Energy-saving fabric setting machine

Abstract

The utility model provides a kind of energy-saving fabric setting machine, by elevated platform integration layout is combined solar power supply system, significantly improve the equipment space utilization and energy utilization efficiency.Solar power supply component as main power supply, effectively reduce the dependence on traditional power grid and operating cost, reduce carbon emissions;Drying room adopts subarea circulating air duct design and is combined electric heater and top exhaust fan, supplemented by closed air damper, significantly improve the thermal efficiency and reduce loss;And tight cloth component, centering device, whole weft device, car head box component, rolling mill, cooling component, cloth drop and roll component etc. Key process unit orderly runs under the coordination of control system, cooperate with the tension detection device set in multiple places, ensure the stability of setting process and fabric quality.The device overall structure is compact, energy-saving effect is remarkable, it is economical and environment-friendly to run, and it is convenient and safe to maintain.

Description

Technical Field

[0001] This utility model relates to the field of fabric setting, and in particular to an energy-saving fabric setting machine and its operating method. Background Technology

[0002] Fabric setting machines are key equipment in dyeing and finishing processes. Their function is to eliminate internal stress in fabrics through heat and mechanical action, stabilize fabric size and shape, and give fabrics the required hand feel, luster and other properties.

[0003] Traditional fabric setting machines are typically arranged on a horizontal floor and consist of sequentially connected units such as fabric feeding, liquid injection, weft straightening, needle insertion, drying, cooling, and fabric unloading. Power mainly relies on industrial power grid supply, and the drying process generally uses electric heating or gas heating.

[0004] With increasingly stringent environmental protection requirements and continuously rising energy costs, the dyeing and printing industry faces enormous pressure to conserve energy and reduce emissions. Related data shows that the energy consumption of the setting process can account for 25%-30% of the total energy consumption of a dyeing and printing plant, making it a veritable "energy giant." Although existing technologies include localized energy-saving measures such as waste heat recovery and frequency conversion control, the overall energy consumption of the equipment remains high, especially with significant shortcomings in spatial layout and energy structure: on the one hand, flat-lay equipment occupies a large area, requiring maintenance personnel to frequently enter the bottom of the equipment or narrow spaces for inspection and cleaning, which is inconvenient and poses safety hazards; on the other hand, energy supply is highly dependent on traditional power grids or fossil fuels, resulting in high operating costs, significant carbon emission pressure, and limiting the company's ability to deploy in remote areas or regions without a stable power grid. Furthermore, the thermal efficiency of existing setting machine drying chambers still has room for improvement, and heat loss is quite common.

[0005] Therefore, how to achieve compact equipment layout, reduce overall 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 problem that urgently needs to be solved in this field. Utility Model Content

[0006] The purpose of this invention is to provide an energy-saving fabric setting machine and its operating method to solve the problems existing in the prior art.

[0007] To achieve the above objectives, this utility model provides the following solution:

[0008] This utility model provides an energy-saving fabric setting machine, comprising:

[0009] An elevated platform is provided, with guardrails on both sides and stairs at both ends.

[0010] A fabric feeding frame is located at the first end of the elevated platform;

[0011] A fabric tensioning assembly, which is mounted on the fabric feed frame;

[0012] A centering device is disposed at the rear end of the tight fabric assembly;

[0013] A rolling mill, which is disposed at the rear end of the centering device;

[0014] A weft straightening device, wherein the weft straightening device is disposed at the rear end of the rolling mill;

[0015] A headstock assembly, wherein the headstock assembly is disposed at the rear end of the weft straightening device;

[0016] A drying oven is located at the rear end of the front end assembly;

[0017] A cooling assembly is disposed at the rear end of the drying chamber;

[0018] A fabric feeding and rolling assembly is disposed at the rear end of the cooling assembly;

[0019] A drive assembly is disposed on both sides of the elevated platform;

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

[0021] The control system communicates with the tensioning assembly, the centering device, the rolling mill, the weft straightening device, the headstock assembly, the drying room, the cooling assembly, the fabric unloading and rolling assembly, the drive assembly, and the solar power supply assembly for operation control.

[0022] Preferably, the fabric tensioning assembly includes two parallel stainless steel pipes, which are rotatably mounted on the fabric feeding frame.

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

[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 which is provided with an active needle-feeding brush, and the rear end of which is provided with an anti-needle-drop passive brush.

