Continuous production device and method for realizing open-width washing dehydration of fabric

Abstract

A continuous production device for achieving fabric open-width washing dehydration comprises a rack, one end of the rack is arranged as an input end, the other end of the rack is arranged as an output end, a cloth spreading centering and traction device is installed on the portion, on one side of the input end, of the rack, and a dehydration component is installed on the portion, on one side of the output end, of the rack. At least one structure of a washing part, a jet flow part and a spraying part is sequentially arranged on the rack from the input end to the output end, the washing part, the jet flow part and the spraying part are arranged in a step-by-step lifting mode, and an overflow channel is communicated between any two adjacent parts. The invention further provides a continuous production method for achieving open-width washing and dewatering of the fabric, continuous production of the knitted thin cloth from washing to dewatering to shaping can be achieved, manual intervention is not needed, and therefore the production cost is greatly reduced, and personnel expenditure is saved.

Description

Technical Field

[0001] This invention relates to the field of fabric production technology, and in particular to a continuous production apparatus for realizing flat-width washing and dewatering of fabrics. Background Technology

[0002] In traditional production methods, after washing and rolling, the moisture content of the fabric is approximately 60%. If it were to directly enter the setting stage at this point, evaporating the remaining moisture would consume a large amount of steam or natural gas, and the fabric's residence time in the setting machine would be significantly prolonged. Therefore, many manufacturers add a step between washing and setting: dehydration. Current technology typically uses centrifugal dehydrators. In this case, the washed fabric must be manually fed into the centrifugal dehydrator. After dehydration, it is then sent to the setting machine for setting. However, because dehydration requires manual intervention, it not only increases labor costs but also extends the production cycle.

[0003] Currently, there are corresponding continuous production methods for woven fabrics, especially thick fabrics (such as blankets). Due to the tight structure and low elasticity of woven fabrics, some manufacturers add vacuum dehydration devices after washing. Through vacuum adsorption, most of the residual moisture in the fabric is removed, and the treated fabric can meet the requirements of finishing production, basically enabling continuous production. However, for knitted fabrics, especially low-weight knitted fabrics, due to their greater elasticity, they are easily stretched and deformed or their loop structure is damaged during dehydration, so vacuum dehydration is not suitable. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing a continuous production device for washing and dewatering fabrics in a flat width. This device enables continuous production of knitted thin fabrics from washing to dewatering to setting, without the need for manual intervention, thereby greatly reducing production costs and saving personnel expenses.

[0005] The technical problem to be solved by the present invention is achieved through the following technical solution. The present invention is a continuous production device for washing and dewatering fabrics in open width, comprising a frame, one end of which is set as an input end and the other end of which is set as an output end. A fabric spreading and centering and traction device is installed on the frame on the input end side, and a dewatering component is installed on the frame on the output end side. At least one of the following structures is arranged sequentially on the frame from the input end to the output end: a washing component, a jet component, and a spray component. The washing component, jet component, and spray component are arranged in a progressively higher manner, and an overflow channel is connected between any two adjacent components.

[0006] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics as described above, a curved roller for maintaining the flat-width state of the fabric is also installed on the frame at the fabric spreading centering and traction device, and a spreading roller and a regular rolling mill are installed on the frame at the washing component, jet component and spray component.

[0007] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing the flat-width washing and dewatering of fabrics described above, guide rollers are installed at the inlet and outlet of the washing component, the jet component and the spray component, and a tension detection mechanism is installed on the guide rollers to facilitate the adjustment of the fabric stretching tension according to the settings.

[0008] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics described above, the washing component, jet component and spray component all adopt a modular structure and their bottoms are all non-completely planar structures.

[0009] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing the flat-width washing and dewatering of fabrics described above, a heavy-duty rolling mill and a fabric storage tank are also installed on the frame between the spraying component and the dewatering component.

[0010] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics as described above, the washing component includes a washing tank and a number of washing rollers for guiding the fabric. The washing rollers are arranged alternately, and a guiding gap is left between the washing rollers to cooperate with the fabric.

