Needle-cutting machine and method for operating such a needle-cutting machine

Abstract

A method according to the invention for operating a needle-tapping machine (2) comprises the superposition of a first horizontal stroke component of the needle points of a plurality of needles (12) and a second horizontal stroke component of the needle points of the plurality of needles (12), thereby producing a predetermined horizontal stroke (H) whose value is both greater than a value of the first horizontal stroke component and greater than a value of the second horizontal stroke component. [Fig. 1a]

Description

Title of the invention: Needle-cutting machine and method for operating such a needle-cutting machine

[0001] The present invention relates to a needle-punching machine for needle-punching a flat textile structure, such as, for example, a sheet of fibers, a non-woven fabric, a fabric or a canvas, as well as a method for operating such a needle-punching machine.

[0002] Needle-makers are well known and described for example in Fuchs and Albrecht, Vliesstoffe, Weinheim: Editions Wiley-VCH, 2nd edition (2012), as well as in Albrecht, Fuchs and Kittelmann, Vliesstoffe, Weinheim: Editions Wiley-VCH (2000).

[0003] Typically, with needle-punching machines, a flat textile structure is fed into the machine's inlet and then conveyed in a direction that directs the flat textile structure towards a needle zone. Within the needle zone, there is an arrangement of needle bars, with at least one needle bar against which a needle board is positioned. This board is equipped with a plurality of needles designed to reinforce the flat textile structure. The plurality of needles reinforces the flat textile structure by being inserted into, and then withdrawn from, the flat textile structure by means of a high-frequency vertical stroke.Those skilled in the art are familiar with the most diverse forms of needle-tapping machines, including those in which the plurality of needles is moved with the flat textile structure during the consolidation process by means of a horizontal stroke in the direction of transport of the flat textile structure.

[0004] It is desirable to be able to adapt both the vertical and horizontal strokes to the requirements of each case, such as, for example, the transport speed, the thickness, the material, and the material density of the flat textile structure. In doing so, the mechanisms known for producing vertical and horizontal strokes reach their limits insofar as, for example, an increasing stroke produces stronger vibrations, or the plurality of needles undergoes an increasing inclination relative to the stitching and transport direction, which increases the risk of needle breakage.

[0005] The present invention aims to provide a needle-tapping machine and a method for operating a needle-tapping machine which allow a large horizontal stroke with the simplest and most economical assembly of the needle-tapping machine possible, as well as with less stress on the plurality of needles and other components of the needle-tapping machine.

[0006] A method according to the invention for operating a needle-punching machine with an arrangement of needle bars for needle-punching a flat textile structure, The arrangement of needle bars having at least one needle bar with a plurality of needles, includes: the production of a vertical stroke of the needle bar arrangement by means of a first drive arrangement comprising a first shaft, a second shaft, a first connecting rod and a second connecting rod, the first connecting rod and the second connecting rod being respectively articulated coupled with the needle bar arrangement, the first connecting rod being eccentrically mounted on the first shaft and the second connecting rod being eccentrically mounted on the second shaft, and the first shaft and the second shaft being driven in rotation in opposite directions; the production of a first horizontal stroke component of needle tips of the plurality of needles by means of the first drive arrangement, the first shaft and the second shaft having a phase difference; the production of a second horizontal stroke component of the needle points of the plurality of needles by means of a second drive arrangement which includes a third connecting rod which is articulatedly coupled with the needle bar arrangement and has a horizontal motion component which it transmits to the needle bar arrangement.

[0007] The first horizontal stroke component and the second horizontal stroke component overlap and thus produce a predetermined horizontal stroke whose value is both greater than a value of the first horizontal stroke component and greater than a value of the second horizontal stroke component.

[0008] A method for operating a needle-tapping machine is thus proposed, in which the horizontal stroke is produced by superimposing the first horizontal stroke component and the second horizontal stroke component, which are themselves created by various kinematics corresponding to the first and second drive arrangements. In this way, a predetermined horizontal stroke can be obtained, although the value of the first and second horizontal stroke components can be respectively lower than the desired or required predetermined horizontal stroke, which in turn has a positive effect on the first and second drive arrangements as well as on the needle bar arrangement.