[0026] Preferably, the drying chamber includes circulating fans on both sides, the air inlets of the circulating fans are connected to the interior of the drying chamber, and electric heaters are provided at the air inlets. The air outlet of the circulating fan on one side is connected to the upper spray pipe through the upper air chamber, and the air outlet of the circulating fan on the other side is connected to the lower spray pipe through the lower air chamber. The fabric runs between the upper spray pipe and the lower spray pipe. An exhaust fan is provided at the top of the drying chamber.

[0027] Preferably, the drying chamber is provided with an air-sealing damper on its side.

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

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

[0030] Preferably, the fabric dropping and rolling assembly includes a swing-type fabric dropping frame, and a rolling fabric dropping frame is connected to the lower part of the swing-type fabric dropping frame via a rolling cylinder.

[0031] The present invention achieves the following beneficial technical effects compared to the prior art:

[0032] This utility model provides an energy-saving fabric setting machine that significantly improves space utilization and energy efficiency through an integrated layout with a raised platform and a solar power supply system. The solar power supply serves as the main power source, effectively reducing reliance on the traditional power grid and operating costs, while also reducing carbon emissions. The drying chamber employs a zoned circulating air duct design combined with electric heaters and top exhaust fans, supplemented by closed-loop dampers, significantly improving heat utilization efficiency and reducing heat loss. Key process units such as the fabric tensioning assembly, centering device, weft straightening device, headstock assembly, rolling mill, cooling assembly, and fabric unwinding and rolling assembly operate in an orderly manner under the coordination of the control system. Multiple tension detection devices ensure the stability of the setting process and the quality of the fabric. The device has a compact overall structure, significant energy-saving effect, economical and environmentally friendly operation, and convenient and safe maintenance. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 A schematic diagram of an energy-saving fabric setting machine provided by this utility model;

[0035] Figure 2This is a schematic diagram of the drying chamber section in an energy-saving fabric setting machine provided by this utility model. Detailed Implementation

[0036] The serial numbers assigned to components in this document, such as "first" and "second," are used only to distinguish the described objects and have no sequential or technical meaning. The terms "connection" and "linkage" used in this application, unless otherwise specified, include both direct and indirect connections (linkages). In the description of this utility model, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0037] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0038] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

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

[0040] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be 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, such as... Figure 1As shown, the system includes: a raised platform 1, a fabric feeding rack 2, a fabric tensioning assembly 3, a centering device 4, a rolling mill 5, a weft straightening device 6, a machine head box assembly 7, a drying oven 8, a cooling assembly 9, a fabric unloading and rolling assembly 10, a drive assembly 11, a solar power supply assembly, and a control system. Except for the raised platform 1, all the above components are installed on the raised platform 1, creating a reusable storage or equipment expansion space beneath the platform, thus significantly saving the user's factory floor space.

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

[0044] Furthermore, the fabric feeder 2 is located at the first end of the elevated platform 1. It is made of 4mm thick Q235-A plate bent and welded into a "door" shaped frame. The top of the frame is equipped with two sets of φ120mm stainless steel guide rollers. The surface of the guide rollers is covered with EPDM rubber to prevent the fabric from being scratched. A forklift insertion port is reserved at the front end of the fabric feeder for easy loading of fabric rolls.

[0045] Furthermore, the fabric tightening assembly 3 is installed below the fabric feed frame and includes two parallel stainless steel pipes with a diameter of 50mm and a wall thickness of 3mm. These pipes can be made of SUS304 material. Each pipe is fixed to the fabric feed frame at both ends by bearings with seats and is driven by a 0.37kW geared motor with stepless speed adjustment from 0 to 20rpm. The control system controls the wrap angle of the pipes in contact with the fabric to change the friction force with the fabric, thereby achieving the purpose of tightening or loosening the fabric.

[0046] Furthermore, the centering device 4 is located at the rear end of the fabric tensioning assembly 3, and consists of two through-beam phototubes (detection accuracy ±1mm) and a φ100mm rubber-coated correction roller. The phototubes detect the fabric edge position in real time, and the signal is fed back to the correction roller servo motor. The 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, rolling mill 5 adopts a twin-roll vertical structure. The upper roll is a passive roll with a rubber coating hardness of Shore A 85°; the lower roll is an active roll with a chrome-plated and polished surface. The pressure between the two rolls is provided by a 0.6MPa double-acting cylinder, and the pressure value is linearly adjustable between 0-60kN through a closed-loop proportional valve. A residual liquor recovery tank is installed at the outlet of rolling mill 5, equipped with a low-speed agitator (20rpm) to prevent dye liquor sedimentation. The residual yield is stably controlled at 60% ± 3%.