[0011] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics described above, the jet component includes a jet channel and an outer jet cylinder and an inner jet cylinder installed in the jet channel. Both the outer jet cylinder and the inner jet cylinder are driven by motors. The rotation direction of the outer jet cylinder is consistent with the direction of fabric movement, and the rotation direction of the inner jet cylinder is opposite to the rotation direction of the outer jet cylinder. The outer jet cylinder is provided with a uniformly distributed mesh.

[0012] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics as described above, the spraying component includes a spraying tank and a rotating drum installed in the spraying tank. Several spraying pipes are also installed in the spraying tank above the rotating drum, and several nozzles are installed on the spraying pipes. The rotating drum has a hollow structure, and mesh is evenly distributed on the surface of the rotating drum.

[0013] The technical problem to be solved by the present invention can also be further achieved by the following technical solution: For the continuous production device for realizing flat-width washing and dewatering of fabrics as described above, the dewatering component includes several height-adjustable air knives, and an adjustable-sized bracket is installed below the air knives. The bracket includes a lower left support and a lower right support for mutual cooperation. The lower left support is fixedly set, and the lower right support is installed by a horizontal driving device (such as a horizontally installed cylinder) to adjust the distance between the lower left support and the lower right support. The distance between the lower left support and the lower right support is 2-10mm.

[0014] The technical problem to be solved by the present invention can also be further achieved through the following technical solution: For the continuous production apparatus for realizing flat-width washing and dewatering of fabrics described above, a continuous production method for realizing flat-width washing and dewatering of fabrics is provided, the steps of which are as follows: (1) The fabric first enters the production process through the spreading and centering and traction device. After passing through the bending roller, it enters the washing part for preliminary washing. During the washing process, the tension detection mechanism of the guide roller at the inlet and outlet of the washing part adjusts the stretching tension of the fabric according to the setting. (2) After washing, the fabric is fully expanded by spreading rollers to prevent curling, and then it enters ordinary rolling mill for pressing to initially reduce the moisture content; (3) The fabric then passes through the jet component and the spray component for further cleaning and impurity removal. The jet component uses the special structure and movement of the jet outer cylinder and the jet inner cylinder to drive water through the fabric to clean impurities; the spray component uses water sprayed through the spray pipe to penetrate the fabric and carry away residual impurities. During the cleaning process, the overflow channels between each component ensure smooth water flow, and the last component is replenished with clean water to ensure cleaning quality. (4) The washed fabric is then rolled again in a heavy-duty rolling mill to further reduce the moisture content; (5) After rolling, the fabric enters the dewatering unit. The number of air knives, the opening size, the height of the air knife from the fabric surface, and the angle between the air knife and the fabric surface are adjusted according to the fabric condition. Under the action of the air knife, the surface moisture of the fabric is effectively removed, and the dewatering purpose is achieved. The angle between the air blade and the fabric surface is 60°-90°. (6) The dehydrated fabric is put into the setting machine for setting treatment, realizing continuous production from washing to dehydration to setting.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Reduced production costs: This invention enables continuous production of knitted fabrics from washing to dehydration to setting, eliminating the need for manual intervention in the dehydration process, which greatly reduces labor costs. At the same time, it reduces production delays and defect rates that may be caused by manual operation, further reducing production costs. 2. Energy saving: This invention reduces the moisture content of the fabric before it enters the setting machine through an effective dehydration method, thereby reducing the consumption of steam or natural gas required for evaporation and saving energy. 3. Improved production efficiency: The continuous production method of this invention shortens the production cycle, improves production efficiency, and can meet the needs of large-scale production. 4. Ensure fabric quality: This invention addresses the characteristics of knitted thin fabrics, which are highly elastic and easily deformed, by using an air knife dehydration method to effectively remove moisture without damaging the fabric loop structure, thus ensuring fabric quality. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of one structure of the present invention; Figure 2 This is a schematic diagram of the installation structure of the jet outer cylinder and the jet inner cylinder of the present invention; Figure 3 This is a schematic diagram of the installation structure of the rotating drum and spray pipe of the present invention; Figure 4 This is a schematic diagram of the installation structure of the air knife of the present invention; Reference numerals in the attached drawings: 1. Fabric spreading and traction device; 2. Bending roller; 3. Washing component; 4. Fabric spreading roller; 5. Ordinary rolling mill; 6. Overflow channel; 7. Jet component; 8. Spray component; 9. Heavy-duty rolling mill; 10. Fabric storage tank; 11. Dewatering component; 12. Jet outer cylinder; 13. Jet inner cylinder; 14. Spray pipe; 15. Rotary drum; 16. Guide roller; 17. Air knife; 18. Lower left support; 19. Lower right support. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Reference Figures 1 to 4A continuous production apparatus for washing and dewatering fabrics in open width includes a frame, with one end of the frame serving as an input end and the other end as an output end. A fabric spreading and traction device 1 is installed on the frame at the input end, and a dewatering component 11 is installed on the frame at the output end. At least one of the following structures is sequentially arranged on the frame from the input end to the output end: a washing component 3, a jetting component 7, and a spraying component 8. These components are arranged in a progressively elevated manner, and an overflow channel 6 connects any two adjacent components. Specifically: A bending roller 2 is installed on the frame at the fabric spreading, centering and traction device 1 to maintain the flatness of the fabric. The bending roller 2 is usually a rubber bending roller, but a stainless steel bending roller can also be used. The fabric first enters the production process through the fabric spreading, centering and traction device 1. After passing through the bending roller 2, it can effectively maintain the flatness of the fabric, providing a good foundation for subsequent processing. The washing component 3 includes a washing tank and several washing rollers for guiding the fabric. The washing rollers are arranged alternately, with guide gaps between them to accommodate the fabric. Tension detection mechanisms are installed on the guide rollers at the inlet and outlet of the washing component 3 to adjust the fabric's stretch tension. The bottom of the washing tank in the washing component 3 is not a completely flat structure, usually higher on both sides and lower in the middle, so that waste lint or impurities from the washing process will accumulate in the bottom area for easy cleaning. After the fabric enters the washing component 3, it undergoes preliminary washing in the washing tank. During the washing process, the tension detection mechanism adjusts the fabric's stretch tension in real time according to the settings to ensure uniform washing effect.

