The movable cover plate component includes a beam body outer frame 11, a lower base 12 and a limiting bar 131. The beam body outer frame 11 is connected to the lower base 12, and the limiting bar 131 is connected to the beam body outer frame 11. The material of the limiting bar is carbon fiber material and is used to eliminate the curvature deformation of the lower base 12 caused by thermal expansion.

[0036] It should be noted that the length of the restriction bar is typically set to the length of the beam outer frame 11, and the maximum thermal deformation capacity of the movable cover is limited by the bar being fixed at the extreme ends. The restriction bar 131 itself hardly expands when heated, and its elongation upon heating is less than that of the lower base 12, thus limiting the elongation of the cover's lower base 12. Due to the placement of the restriction bar 131 within the beam outer frame 11, the extension of the lower base 12 after thermal deformation, i.e., the convex or concave curvature, can be limited. Assuming the movable cover does not undergo any preset deformation, the curvature caused by thermal expansion during operation will be automatically eliminated by the restriction bar, achieving the same precision as when the movable cover is cooled.

[0037] In a further implementation of this embodiment, the length of the limiting bar 131 is the same as the length of the outer frame of the beam body 11, and the limiting bar 131 is connected to the lower base 12 by multiple fastening screws 13. Of course, the connection by fastening screws 13 can also be replaced by connection in the form of rivets.

[0038] In a further implementation of this embodiment, the number of the fastening screws 13 is 2-15, and the fastening screws 13 pass through and connect the upper limiting bar 131 and the bottom surface of the beam outer frame 11 from top to bottom.

[0039] In a further implementation of this embodiment, the height of the beam body outer frame 11 is 48-75 mm, and a stress release hole 14 is provided on the top of the beam body outer frame 11, which not only facilitates the installation of screws, but also serves as a stress release hole for the beam body outer frame 11, thereby offsetting part of the stress deformation of the beam body outer frame 11.

[0040] The experimental data in Table 1 below show that, for the same material, deflection decreases as height increases. According to the requirements for the use of movable covers, the flatness should be ≤ 0.02 mm. Therefore, the height of the beam outer frame 11 is preferably between 48 and 75 mm.

[0041] Table 1

[0042]

[0043]

[0044] Deflection calculation formula Y = FXL 3 / 48×E×J 2

[0045] Y: deflection (m); L: length (m); E: elastic modulus (Pa); F: applied force (N); J: section moment of inertia (m 4) .

[0046] In a further implementation of this embodiment, the material of the beam body outer frame 11 is one of carbon fiber material, steel and aluminum alloy; within the temperature range of 20-60°C, the thermal deformation resistance of the three materials of resin mixed carbon fiber material (carbon fiber reinforced composite material, CFRP), aluminum alloy and steel when applied to the profile is compared as follows, and the analysis is carried out in combination with material properties and data.

[0047] Comparison of thermal deformation resistance: The ability to resist thermal deformation depends on the material's coefficient of thermal expansion (CTE) and elastic modulus (stiffness): the lower the thermal expansion coefficient, the smaller the dimensional deformation when the temperature changes; the higher the elastic modulus, the stronger the ability to resist deformation caused by thermal stress.

[0048] Thermal expansion coefficient of resin-mixed carbon fiber materials: The longitudinal thermal expansion coefficient of unidirectional carbon fiber reinforced composite materials can be as low as -1 to 1 ppm / °C, and the transverse thermal expansion coefficient is about 20 to 30 ppm / °C. If the profile is designed with directional fiber arrangement, the thermal deformation along the fiber direction is extremely small, close to the level of Invar alloy in metals.

[0049] Elastic modulus: The longitudinal elastic modulus can reach 230-430GPa, far exceeding that of steel and aluminum alloy. When the temperature rises to 60°C, the elastic modulus decreases by only 2-3% (such as T700 carbon fiber / epoxy resin composite material, the elastic modulus at 60°C is about 225GPa). It has the strongest resistance to thermal deformation, especially in the fiber direction, which is almost unaffected by temperature. However, its cost is relatively high compared to steel and aluminum profiles.