[0048] Furthermore, the weft straightening device 6 adopts a four-bending roller structure, with the rollers made of aluminum alloy and anodized. Each roller is driven by an independent servo motor, which can adjust the bending amount (0-25mm) in real time according to the weft skew detection data (±0.5° accuracy), while simultaneously smoothing 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 the installation of the coating machine 12. The coating machine 12 is a three-roll reverse scraper type with an electrically adjustable gap of 0-2mm between the rollers. The glue tank has a volume of 20L and is equipped with a constant temperature oil bath (20-80℃). When the user needs functional finishing (such as waterproofing and UV protection), it can be directly hoisted and embedded into this workstation without additional space requirements.

[0050] Furthermore, the front box assembly 7 includes:

[0051] The overfeed roller 71 consists of two sets of φ200mm rubber rollers, with the upper overfeed roller having a linear speed 0-15% faster than the main chain and the lower overfeed roller having a linear speed 0-10% slower. It is driven independently by a variable frequency motor and is used to adjust the radial density of the fabric.

[0052] The active needle brush 72 uses a φ150mm pig bristle brush roller with a rotation speed of 50rpm to evenly press the fabric edge into the needle plate.

[0053] The anti-needle slippage passive brush 73 uses a φ100mm soft brush to prevent the fabric edge from slipping off during high-speed operation.

[0054] The top of the machine head box is equipped with a 10-inch industrial touch screen, which displays parameters such as overfeed rate, needle plate position, and tension in real time.

[0055] Furthermore, such as Figure 2 As shown, the drying chamber 8 is 15m long in total, divided into 5 sections, each 3m long, and equipped with manually operated, openable insulated doors. Each section is equipped with four 1.5kW high-temperature resistant circulating fans 81 (maximum temperature resistance 220℃), with stainless steel finned electric heaters 82 installed at the fan inlets, and the heating power is infinitely adjustable from 0-30kW. Hot air passes through the upper air chamber 83 and the lower air chamber 84, and is then vertically blown onto the fabric surface through air-knife type upper spray pipes 85 and lower spray pipes 86, respectively. Filters 89 are installed below both, and the air velocity is adjustable from 5-15m / s. A 2.2kW variable frequency exhaust fan 87 is installed at the top of the drying chamber, with an exhaust volume of 0-5000m³ / s. 3 / h, used to exhaust hot and humid waste gas. Each drying chamber section is equipped with an air-sealing damper 88 on its side wall: when the equipment stops suddenly, the damper closes within 2 seconds, cutting off the heat source and preventing the fabric from overheating and yellowing. The spacing between the drying chamber tracks is adjusted by a servo motor and ball screw, with an adjustment range of 600-3200mm to adapt to changes in fabric width.

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

[0057] Cooling air chamber 91 uses a 3kW centrifugal fan for air supply, with an air temperature of 20-25℃ and an air speed of 10m / s;

[0058] The cold water roller 92 uses a φ300mm double-layer roller with 15℃ chilled water flowing inside, and the roller surface temperature is ≤25℃ to prevent the fabric from becoming damp again.

[0059] Furthermore, the drive assembly 11 is located on both sides of the elevated platform, and is driven by two 11kW AC variable frequency motors via helical gear reducers (reduction ratio 1:40) to drive the left and right tensioning chains respectively. The chain pitch is 50.8mm, equipped with self-lubricating bearings, and the running speed is steplessly adjustable from 5-60m / min; encoder + PLC closed-loop synchronization, and the speed difference between the left and right chains is ≤0.1%.

[0060] Furthermore, the solar power supply components include:

[0061] Photovoltaic array: peak power 150kW, composed of 600 250W monocrystalline silicon solar panels, installed on the roof of the factory building at a tilt angle of 30°;

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

[0063] Energy storage system: 200kWh lithium iron phosphate battery, for use in rainy days or night shifts;

[0064] The EMS energy management system monitors power generation, load, and energy storage status in real time, prioritizing the use of photovoltaic power and automatically switching to grid power for any shortfall, ensuring zero power outages. The entire system reduces CO2 emissions by approximately 120 tons per year.

[0065] Furthermore, the fabric roll-up assembly 10 is located at the rear end of the cooling assembly 9 and includes:

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

[0067] The fabric rolling and unwinding frame 102 uses a φ400mm air shaft with a maximum roll diameter of 1200mm; the rolling cylinder (80mm diameter, 300mm stroke) enables rapid switching between spreading and winding.