[0019] The washing unit 3, jetting unit 7, and spraying unit 8 are all equipped with spreading rollers 4 and ordinary rolling mills 5 on their frames. After washing, the fabric is fully expanded by the spreading rollers 4 to prevent edge curling, and then enters the ordinary rolling mill 5 for pressing to initially reduce the moisture content. For example, for a plain fabric with a weight of 160 g / m², the moisture content after heavy pressing (roller pressure 4 kg / cm²) is approximately 49.49%-59.6%.

[0020] The jet component 7 includes a jet channel and an outer jet cylinder 12 and an inner jet cylinder 13 installed inside the jet channel. Both the outer jet cylinder 12 and the inner jet cylinder 13 are driven by motors. The rotation direction of the outer jet cylinder 12 is the same as the direction of fabric movement, while the rotation direction of the inner jet cylinder 13 is opposite to that of the outer jet cylinder 12. The surface of the outer jet cylinder 12 has evenly distributed mesh, and the cross-section of the inner jet cylinder 13 is petal-shaped, or it can adopt a triangular beating rib structure similar to a beating roller. After the fabric enters the jet component 7, the inner jet cylinder 13 drives the water to pass through the mesh and penetrate the fabric under the action of centrifugal force, thereby achieving the purpose of removing and cleaning impurities.

[0021] The spraying component 8 includes a spray tank and a rotating drum 15 installed inside the spray tank. Several spray pipes 14 are also installed in the spray tank above the rotating drum 15. The number of spray pipes 14 is two or four, and each spray pipe 14 is equipped with a number of nozzles. The nozzle direction is adjustable. Guide rollers 16 are installed on both sides below the rotating drum 15 to facilitate better spraying of the fabric. The rotating drum 15 has a hollow structure with evenly distributed mesh on its surface. After the fabric enters the spraying component 8, the water sprayed from the nozzles penetrates the fabric and carries away residual impurities. These impurities enter the rotating drum 15 and fall through the mesh below to the bottom of the water tank. The spraying component 8 is equipped with a circulation device, and a filter screen is installed in the circulation tank to recycle the water, saving water resources.