[0050] Taking stainless steel as an example: its thermal expansion coefficient is about 10-17ppm / ℃ (depending on the type of steel, such as 17ppm / ℃ for 304 stainless steel), the elastic modulus is about 193-200GPa at 20℃, and decreases by about 1-2% at 60℃ (about 190-196GPa), the stiffness loss is very small, and the resistance to thermal deformation is second. The thermal expansion coefficient is 10-20 times that of the aforementioned carbon fiber material in the longitudinal direction, but the elastic modulus is high and its cost is relatively low.

[0051] The carbon emissions per ton of material produced are 2 tons for steel, 16.5 tons for aluminum, and 20 tons for carbon fiber. For the same weight of movable cover ribs, steel emits 12% of the carbon emissions of aluminum. However, for movable cover ribs of the same rigidity, the amount of carbon fiber used is 25% of that of aluminum, still significantly reducing carbon emissions. Combined with the previous analysis of rigidity, steel, while slightly less rigid than carbon fiber, offers the greatest carbon footprint advantage. While meeting the basic rigidity requirements for carding machine movable cover ribs, choosing steel can significantly reduce the carbon footprint of the production process and is environmentally friendly. Considering both carbon emissions and rigidity, steel is the most suitable material for carding machine movable cover ribs.

[0052] The outer frame 11 of the beam body serves as the main keel structure. The simulation data is shown in Table 2. The structure, height, material, elastic modulus, and weight per meter of the outer frame 11 of the beam body and the lower base 12 are all important factors affecting the strength of the movable cover plate. Under the same structure, height, and load, the static stress deformation resistance of steel and carbon fiber materials is three times that of aluminum. From the perspective of rigidity, carbon fiber materials are preferred, and the movable cover plate bones of the carding machine are designed in combination with optimized structural design and manufacturing processes. From a cost perspective, steel is preferred, and its rigidity can be improved by rationally designing the steel structure and adopting appropriate manufacturing processes.

[0053] Table 2

[0054]

[0055] In a further embodiment of this embodiment, the beam outer frame 11 has a bottom-enclosed structure. Bends 16 are provided on both sides of the bottom of the beam outer frame 11, and grooves are provided on both sides of the top of the lower base 12. The bends 16 are embedded in the corresponding grooves. This design not only improves the stability of the overall structure but also facilitates disassembly and installation, further reducing maintenance time and costs. Furthermore, the presence of the bends 16 effectively disperses pressure, extending the service life of components and ensuring the stability and reliability of the carding machine during long-term operation.

[0056] In a further implementation of this embodiment, the lower base 12 is made of one of aluminum profiles, steel and carbon fiber materials.

[0057] In a further implementation of this embodiment, it also includes an end 4, which is respectively installed at both ends of the outer frame 11 of the beam body, and the plug 42 is inserted into the inner cavity at both ends of the outer frame 11 of the beam body, and the top of the plug 42 is connected to the outer frame 11 of the beam body by screws.

[0058] The connection between the beam body outer frame 11 and the lower base 12 is one of screw connection, rivet connection, strong glue connection or structural snap connection; through the above connection method, the stability of the overall structure can be effectively enhanced.

[0059] The plug 42 is provided with a circular reinforcing rib 43 in the middle, a heat dissipation hole 44 is formed in the middle of the circular reinforcing rib, and vertical reinforcing ribs 43 are provided at the upper and lower parts; a steel plate 41 is provided inside the end head, and the steel plate 41 is completely wrapped into the interior through the injection molding process, which has a better reinforcing effect on the structure.

[0060] In a further implementation of this embodiment, the material of the outer contour of the end head is a carbon fiber composite material, and the steel plate 41 is completely wrapped inside through an injection molding process, so that the end head, the plug 42, the steel plate 41, and the conveyor belt mounting hole 3 are a whole. The end head has higher strength, is not easy to deform or damage, and can be installed and replaced conveniently and quickly.

[0061] It should be noted that the modules within the movable cover assembly of this embodiment can be replaced and repaired individually, reducing maintenance costs. Advantageously, even if the card cloth base is damaged, it can be quickly repaired or replaced individually, rather than having to replace the entire assembly. This reduces maintenance costs and downtime. Furthermore, the modular design allows for interchangeable combinations of movable cover beams made of different materials, allowing for flexible matching of beams and bases, optimizing performance and costs, and enabling efficient production and maintenance.