[0009] The first drive arrangement causes, for example due to the phase difference, a tilting movement of the needle bar arrangement around an axis that is oriented vertically with respect to the transport direction and vertically with respect to the pricking direction, the first horizontal stroke component of the needle points resulting from this movement of tilting. If the required value of the first horizontal stroke component to obtain the predetermined horizontal stroke can be kept low, less tilting of the needle bar arrangement, and thus less inclination of the plurality of needles, will be required, thereby reducing the stress on the arrangement. The risk of needle breakage is reduced.

[0010] The second drive arrangement includes the third connecting rod driven by oscillation with a horizontal motion component. If the required value of the second horizontal stroke component to obtain the predetermined horizontal stroke can be kept low, less vibration will be induced, thereby allowing the (bearing) components of the needle bar arrangement and the second drive arrangement to be reduced and / or to be smaller in size.

[0011] The fact that the first and second horizontal stroke components overlap makes it possible to obtain the desired predetermined horizontal stroke. Preferably, the first and second horizontal stroke components overlap constructively. In other words, the first and second horizontal stroke components overlap such that the value of the first horizontal stroke component and the value of the second horizontal stroke component add up to give the predetermined value of the horizontal stroke. The resulting horizontal stroke can thus be maximized.

[0012] The first and second horizontal stroke components are preferably oriented parallel to each other, as well as parallel to a transport direction of the flat textile structure through the needle-punching machine. Consequently, the horizontal stroke is also oriented parallel to the transport direction, and the plurality of needles are moved in the transport direction along with the flat textile structure. In this way, deformation of the flat textile structure and stress on the plurality of needles can be reduced.

[0013] The vertical stroke of the needle bar arrangement and the horizontal stroke overlap and produce an essentially elliptical path of movement for the needle tips of the plurality of needles. The elliptical path of movement may have a component parallel to the stitching direction due to the vertical stroke and a component parallel to the transport direction due to the horizontal stroke. Along this path of movement, the plurality of needles pierce the flat textile structure, are moved with the flat textile structure in the transport direction, and then withdrawn again from the flat textile structure.

[0014] The value of the first horizontal stroke component can in principle be constant, thereby allowing for a particularly simple mounting of the first This makes the drive arrangement possible. Particularly flexible operation and adaptability of the stroke can be achieved because the value of the first horizontal stroke component is variable. For example, if the value of the first horizontal stroke component approaches zero, the resulting horizontal stroke value will approach the value of the second horizontal stroke component. Conversely, if the value of the first horizontal stroke component is increased, the resulting horizontal stroke value will increase accordingly. The horizontal stroke can thus be easily adjusted and set to a desired value.

[0015] The value of the first horizontal stroke component can, for example, be made variable because the phase difference between the first and second shafts can be adjusted. The method for operating the needle-pointer then preferably includes adjusting the phase difference and thus the value of the first horizontal stroke component. The value B1 can preferably be set within a range of 0 < B1 < Blmax between zero and a maximum value Blmax.

[0016] The phase difference can be adjusted when the needle-tapping machine is stopped. This facilitates the assembly of the needle-tapping machine, particularly the initial drive arrangement. However, the phase difference can also be adjusted while the needle-tapping machine is running, allowing for a quick adjustment and preventing an unwanted stoppage of the machine.

[0017] In principle, the first shaft and the second shaft preferably rotate synchronously, i.e., at the same rotational speed or the same number of revolutions. It is also advantageous for the first and second shafts to rotate at a constant rotational speed during the operation of the needle-tapping machine.

[0018] The phase difference is generally defined between a first phase angle of the first shaft and a second phase angle of the second shaft. The first phase angle is preferably defined as the crank angle of the first shaft and the second phase angle as the crank angle of the second shaft. The first and second phase angles must be defined in the direction of rotation of the respective shaft. If, for example, the first shaft rotates counterclockwise and the second shaft clockwise, the first phase angle must be determined counterclockwise and the second phase angle clockwise. Both phase angles are therefore positive even if the first and second shafts rotate in opposite directions. If the first and second shafts rotate at the same speed, the phase difference will then be constant.In this case, the phase difference can be taken into account at each angular position or set to a desired value. The phase difference can also be taken. taken into consideration when the first or second shaft is in a determined angular position, for example when the first shaft is at top dead center or bottom dead center.

[0019] The phase difference can preferably be adjusted by setting the first phase angle and / or the second phase angle. Preferably, only the first or second phase angle is adjusted. The phase angle that is not adjusted must then be held as is, for example, by completely braking the corresponding shaft. Those skilled in the art are aware of various mechanisms for setting the first and / or second phase angle. A particularly preferred embodiment is described with reference to the needle-tapping machine according to the invention and is correspondingly applicable to the process according to the invention.

