Stepping device

Abstract

Fiber mat production device in which the fiber mat is quilted by means of a plurality of parallel quilting needles in conjunction with threads grasped by the quilting needles, preferably with a chain stitch, wherein the mat material is a natural fiber material, namely straw, coconut, jute or wood wool fibers, wherein, in order to improve the performance of the fiber mat production device, namely the throughput speed, as well as to increase the number of stitches, the quilting needles each have a needle head (2) and a needle body (3) arranged below it, wherein the needle body (3) has a substantially rectangular or square cross-section, wherein the needle body (3) has a width (B) and a thickness (D), wherein the needle head (2) tapers to a point and the quilting needle has a weight of less than 15 grams, preferably only about 4 to 10 grams, particularly preferably only about 10 grams.weighs 6 grams and the area which the needle head (2) penetrates into the fiber mat is less than 15 mm. 2 , preferably only about 5 mm 2 the stitch length of the quilting needles is adjustable from 2 to 15 cm and the stitch spacing from 2 to 25 cm, and the quilting needle is positively received in the foot area by a cylindrically shaped body (15), wherein the cylindrical body (15) has a cylindrical basic cross-section and a groove (16) along its length in which the needle body (3) is positively inserted and the cylindrical body (15) is housed and fixed in a bore (13) of a needle bar (10) of the fiber mat production device.

Description

[0001] The invention relates to a quilting device. Such quilting devices are known from DE 94 03 153 U1 or DE 93 18 451 U1.

[0002] The content of these aforementioned publications is also incorporated into the present application in order to provide a basic understanding of the functioning of such quilting devices according to the invention.

[0003] The prior art refers in particular to “Technical advancements in close-knitting machines: Technical advancements in close-knitting machines. In: Technical advancements in close-knitting machines. Chemnitz: Technical advancements in close-knitting machines. 09.11.2006. 28. - Company publication, https: / / hofer-vliesstofftage.de / vortrag-2006.php2”, DE 103 33 656 B3, DE 30 42 335 A1, DD 63 840 A1, US 2002 / 0 152 774 A1, US 2002 / 0 134 115 A1, US 2002 / 0 020 195 A1 and GB 1 309 609 A.

[0004] Stepping devices of the known type as well as of the inventive type are preferably used to produce mats of all kinds, preferably erosion control mats, roof greening mats, i.e. mats that contain a high proportion of natural fibers.

[0005] In such a quilting machine or quilting device, a needle held in a needle bar executes a quilting seam, piercing the material to be quilted. In so-called multi-needle quilting machines—which are also the subject of the present application according to the invention—several quilting needles arranged side by side on a common needle bar each execute a quilting seam. The needles are arranged perpendicular to the feed direction of the material to be quilted and each executes a simple or offset chain stitch. Several needle guide systems are known for such machines.

[0006] It is also known to use different types of quilting needles, especially quilting needles without a flap with a thread gripper or quilting needles with a flap.

[0007] In a system using bar-tipped sewing needles, the quilting is performed by bar-tipped needles that pierce the material from bottom to top. During the quilting process, the feed mechanism of a system with non-running bar-tipped sewing needles briefly stops. The material is advanced in increments as the bar-tipped needles are withdrawn from the quilted material. The sewing needles perform only a vertical stroke. The material feed alone determines the stitch length.

[0008] In the "moving quilting needles with flaps" system, the flap needles pierce the layers of material to be quilted in the fiber mat being produced during transport from top to bottom (or bottom to top). Simultaneously, the needles perform a tilting motion, with the needle tip moving in the direction of material transport. The combination of these two movements ensures that the needle and the quilting material move at approximately the same speed in the transport direction during the penetration phase.

[0009] From DE 94 03 153 U1, it is known that the quilting needle holder is guided by a first linear guide parallel to the needle axis, generally perpendicular to the workpiece plane (the plane in which the fiber mat lies), and by a second linear guide in the direction of material feed during insertion. This ensures that the needle and quilting material have approximately the same speed in the transport direction, thus minimizing friction and wear of the needles and producing small puncture holes even with thick materials.