[0068] Furthermore, it also includes a tension detection device 13, which can use a φ120mm tension roller with integrated 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 Profibus-DP bus for the whole machine tension closed loop, ensuring constant tension operation of the fabric throughout the entire process.

[0069] Furthermore, the control system is based on a Siemens S7-1500 PLC and communicates with all frequency converters, servo drives, temperature control modules, and tension modules via Profinet. The human-machine interface is a 15-inch color touchscreen, and the recipe management system can store 100 sets of process parameters, supporting one-click recall. The system has an Ethernet interface, which can be connected to the user's MES and ERP systems to realize functions such as order management, energy consumption statistics, and remote diagnostics.

[0070] The operating method of an energy-saving fabric setting machine provided by this utility model includes:

[0071] S1: Start the solar power supply components. EMS self-checks the status of photovoltaics, energy storage, and load to confirm that the power supply is normal.

[0072] S2: Based on 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: The fabric roll is manually placed on the fabric feeding frame, and the fabric feeding drive is started. The fabric enters the head box after passing through the tensioning assembly, centering device, rolling machine, and weft straightening device.

[0074] s4: After the selvage is automatically aligned by the selvage probe, the upper needle brush presses the selvage into the needle plate; the chain starts and the fabric enters the drying room.

[0075] S5: Once the oven temperature reaches the set value, the circulating fan and exhaust fan will automatically engage PID regulation; in case of a temporary shutdown, the air-closing damper will immediately close.

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

[0077] s7: After the fabric tension is tested, the fabric is evenly stacked by the swing-type fabric dropping frame or switched to the winding state by the rolling cylinder to complete the fabric dropping / rolling.

[0078] S8: During production, the control system records data such as vehicle speed, tension, temperature, and energy consumption in real time, and automatically generates batch reports for quality traceability and energy efficiency analysis. When processing the sidewalls, electrodes with better surface quality and higher material removal rates can be obtained.

[0079] The technical features of the above embodiments can be combined in any way. For the sake of brevity, 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 general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0081] This utility model uses specific examples to illustrate its principles and implementation methods. The above description of the embodiments is only for the purpose of helping to understand the method and core idea of ​​this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the idea of ​​this utility model. In summary, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. An energy-saving fabric setting machine, characterized in that: include: An elevated platform is provided, with guardrails on both sides and stairs at both ends. A fabric feeding frame is located at the first end of the elevated platform; A fabric tensioning assembly, which is mounted on the fabric feed frame; A centering device is disposed at the rear end of the tight fabric assembly; A rolling mill, which is disposed at the rear end of the centering device; A weft straightening device, wherein the weft straightening device is disposed at the rear end of the rolling mill; A headstock assembly, wherein the headstock assembly is disposed at the rear end of the weft straightening device; A drying oven is located at the rear end of the front end assembly; A cooling assembly is disposed at the rear end of the drying chamber; A fabric feeding and rolling assembly is disposed at the rear end of the cooling assembly; A drive assembly is disposed on both sides of the elevated platform; A solar power supply component, which is used to power the entire device; The control system communicates with the tensioning assembly, the centering device, the rolling mill, the weft straightening device, the headstock assembly, the drying room, the cooling assembly, the fabric unloading and rolling assembly, the drive assembly, and the solar power supply assembly for operation control.

2. The energy-saving fabric setting machine according to claim 1, characterized in that: The fabric tensioning assembly includes two parallel stainless steel pipes, which are rotatably mounted on the fabric feeding frame.

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

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 which is provided with an active needle-feeding brush, and the rear end of which is provided with an anti-needle-drop passive brush.

6. The energy-saving fabric setting machine according to claim 1, characterized in that: The drying chamber includes circulating fans on both sides. The air inlets of the circulating fans are connected to the interior of the drying chamber, and electric heaters are provided at the air inlets. The air outlet of the circulating fan on one side is connected to the upper spray pipe through the upper air chamber, and the air outlet of the circulating fan on the other side is connected to the lower spray pipe through the lower air chamber. The fabric runs between the upper spray pipe and the lower spray pipe. An exhaust fan is provided at the top of the drying chamber.

7. The energy-saving fabric setting machine according to claim 6, characterized in that: The drying room is equipped with a closed air vent on its side.

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: Tension detection devices are provided at the rear end of the rolling mill and at the rear end of the cooling assembly.

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

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