[0020] For driving the first shaft and the second shaft in opposite directions and preferably synchronously, the first drive arrangement preferably includes a first reversing gear between the first shaft and the second shaft. The first reversing gear can, for example, be designed as a spur gear.

[0021] Adjusting the phase difference preferably includes decoupling a rotation of the first shaft from a rotation of the second shaft and rotating either the first or second shaft by means of a rotational drive, also called the first rotational drive. In this way, despite the transmission of torque between the first and second shafts by the first reversing gear in a coupled state, rotation of the first and second shafts relative to each other in a decoupled state can be made possible. For the selective coupling and decoupling of the rotation of the first and second shafts, the first drive arrangement preferably includes a first coupling, as described in detail below.

[0022] The method preferably comprises the steps of: determining a setpoint value for the first horizontal stroke component, in particular on the basis of the predetermined horizontal stroke value and the value of the second horizontal stroke component, determining a setpoint phase difference on the basis of the setpoint value for the first horizontal stroke component, rotating the first shaft or the second shaft by means of the rotation drive so that an actual phase difference corresponds to the setpoint phase difference.

[0023] The setpoint value of the first horizontal stroke component can be determined manually, for example by predefining the setpoint value. The setpoint value of the first component The horizontal stroke is preferably controlled by a needle-tapping machine control device. A desired horizontal stroke can, for example, be predefined by a needle-tapping machine operator, preferably via a human-machine interface, or be stored in a needle-tapping machine operating program, for example, in relation to a specific flat textile structure, or be preset. The second horizontal stroke component preferably has a constant value, but can also be adjustable and therefore predefined, stored, or preset. Consequently, the setpoint value of the first horizontal stroke component can be determined as the difference between the predetermined horizontal stroke value and the value of the second horizontal stroke component.

[0024] The value of the first horizontal stroke component (also called the first value) can, for example, be between 5 mm and 20 mm, preferably between 8 mm and 15 mm. The value of the second horizontal stroke component (also called the second value) can, for example, be between 5 mm and 40 mm, preferably between 10 mm and 30 mm. If the value of the first and / or second horizontal stroke component(s) is / are variable, these ranges will respectively refer to the maximum value of the respective stroke component that can be obtained.

[0025] Starting from this point and in this manner, a horizontal stroke value between 45 mm and 60 mm can be obtained, which would not be possible with the first or second drive arrangement alone. Typically, a horizontal stroke value obtainable with the first and second drive arrangements is between 10 mm and 15 mm.

[0026] Preferably, the value of the first horizontal stroke component and the value of the second horizontal stroke component are each half of the predetermined horizontal stroke value. This ensures that as wide a range as possible of the resulting horizontal stroke can be set without having to oversize a drive arrangement or the stroke component it produces. For example, for a resulting horizontal stroke value of 20 mm, this would result in a first value of 10 mm and a second value of 10 mm. If the first value were variable and the second value were constant, the horizontal stroke could be set at least between 10 mm and 20 mm.

[0027] The value of the second horizontal stroke component is preferably constant. This allows for a simple assembly of the second drive arrangement. In a preferred embodiment, the second drive arrangement includes a third shaft, the third connecting rod being mounted from The third shaft is eccentrically driven. The third shaft is preferably rotated, particularly at a constant rotational speed. This imparts a horizontal motion component to the third connecting rod, which transmits it to the needle bar arrangement to produce the second horizontal stroke component. The third connecting rod is preferably oriented essentially horizontally. Instead of rotating the third shaft, it would be conceivable to move the third shaft by oscillating in a reciprocating motion at a predetermined angle of rotation.

[0028] The advantageous characteristics of the needle-tapping machine operating by means of the method are described below. To increase torsional rigidity and for uniform force transmission, it is advantageous for the needle-tapping machine to comprise a plurality of first connecting rods, a plurality of second connecting rods, and a plurality of third connecting rods. The plurality of first connecting rods are arranged one behind the other at intervals between them in the axial direction of the first shaft, the plurality of second connecting rods are arranged one behind the other at intervals between them in the axial direction of the second shaft, and the plurality of third connecting rods are arranged one behind the other at intervals between them in the axial direction of the third shaft.The first, second, and third connecting rods are described here representatively for the plurality of first, second, and third connecting rods. Regardless, the axial direction of the first, second, and third shafts is preferably oriented parallel to each other. A longitudinal axis of the first shaft and a longitudinal axis of the second shaft are preferably located in a common horizontal plane.