[0022] A heavy-duty rolling mill 9 and a fabric storage tank 10 are also installed on the frame between the spraying unit 8 and the dewatering unit 11. The washed fabric enters the heavy-duty rolling mill 9 for further rolling to reduce the moisture content. The fabric storage tank 10 is not a necessary component; the aforementioned components can be linked with the dewatering unit 11 through program settings, and can be flexibly adjusted according to actual production conditions.

[0023] The main component of the dewatering unit 11 is the air knife 17. There are 1 to 4 air knives 17, and the opening of the air knife 17 is adjustable, usually with an opening size of 0.3-5mm. The height of the air knife 17 opening from the fabric surface is also adjustable. Each air knife 17 has an adjustable opening size bracket installed at its lower part. The bracket includes a lower left support 18 and a lower right support 19 that cooperate with each other. The lower left support 18 is fixedly set, and the lower right support 19 is installed via a horizontal drive device to adjust the distance between the lower left support 18 and the lower right support 19. The distance is usually controlled between 2mm and 10mm. If the distance is too large, the fabric will be stretched and deformed under the action of the air knife 17. By optimizing the air pressure and opening distance of the air knife 17, the dewatering efficiency can be improved. The air knife 17 is usually perpendicular to the fabric surface. Depending on the fabric, the angle between the air knife 17 and the fabric surface is adjustable, usually between 60 and 90 degrees. For example, under the conditions of air knife 17 air pressure of 40 kPa, air knife 17 width of 0.5 mm, air knife 17 distance from the fabric of 10 mm, fan power of 11 kW, and plain fabric width of 1800 mm, the corresponding moisture contents after single-knife, double-knife, triple-knife and quadruple-knife dehydration are 42.3%, 38.5%, 34.5%, and 30.6%, respectively.

[0024] A continuous production method using a continuous production apparatus for achieving flat-width washing and dewatering of fabrics, comprising the following steps: (1) The fabric first enters the production process through the spreading and centering and traction device 1, and after passing through the bending roller 2, it enters the washing component 3 for preliminary washing. During the washing process, the tension detection mechanism of the guide roller at the inlet and outlet of the washing component 3 adjusts the stretching tension of the fabric in real time according to the setting to ensure uniform washing.

[0025] (2) After washing, the fabric is fully expanded by the spreading roller 4 to prevent curling, and then enters the ordinary rolling mill 5 for rolling to initially reduce the moisture content.

[0026] (3) Then the fabric passes through the jet component 7 and the spray component 8 in sequence for further cleaning and impurity removal. The jet component 7 uses the special structure and movement of the jet outer cylinder 12 and the jet inner cylinder 13 to drive water through the fabric to clean impurities. The spray component 8 uses the water sprayed through the spray pipe 14 to penetrate the fabric and remove residual impurities. During the cleaning process, the overflow channel 6 between each component ensures smooth water flow. The last component is replenished with clean water to ensure the cleaning quality.

[0027] (4) The washed fabric is then rolled again in a heavy-duty rolling mill 9 to further reduce the moisture content.

[0028] (5) The rolled fabric enters the dewatering unit 11. The number of air knives 17, the opening size, the height of the air knife 17 from the fabric surface, and the angle between the air knife 17 and the fabric surface are adjusted according to the fabric condition. Under the action of the air knife 17, the moisture on the fabric surface is effectively removed to achieve the purpose of dewatering. The angle between the air knife 17 and the fabric surface is 60-90°.

[0029] (6) The dehydrated fabric is put into the setting machine for setting treatment, realizing continuous production from washing to dehydration to setting, without manual intervention, greatly reducing production costs and saving personnel expenses.

[0030] The continuous production apparatus and method of the present invention effectively solves the problems in the flat-width washing and dehydration process of knitted thin fabrics through the rational design and coordinated operation of each component, realizing continuous production and having significant economic and social benefits.