[0062] On the other hand Figures 1-4 and Figure 6 As shown, an embodiment of the present invention further provides a carding element for a carding machine, comprising a movable cover member and a card clothing strip 7, wherein the card clothing strip 7 is connected to the bottom surface of the movable cover member;

[0063] The movable cover component includes a beam body outer frame 11 and a lower base 12. The lower base 12 is made of carbon fiber material. A plurality of elastic mushroom nails 21 are provided in the length direction of the lower base 12 and are integrally formed through an injection molding process. The elastic mushroom nails 21 automatically pop open and clamp with the corresponding holes at the bottom of the beam body frame 11.

[0064] On the other hand, an embodiment of the present invention further provides a carding machine having the above-mentioned carding element.

[0065] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0066] While the embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various changes, modifications, substitutions, and alterations can be made to the embodiments without departing from the principles and spirit of the invention.

[0067] The present invention and its embodiments are described above. This description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if a person skilled in the art is inspired by this and, without departing from the inventive purpose of the embodiments of the present invention, designs structures and embodiments similar to the technical solution without creatively designing them, they shall fall within the scope of protection of the present invention.

Claims

1. A carding element for a carding machine, characterized in that: It comprises a movable cover member and a card clothing strip, wherein the card clothing strip is connected to the bottom surface of the movable cover member through a magnetic card clothing; The movable cover plate component includes a beam body outer frame, a lower base and a limiting strip. The beam body outer frame is connected to the lower base, and the limiting strip is connected to the beam body outer frame. The limiting strip is made of carbon fiber material to eliminate the curvature deformation caused by thermal expansion of the lower base.

2. The carding element for a carding machine according to claim 1, characterized in that: The length of the limiting strip is the same as the length of the outer frame of the beam body, and the limiting strip is connected to the lower base through a plurality of fastening screws.

3. The carding element for a carding machine according to claim 2, characterized in that: The number of the fastening screws is 2-15, and the fastening screws penetrate and connect the upper limiting bar and the outer frame of the beam body in sequence from top to bottom.

4. The carding element for a carding machine according to claim 1, characterized in that: The height of the outer frame of the beam body is 48-75 mm, and a stress relief hole is provided on the top of the outer frame of the beam body.

5. The carding element for a carding machine according to claim 1, characterized in that: The material of the beam body outer frame is one of carbon fiber material, steel and aluminum alloy.

6. The carding element for a carding machine according to claim 1, characterized in that: The outer frame of the beam body is a closed structure, and the interior of the outer frame of the beam body is a hollow cavity; The lower base is made of one of aluminum profiles, steel and carbon fiber materials.

7. The carding element for a carding machine according to claim 1, characterized in that: It also includes end heads, which are respectively installed at both ends of the outer frame of the beam body, and the plugs of the end heads are inserted into the inner cavities at both ends of the outer frame of the beam body. The tops of the plugs of the end heads are connected to the outer frame of the beam body by screws, and the connection between the outer frame of the beam body and the lower base is one of screw connection, rivet connection, strong glue connection or structural snap connection.

8. The carding element for a carding machine according to claim 1, characterized in that The plug part of the end head is provided with a circular reinforcing rib in the middle, a heat dissipation hole is formed in the middle of the circular reinforcing rib, and vertical reinforcing ribs are provided at the upper and lower parts; a steel plate is provided inside the end head, and the steel plate is completely wrapped inside by an injection molding process.

9. A carding element for a carding machine, characterized in that: It comprises a movable cover plate component and a card clothing strip, wherein the card clothing strip is connected to the bottom surface of the movable cover plate component; The movable cover component includes a beam body outer frame and a lower base. The lower base is made of carbon fiber material. A plurality of elastic mushroom nails are provided in the length direction of the lower base and are integrally formed through an injection molding process. The elastic mushroom nails automatically pop open and clamp with the corresponding holes at the bottom of the beam body outer frame.

10. A carding machine, characterized in that: Carding machine comprising a carding element according to any one of claims 1 to 9.

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