[0029] The needle bar arrangement comprises at least one needle bar with a plurality of needles. The needle bar arrangement preferably includes a support against which at least one needle bar is rigidly fixed. A plurality of needle bars is preferably fixed to the support, with at least two needle bars arranged one behind the other in a direction parallel to the direction of travel. At least one needle board or a plurality of needle modules, equipped with the plurality of needles, may be removably fixed to the at least one needle bar. Furthermore, the first, second, and third connecting rods are preferably articulated with the support.

[0030] The part in which the first connecting rod is eccentrically mounted on the first shaft is also called the first crank portion of the first shaft, and the part in which the second connecting rod is eccentrically mounted on the second shaft is also called the second crank part of the second shaft.

[0031] On the one hand, a needle-tapping machine according to the invention is characterized in that it comprises a first drive arrangement designed to produce the vertical stroke of the needle bar arrangement and the first horizontal stroke component of the needle points of the plurality of needles, and a second drive arrangement designed to produce the second horizontal stroke component of the needle points of the plurality of needles. For the first time, a needle-tapping machine is thus proposed that includes two mechanisms for producing horizontal stroke components that can be superimposed on a predetermined horizontal stroke. The limitations of individual mechanisms can thus be overcome, and a longer horizontal stroke can be obtained.

[0032] On the other hand, the needle-tapping machine is characterized in that the first reversing gear couples a first transmission part of the first shaft with a second transmission part of the second shaft, and the first drive arrangement further includes a first switchable coupling which separably connects the first crank part and the first transmission part.

[0033] In this way, the needle-tapping machine allows, via simple and inexpensive mechanical elements, a decoupling of the first part of the crank from the first part of the transmission, and therefore from the second shaft, in order to be able to adjust the phase difference.

[0034] The first coupling can preferably be switched between a coupled and an uncoupled state. In the coupled state, the first coupling connects the first crank portion and the first transmission portion so that torque can be transmitted. In the uncoupled state, the first coupling separates the first crank portion and the first transmission portion so that no torque can be transmitted.

[0035] The first reversing gear transmits torque between the first shaft and the second shaft by reversing the direction of rotation and is preferably designed as a spur gear, in particular as a single-stage spur gear. The first reversing gear preferably has a transmission ratio of i = 1. The first and second shafts then have the same rotational speed or the same number of revolutions. The first coupling can, e.g., be designed as a plate coupling or as a disc coupling. Other suitable embodiments of the first coupling will be obvious to those skilled in the art.

[0036] The first drive arrangement may further include a first rotary drive coupled to the first crank section or the first transmission section. The first rotary drive is designed to rotate the first crank section or the first transmission section. In this respect, the first rotary drive may be mounted directly against the first crank section or the first transmission section, or coupled to them, for example, via a gear or a belt drive. The first rotary drive allows for the adjustment of the phase difference. If the first rotary drive is coupled to the first crank section, the first rotary drive can adjust the first phase angle.If the first rotary drive is coupled with the first transmission part, which is itself connected to the second transmission part and the second crank part via the first reversing gear, the first rotary drive will be able to adjust the second phase angle.

[0037] Regardless of this, the first rotary drive may be the sole drive of the first drive arrangement. The first rotary drive is then configured so that it provides all the torque required to drive the first and second shafts during the operation of the needle-tapping machine.

[0038] The first drive arrangement may further include a second rotary drive. The first and second rotary drives are preferably synchronized. The use of the second rotary drive has the advantage of producing a damping effect on the first drive arrangement and, independently of this, the first and second rotary drives can together provide the torque required to drive the first and second shafts during the operation of the needle-tapping machine. In doing so, the torque to be applied by each of the two rotary drives can be halved. Smaller and therefore less expensive drives can be used. Furthermore, at least the first coupling is relieved when both the first crank portion and the first transmission portion of the first shaft are driven in rotation.It would also be possible to operate the needle-tapping machine in a disengaged coupling.

[0039] It would also be conceivable that only the first or second rotary drive would drive the first and second shafts during the operation of the needle-tapping machine, and that the other rotary drive would be designed as an auxiliary drive used solely for adjusting the first or second phase angle. The auxiliary drive can be designed to be very small and inexpensive.