[0010] It is also known from DE 94 03 153 U1 that one or both linear guides are driven by a crank drive with linkage, and it is further known that both linear guides are driven by crank drives running synchronously at the same speed, which are preferably positively coupled, so that the rotation of a drive shaft is converted into two linear movements with a fixed phase relationship to each other. The workpiece (i.e., the fiber mat material to be quilted) is transported on a belt whose drive is coupled to the needle drive. This allows for precise adjustment of the speed of the material feed (the fiber material) and the needle feed in the transport direction during stitching, and also allows for adjustment of the stitch length. The seam produced by the quilting stitch is preferably a simple chain stitch – also known from DE 93 18 451 U1 – but can also be an offset chain stitch.

[0011] The material used to manufacture the mat is preferably a natural fiber, such as straw, coconut, jute, wood wool, or polypropylene fibers. However, existing systems have certain disadvantages. One particular disadvantage is that customers or operators of existing quilting machines desire a higher material throughput or an increase in processing speed.

[0012] The quilting machines (quilting devices) put into operation so far work with a stitch count of approximately 300 per minute, and possibly up to 500 stitches per minute when a very thin fiber mat is being produced, meaning that each individual quilting needle performs 300 to 500 stitches per minute.

[0013] However, the operators of such a quilting machine desire a significant increase in the stitch count. At the same time, customers increasingly demand lower energy consumption per square meter. 2The manufactured fiber mat is reduced.

[0014] While it would theoretically be possible to increase the stitch count by replacing the existing drives of known quilting machines with more powerful ones, this is not feasible for many reasons, quite apart from the fact that it is a very expensive measure and conflicts with the desire for lower energy consumption in the production of a [missing information]. 2This is contrary to the nature of the fiber mat. A particular problem also arises from the fact that significantly more powerful drives can lead to structural issues, causing the entire quilting machine to vibrate undesirably strongly. This is because the moving mass is supplied with considerably more kinetic energy, and consequently, the entire structure is pushed to its limits in terms of both static and dynamic strength.

[0015] The object of the invention is to avoid the aforementioned problems and, in particular, to increase the processing speed of a quilting machine, while continuing to use existing drives wherever possible, and furthermore to reduce the energy consumption for the production of a m 2the fiber mat is reduced while ensuring the greatest possible compatibility with existing quilting machines, so that these can continue to be operated.

[0016] The problem is solved according to the invention with a quilting machine having the features of claim 1. Advantageous further developments are described in the dependent claims.

[0017] According to the invention, a new quilting needle is used instead of the previously known needles. Previously known quilting needles are relatively heavy; for example, even the lightest version weighs 35 grams, but the weight can also be as high as 60 grams. An image of a known needle is shown in Fig. Figure 1 shows that the circular cross-sectional area of ​​such known needles is approximately 25 to 30 mm² in the head region of the needle. 2or more. This means that when the needle pierces the fiber mat, it creates at least a hole in the workpiece (i.e., the fiber material) with a diameter of 25-30 mm. 2 must pierce the fiber material which corresponds to the maximum cross-sectional area of ​​the needle in the head and body area of ​​the needle.

[0018] If, as proposed according to the invention, a needle type is used which, unlike previous quilting needles, does not have a circular cross-section in the middle needle body, but is essentially rectangular or square in shape there, and which is significantly lighter than previous quilting needles, the processing speed of the quilting machine can be considerably increased with such a small conversion, e.g. up to 1,000 stitches per minute, but at least 600 to 800 stitches per minute.

[0019] This also means that, with the same drive system, the energy input for producing a m 2(or any other reference surface) of the fiber mat is significantly reduced, e.g. up to 20% less than before, and the performance of an existing quilting machine can be considerably increased with a very simple and quick needle changeover.

[0020] The invention is explained in more detail below using an exemplary embodiment. The figures show: Fig. 1 Views of various well-known quilting needles with a circular cross-section at the head of the needle as well as in the needle body; Fig. 2a - i different views of new quilting needles for the device according to the invention; Fig. 3 a view of part of a device according to the invention; Fig. 4 a view of a stepping device known from G 94 03 153 and Fig. 5a - d different views of a needle mounting block.

[0021] Fig. Figure 1 shows views of known quilting needles 1, which have a needle head 2 and a needle body 3 extending longitudinally below it. In the area of ​​the needle body (cross-section AA), the needles have a circular cross-section, e.g., between 6 and 10 mm in diameter. The cross-section of the needles is also essentially round in the area of ​​the uppermost needle head 4; in any case, the needles taper to a point at the top.