Claims

1. A continuous production apparatus for implementing fabric open-width water washing and dewatering, characterized in that: The machine frame is provided with an input end and an output end, a cloth spreading and centering and traction device is arranged on the machine frame at the input end side, a dehydration device is arranged on the machine frame at the output end side, and at least one of a water washing device, a jet flow device and a spraying device is arranged on the machine frame from the input end to the output end in sequence.

2. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: A bending roller for keeping the fabric in a flat state is arranged on the machine frame at the cloth spreading and centering and traction device, and a cloth spreading roller and a common roller are arranged on the machine frame at the water washing device, the jet flow device and the spraying device.

3. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: Tension detection mechanisms for adjusting the fabric tension according to the setting are arranged on the guide rollers at the water washing device, the jet flow device and the spraying device.

4. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: The water washing device, the jet flow device and the spraying device are all modular structures, and the bottoms of the water washing device, the jet flow device and the spraying device are all non-complete plane structures.

5. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: A heavy roller and a cloth storage tank are arranged on the machine frame between the spraying device and the dehydration device.

6. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: The water washing device comprises a water washing tank and a plurality of water washing rollers for guiding the fabric, the water washing rollers are arranged in an up-and-down staggered manner, and a guiding gap for the fabric is left between the water washing rollers.

7. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: The jet flow device comprises a jet flow tank, a jet flow outer cylinder and a jet flow inner cylinder arranged in the jet flow tank, the jet flow outer cylinder and the jet flow inner cylinder are both driven by motors, the rotation direction of the jet flow outer cylinder is consistent with the running direction of the fabric, the rotation direction of the jet flow inner cylinder is opposite to that of the jet flow outer cylinder, and a plurality of meshes are uniformly arranged on the jet flow outer cylinder.

8. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: The spraying device comprises a spraying tank and a rotating cylinder arranged in the spraying tank, a plurality of spraying pipes are arranged above the rotating cylinder in the spraying tank, a plurality of nozzles are arranged on the spraying pipes, the rotating cylinder is a hollow structure, and a plurality of meshes are uniformly arranged on the surface of the rotating cylinder.

9. The continuous production apparatus for realizing fabric open-width water washing dewatering according to claim 1, characterized by: The dehydration device comprises a plurality of height-adjustable air knives, an open-size-adjustable support is arranged below the air knives, the support comprises a lower left support and a lower right support for mutual cooperation, the lower left support is fixedly arranged, the lower right support is arranged by means of a horizontal driving device, and the distance between the lower left support and the lower right support is adjusted, the distance between the lower left support and the lower right support is 2-10 mm.

10. A continuous production process for the implementation of fabric open-width aqueous washing dewatering, characterized by: The method uses the continuous production device for realizing fabric flat washing and dehydration according to any one of claims 1-9, and the steps of the method are as follows: (1) The fabric first passes through the cloth spreading and centering and traction device to enter the production process, passes through the bending roller to enter the water washing device to be preliminarily washed, and the tension detection mechanisms of the guide rollers at the water washing device inlet and outlet adjust the draft tension of the fabric according to the setting during the washing process; (2) The washed fabric is fully expanded by the cloth spreading roller to prevent edge curling, and then enters the common roller to be rolled to preliminarily reduce the water content; (3) Then, the fabric sequentially passes through the jet flow device and the spraying device to be further cleaned and impurities removed, the jet flow device drives water to penetrate the fabric to clean the impurities through the special structure and movement mode of the jet flow outer cylinder and the jet flow inner cylinder, and the spraying device removes the residual impurities through the water sprayed by the spraying pipes. During the cleaning process, the overflow channels between the components ensure smooth water flow, and the last component supplements clean water to ensure cleaning quality; (4) The cleaned fabric enters the heavy mangle for re-rolling, further reducing the moisture content; (5) The rolled fabric enters the dehydration component, and according to the fabric condition, the number of air knives, opening size, height of air knife opening from the fabric surface, and the angle between the air knife opening and the fabric surface are adjusted. Under the action of the air knife, the water on the fabric surface is effectively removed, achieving the purpose of dehydration; Among them, the angle between the air knife opening and the fabric surface is 60°-90°; The dehydrated fabric enters the setting machine for setting treatment, realizing continuous production from washing to dehydration to setting.

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