[0040] If a second rotary drive is planned, different configurations of the first drive arrangement are possible. In principle, the second rotary drive can be mounted directly against the respective part of the first or second shaft or be indirectly coupled to it, for example via a gear or a belt drive.

[0041] In one embodiment, the first rotary drive is coupled to one of the first crank portion and the first transmission portion, and the second rotary drive is coupled to the other of the first crank portion and the first transmission portion. In the open state of the first coupling, the one of the first and second rotary drives that is coupled to the first crank portion can then adjust the phase angle of the first shaft. The other of the first and second rotary drives that is coupled to the first transmission portion can completely brake the transmission portion and thus the second shaft. In the closed state of the first coupling, the first and second rotary drives can together drive the first shaft and, via the first reversing gear, the second shaft.

[0042] In another embodiment, the second rotary drive is coupled with the second transmission section or the second crank section of the second shaft. The drive power is thus distributed between the two shafts, and the first reversing gear is subjected to less stress. If the second rotary drive is coupled with the second crank section, it can adjust the second phase angle.

[0043] The first drive arrangement may further include a second switchable coupling that separably connects the second crank portion and a transmission portion of the second shaft. The second coupling can preferably be switched between a coupled and an uncoupled state. In the coupled state, the second coupling connects the second crank portion and the transmission portion so that torque can be transmitted. In the uncoupled state, the second coupling separates the second crank portion and the transmission portion so that no torque can be transmitted. The second coupling can, for example, be designed as a plate coupling or as a disc coupling. Other suitable embodiments of the second coupling will be obvious to those skilled in the art. In this way, the second phase angle can be set independently of the first shaft.

[0044] The transmission part can correspond to the second transmission part in which the first reversing gear described above transmits a torque between the first shaft and the second shaft.

[0045] The first drive arrangement preferably includes a second reversing gear that couples another transmission portion of the first shaft with another transmission portion of the second shaft. If the second reversing gear is provided, the first drive arrangement will also include the second coupling. Preferably, the second coupling then connects the second crank portion and the other transmission portion of the second shaft. The second reversing gear transmits torque between the first shaft and the second shaft by reversing the direction of rotation and is preferably designed as a spur gear, in particular as a single-stage spur gear. The second reversing gear preferably has a transmission ratio of i = 1. The second reversing gear is preferably constructed similarly to the first reversing gear.

[0046] A reinforcement of the first drive arrangement can preferably be achieved by arranging the first crank portion between the first transmission portion and the other transmission portion of the first shaft. The first crank portion is then located between the first and second reversing gears, which support the first shaft on both sides. Similarly, the second crank portion can be arranged between the second transmission portion and the other transmission portion of the second shaft. A symmetrical arrangement and a closed shaft ring are thus obtained, with the crank portions being supported on both sides.

[0047] In one embodiment, the first rotary drive is coupled to the first shaft, specifically to the first transmission section, and the second rotary drive is coupled to the second shaft, specifically to the other transmission section of the second shaft. The first coupling can then be provided between the first crank section and one of the first and second reversing gears, and the second coupling can be provided between the second crank section and the other of the first and second reversing gears. For example, if the first coupling is provided between the first crank section of the first shaft and the first reversing gear, the second coupling will be provided between the second crank section of the second shaft and the second gear. Thus, one of the two rotary drives can respectively adjust the phase angle of one of the two shafts.Generally, it is sufficient to adjust only the first or second phase angle. For this purpose, in this embodiment, both the first and second couplings must be in the open state. In this embodiment, operation of the needle-tapping machine is also possible as long as both the first and second couplings are in the uncoupled state.

[0048] In an embodiment presented by way of example, which includes the first and second reversing gears, the first rotary drive is coupled with the first transmission part of the first shaft, the first coupling connects the first transmission part with the first crank part of the first shaft, the second rotary drive is coupled with the other transmission part of the second shaft and the second coupling connects the other transmission part of the second shaft with the second crank part.

[0049] The needle-tapping machine preferably includes a control device. The control device can be connected in communication with the first rotary drive and, if present, with the second rotary drive. In particular, the control device can drive the first rotary drive so that it sets either the first or the second phase angle. The control device can also drive the second rotary drive so that it sets the other phase angle between the first and second phase angles.