[0022] The needle head itself also features the thread gripping area 5 and a liftable flap 6.

[0023] In known quilting machines and special quilting devices, such needles are currently held by a needle bar on which a large number of such needles are arranged parallel at a predetermined distance. One embodiment of such a known quilting machine with the [features] in Fig. The known needles shown in 1 are in Fig. Figure 4 shows that stitching needles are still present, but that is not important at this point, as there are also quilting machines without stitching needles.

[0024] Fig. Section 4 serves only to illustrate the basic structure of such known quilting machines. The disclosure and operation of such known quilting machines are comprehensively described in DE 94 03 153 U1, and the content of these publications, in particular the description of Fig. 4, is therefore also made the subject of the present application.

[0025] In the Fig. Figure 4 shows that, in addition to the needles 14 and the needle bar 10, other movable parts are also provided, namely the linear guides, connecting rods 38 and 40, linear guides 24 and 26, connecting rods 38 and 40, and crank drives 34 and 36. In a realized embodiment of such a machine, the weight of all the needles is less than 1% of the total weight of all moving parts.

[0026] The typical weight of a previously known needle is in the range between 35 and 60 grams, and the puncture area, i.e., the area formed when the needle pierces the mat material, is in the range between 25 and 50 mm. 2 , which is simply due to the fact that the diameter of the needles in the area of ​​the needle head or needle body is in a range between 6 and 8 mm.

[0027] Fig. Figures 2a to 2e now show different views of needles used according to the invention.

[0028] These needles do not have a circular cross-section like the known needles, but rather an essentially rectangular needle body with a width B (the widest front view in) in the area of ​​the needle body. Fig. 2a) and a thickness D. The thickness is in the Fig. 2d and e are kept dark, and the wide side is in the Fig. Kept 2d to 2e lighter.

[0029] The needles 1' are enclosed in the foot area by a cylindrically shaped body - Fig. 5 - The needles are positively engaged and, together with the cylindrical body 15, are placed in a bore 13 of the needle bar 10 and fixed there with screws 14 screwed laterally into the needle bar. Thus, all needles are aligned exactly the same through this fixing.

[0030] The needles according to Fig. 2 are in the middle area, i.e. in the area of ​​the needle body, approximately 2.5 to 2.8 mm wide and 1.5 to 2 mm thick, so that the entire needle cross-section there is approximately 5 mm 2 amounts.

[0031] The entire needle itself is made of stainless steel and weighs approximately 5-10 grams, preferably only about 6 grams.

[0032] In the area of ​​the needle head 2', the needle, like known needles, has an area 5' for catching the thread and a pivoting flap 6'.

[0033] In the uppermost head region 2', the needle tapers to a point, and the thickness of the needle in the upper head region is significantly reduced compared to the needle body region 3', e.g. to approximately 1 mm, particularly noticeable in Fig. 2i. The thickness D2 of the needle is reduced again in the uppermost needle head area 2', i.e. where the needle tapers to a point and thus the width decreases significantly, so that at the very tip the needle is less than 1 mm thick.

[0034] The cylindrical body 25, which positively engages the needle 1', is in Fig. 5 in different views and in Fig. 2h, Fig. Figure 2i shows the top view. It can be seen that the body 15 has a cylindrical cross-section and a longitudinal groove 16 with internal dimensions that allow the needle body 3' to be inserted into it in a form-fitting manner. In the lower area, the needle block also has a diameter corresponding to the through groove 18, in which the needle foot 17 – see Figure 2i – fits. Fig. 5e - fits perfectly.

[0035] Finally, the cylindrical body has a recess 19 on the side, into which the screw 14 engages to fix the block 25 in the needle bar 10.

[0036] Will the in Fig. 2 needles 1' or needle banks 10 shown from the in Fig. 4. The quilting machine shown (or variations thereof) is used - see below. Fig. 3 -, although the weight of the moving parts of the quilting machine is only slightly reduced, it is now possible without problems to significantly increase the machine throughput and, for example, to raise the stitch count to 600 to 1,000 stitches per minute.