[0050] The control device can also be connected in communication with the first coupling and, if present, with the second coupling, in particular with a respective actuation device for the first or second coupling. Therefore, the control device is preferably arranged to switch the first coupling, and if applicable the second coupling, to the uncoupled state to adjust the phase difference, and to switch the first coupling, and if applicable the second coupling, to the coupled state when the phase difference is adjusted, to allow the needle-tapping machine to operate.

[0051] The control device is preferably arranged, based on a setpoint value for the first horizontal stroke component, to drive the first rotational drive such that the phase difference between the first and second shafts influences the setpoint value of the first horizontal stroke component. If a second rotational drive is provided, the control device can also drive the second rotational drive accordingly, based on the setpoint value of the first horizontal stroke component.

[0052] The first drive arrangement preferably includes at least one rotary angle encoder, more preferably a first rotary angle encoder and a second rotary angle encoder for detecting the angular position of the first and / or second shaft. Preferably, the first rotary angle encoder detects the angular position of the first crank portion and the second rotary angle encoder detects the angular position of the second crank portion. The at least one rotary angle encoder may, for example, be an incremental encoder or an absolute encoder.

[0053] At least one rotary angle encoder is preferably connected in communication with the control device, the first rotary drive, or the second rotary drive. From this connection, the at least one rotary angle encoder can provide the actual angular position of the first crank portion of the first shaft and / or the actual angular position of the second crank portion. In this way, the regulation of the first and second phase angles is made possible. Advantageously, only the first or second phase angle is set, while the other respective crank portion is held in a defined position, for example, by means of a brake or one of the two rotary drives.

[0054] The second drive arrangement preferably includes the third shaft, with the third connecting rod mounted eccentrically on the third shaft. This induces a horizontal motion component in the third connecting rod, which transmits this component to the needle bar arrangement to produce the second horizontal stroke component.

[0055] In a preferred embodiment, the third shaft is driven in rotation, in particular with a constant rotational speed. The second drive arrangement may, for example, include a third rotary drive that drives the third shaft in rotation. Alternatively, the second drive arrangement may be coupled with the first drive arrangement. The first or second shaft may, for example, be coupled to the third shaft by means of a belt drive.

[0056] In another embodiment, the third shaft is moved by oscillation in a reciprocating motion through a predetermined angle of rotation, for example by means of the third rotary drive. The angle of rotation through which the third shaft is moved in a reciprocating motion is characteristic of the second horizontal stroke component that is induced.

[0057] The needle-tapping machine according to the invention is preferably adapted and designed to carry out the process according to the invention. The process according to the invention preferably serves to operate the needle-tapping machine according to the invention. All the characteristics of the needle-tapping machine described in connection with the process according to the invention are themselves transferable to the needle-tapping machine according to the invention, and vice versa.

[0058] Other features and advantages of the present invention will be described below with reference to the drawings which are attached.

[0059] [Fig.la] schematically shows, in front view, an embodiment of a needle-tipping machine intended to operate according to the process of the invention in a position without phase difference in a first drive arrangement ([Fig. aa]) and in a position with phase difference in the first training arrangement ([Fig.lb]).

[0060] [Fig.lb] schematically shows in front view an embodiment of a needle-tipping machine intended to operate according to the process according to the invention in a position without phase difference in a first drive arrangement ([Fig. la]) and in a position with phase difference in the first drive arrangement ([Fig.lb]).

[0061] [Fig.2] schematically shows in front view a needle-tapping machine according to [Fig.la] with another embodiment of a third drive arrangement.

[0062] [Fig.3] schematically shows in front view a needle-tapping machine according to [Fig. 1a] with yet another embodiment of the third drive arrangement.

[0063] [Fig.4] schematically shows in top view an embodiment of the first drive arrangement of a needle-tapping machine according to the invention, in particular according to one of [Fig.la] to 3.

[0064] [Fig.5] schematically shows in top view another embodiment of the first drive arrangement of the needle-tapping machine.

[0065] Fig. 1a schematically represents an embodiment of a needle-punching machine 2 comprising an arrangement of needle bars 4 for needle-punching a flat textile structure 6 which is moved in a transport direction F through the needle-punching machine 2. The flat textile structure 6 can be a fibrous web, a non-woven, a textile fabric or a canvas. The needle bar arrangement 4 comprises at least one needle bar 8, or in the embodiment shown, two needle bars 8, 10, arranged one behind the other in the direction of transport F. Each needle bar 8, 10 is equipped with a plurality of needles 12. As is known, a needle board 14, 16, respectively equipped with a plurality of needles 12, can be removably fixed to each needle bar 8, 10. The needle bar arrangement 4 may further include a support 18 against which the two needle bars 8, 10 are fixed.

[0066] To consolidate the flat textile structure 6, the plurality of needles 12 are inserted and removed from the flat textile structure 6 at a stroke frequency. In this regard, the needle-punching machine 2 includes a first drive arrangement 20 in the form of a crank drive to produce a vertical stroke V of the needle bar arrangement 4 parallel to a stitching direction E. The first drive arrangement 20 itself comprises a first shaft 22, a first connecting rod 24 which is eccentrically mounted on the first shaft 22, a second shaft 26, and a second connecting rod 28 which is eccentrically mounted on the second shaft 26. The first and second connecting rods 24, 28 are coupled in such a way articulated with the needle bar arrangement 4, in particular with the support 18 of the needle bar arrangement 4.

[0067] As shown in [Fig.4] and 5, the first drive arrangement 20 can include a plurality of first connecting rods 24a, b, c and a plurality of second connecting rods 28a, b, c, which are designed similarly to the first connecting rod 24 and the second connecting rod 28. The plurality of first connecting rods 24a, b, c is arranged one behind the other in the axial direction of the first shaft 22 and the plurality of second connecting rods 28a, b, c is arranged one behind the other in the axial direction of the second shaft 26.

[0068] The first shaft 22 and the second shaft 26 are driven in rotation in opposite directions, as indicated by the curved arrows and described in more detail with reference to [Fig.4] and 5. Due to the eccentric mounting of the first connecting rod 24 and the second connecting rod 28, the rotation of the first and second shafts 22, 26 causes a cyclic up-and-down movement of the needle bar arrangement 4 and thus a vertical stroke V.

[0069] A horizontal stroke H of the needle tips of the needles 12 is further produced to move the plurality of needles 12 with the flat textile structure 6 in the transport direction F during the consolidation process.

[0070] A first horizontal stroke component of the needle tips of the plurality of needles 12 is produced by means of the first drive arrangement 20 in that the first shaft 22 and the second shaft 26 have a phase difference, as shown in [Fig. 1b]. Here, for example, the first connecting rod 24 is at top dead center and the second connecting rod 28 is at bottom dead center; the phase difference is therefore 180°. If the first shaft 22 and the second shaft 26 are driven, the phase difference will create a tilting motion of the needle bar arrangement 4 about an axis A. This tilting motion causes the first horizontal stroke component of the needle tips.

[0071] The value of the first horizontal stroke component can be variable. This is particularly easy to achieve thanks to the first drive arrangement 20. The value of the first horizontal stroke component depends on the tilting motion of the needle bar arrangement 4, the magnitude of which itself depends on the phase difference between the first and second shafts 22, 26. If the phase difference is adjusted, the value of the first horizontal stroke component will change. Those skilled in the art are familiar with various mechanisms for adjusting the phase difference between the first shaft 22 and the second shaft 26 of a needle-tapping machine 2, particularly preferred variants being described with reference to [Fig. 4] and [Fig. 5].

[0072] According to the invention, a second horizontal stroke component of the needle points is further produced by means of a second drive arrangement 30, the first horizontal stroke component and the second horizontal stroke component overlapping and thus producing a predetermined horizontal stroke whose value is both greater than the value of the first horizontal stroke component and greater than the value of the second horizontal stroke component.

[0073] The vertical stroke V and the horizontal stroke H overlap in turn, thus producing an essentially elliptical path of movement along which the plurality of needles 12 is cyclically displaced, as shown in [Fig. 1b] for two needles 12 in the extreme positions. Along this path of movement, the plurality of needles 12 first enters the flat textile structure 6, then is displaced with the flat textile structure 6 in the transport direction F before finally being withdrawn from it again.

[0074] The second drive arrangement 30 here includes a third shaft 32 and a third connecting rod 34 which is articulated with the needle bar arrangement 4, in particular with the support 18. The third connecting rod 34 has a horizontal movement component T which it transmits to the needle bar arrangement 4. This horizontal movement component T causes the second horizontal stroke component of the needle points.