[0037] This means that with the same machine drive, the area of ​​fiber mat produced increases significantly, and thus, per reference area, fiber mat, e.g., per m² 2 Fiber mat significantly reduces energy consumption, e.g. up to 35%.

[0038] By using the in Fig. The piercing force of the two depicted sewing needles is significantly reduced compared to known needles.

[0039] The invention is particularly well suited for retrofitting existing quilting machines when their performance is to be improved, especially when their throughput speed, and in particular the stitch count, is to be significantly increased.

[0040] Since the use of the in Fig. Since the piercing force of the two needles shown is significantly reduced compared to previously known needles, the needle bank 10 can now also be made of a lighter metal, e.g., aluminum, and the other moving parts of the quilting machine can also be made significantly smaller or "slimmer" and also made of aluminum, so that the weight of all moving parts is reduced again, which leads to a further increase in the stitch count or the performance of the machine, so that overall, with only minor modifications and effort, the performance of the existing quilting machine can be improved by over 30 to 40%.

[0041] The invention also makes it possible to adjust stitch lengths from 2 to 15 cm and to set a stitch spacing of 2 to 25 cm.

[0042] Fig. Figure 3 shows a view of a quilting machine according to the invention with parallel arranged needles 9' as shown in Fig. 2 are shown.

[0043] A quilting machine typically has a powerful motor, e.g., a power rating of 18 kilowatts. When using the [unclear] Fig. If the same number of stitches as before is to be maintained with the two needles shown, this drive can now be operated with a connected load of 9 to 10 kilowatts, which makes it particularly clear how significant the energy savings per square meter are. 2 Fiber matter is used in production. Above all, it is also possible to significantly increase the stitch count, so that the entire quilting machine then has a much larger operating range in terms of stitch count and thus in terms of production area per unit of time, making the entire machine much more versatile and adaptable for a wide variety of applications.

[0044] Overall, the invention can significantly reduce the total machine costs for the production of fiber mats of all kinds, and the fiber mat production of a single machine can be considerably increased with existing machine capacity simply by replacing the needles.

[0045] The necessary investment costs are covered by the use of the in Fig. The cost of the 2 needles shown, possibly new needle banks, etc., is so low that the additional waste allows for a good reinvestment within a few days / weeks, and the investment costs are recouped several times over through the energy savings of just one year.

Claims

[1] Fiber mat production apparatus in which the fiber mat is quilted by means of a plurality of parallel quilting needles in conjunction with threads grasped by the quilting needles, preferably with a chain stitch, wherein the mat material is a natural fiber material, namely straw, coconut, jute or wood wool fibers, wherein, in order to improve the performance of the fiber mat production apparatus, namely the throughput speed, as well as to increase the number of stitches, the quilting needles each have a needle head (2) and a needle body (3) arranged below it, wherein the needle body (3) has a substantially rectangular or square cross-section, wherein the needle body (3) has a width (B) and a thickness (D), wherein the needle head (2) tapers to a point and the quilting needle has a weight of less than 15 grams, preferably only about 4 to 10 grams, particularly preferably only about 10 grams.weighs 6 grams and the area which the needle head (2) penetrates into the fiber mat is less than 15 mm. 2 , preferably only about 5 mm 2 the stitch length of the quilting needles is adjustable from 2 to 15 cm and the stitch spacing from 2 to 25 cm, and the quilting needle is positively received in the foot area by a cylindrically shaped body (15), wherein the cylindrical body (15) has a cylindrical basic cross-section and a groove (16) along its length in which the needle body (3) is positively inserted and the cylindrical body (15) is housed and fixed in a bore (13) of a needle bar (10) of the fiber mat production device. [2] Device according to claim 1, characterized by, that the needle head (2) and needle body (3) are formed in one piece and are made of stainless steel, and that the needle head (2) has a width (B1) that is significantly less than the width (B) of the needle body (3), and that the needle head (2) has a thickness (D1) that is greater than the thickness (D) of the needle body (3). [3] Device according to any one of the preceding claims, characterized by , that the needle body (3) terminates with a needle foot which fits positively into a block by means of which the needle can be fixed in a needle bank of the device. [4] Device according to any one of the preceding claims, characterized by that the needle bank is made of aluminium.

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