[0075] In the embodiment shown, the third connecting rod 34 is mounted eccentrically on the third shaft 32 and preferably extends essentially horizontally. A rotation of the third shaft 32 thus causes a cyclic reciprocating motion of the needle bar arrangement 4 and therefore the second horizontal stroke component of the needle points. The second drive arrangement 30 preferably has a plurality of third connecting rods 34 which are designed similarly to the third connecting rod 34 and arranged one behind the other in the axial direction of the third shaft 32.

[0076] The third shaft 32 is preferably driven in rotation, in particular with a constant rotational speed. In the embodiment according to [Fig. 1a], a rotational drive (not shown) can be provided for this purpose, which can be mounted directly against the third shaft 32. The stroke of the third connecting rod 34 thus produced, and consequently the second horizontal stroke component, are then constant.

[0077] As shown in [Fig. 2], the second drive arrangement 30 may also include a belt drive 36 which drives the third shaft 32 in rotation. The belt drive 36 has, for example, a drive shaft 38 and a belt 40 which wraps around the drive shaft. 38 and of the third tree 32. For the rest, the embodiment according to [Fig.2] corresponds to the embodiment according to [Fig.la], b.

[0078] As shown in [Fig. 3], in another possible embodiment, the second drive arrangement 30 is coupled with the first drive arrangement 20. A rotation of the first shaft 22 or the second shaft 26 is, for example, transmitted to the third shaft 32, as indicated by the belt 42 which winds around the first shaft 22 and the third shaft 32. Otherwise, the embodiment according to [Fig. 3] corresponds to the embodiment according to [Fig. 1a], b.

[0079] Two preferred embodiments of the first drive arrangement 20 of a needle-tapping machine 2 according to the invention will now be described with reference to [Fig. 4] and 5. For the rest, the needle-tapping machine 2 can be designed as described with reference to [Fig. 1a] to 3.

[0080] The first drive arrangement 20 includes a first reversing gear 44, which couples a first transmission part 46 of the first shaft 22 with a second transmission part 48 of the second shaft 26. The first reversing gear 44 is preferably designed as a single-stage cylindrical gear, which transmits a torque, at a stable number of revolutions, by reversing the direction of rotation between the first shaft 22 and the second shaft 26.

[0081] Furthermore, the first drive arrangement 20 includes a first switchable coupling 50 which separably connects the first transmission part 46 of the first shaft 22 with a first crank part 52 of the first shaft 22, in which at least one first connecting rod 24a, b, c is mounted. If the first coupling 50 is in a coupled state, torque will be transmitted between the first transmission part 46 and the first crank part 52. If the first coupling 50 is in an uncoupled state, no torque will be transmitted from the first crank part 52 to the first transmission part 46, and therefore not via the latter to the second transmission part 48 of the second shaft 26.Therefore, the first crank portion 52 can be rotated to adjust a first phase angle of the first shaft 22 without this rotation being transmitted to the second shaft 26 and in particular to a second crank portion 54 of the same shaft, in which at least one second connecting rod 28a, b, c is mounted. In this way, the phase difference between the first shaft 22 and the second shaft 26 can be adjusted and the value of the first horizontal stroke component can be modified.

[0082] In the embodiment according to [Fig. 4], the first drive arrangement 20 comprises a first rotary drive 56 which is coupled with the first crank portion 52 of the first shaft 22. The first rotary drive 56 can rotate the first crank portion 52 of the first shaft 22 and thus adjust the first phase angle of the first shaft 22. In the coupled state of the first coupling 50, the torque is further transmitted to the first transmission part 48 of the first shaft 22 and via the first reversing gear 44 to the second shaft 26, so that the first rotational drive 56 can also be used for driving both shafts 22, 26 during the operation of the needle-tipping machine 2.

[0083] In the embodiment shown, the first drive arrangement 20 also includes a second rotary drive 58, coupled with the first transmission section 46 of the first shaft 22. The first rotary drive 56 and the second rotary drive 58 are preferably synchronized. This is advantageous because the first shaft 22 is driven on both sides of the first coupling 50, thereby relieving the first coupling 50 of some of the load. The first rotary drive 56 and the second rotary drive 58 can also contribute to driving the first and second shafts 22 and 26 during the operation of the needle-punching machine 2, so that only half of the torque, respectively, needs to be applied.

[0084] Preferably, the second rotary drive 58 completely brakes the first transmission section 46 of the first shaft 22 and the second shaft 26, while in the disengaged state of the first coupling 50, the first phase angle of the first crank section 52 is set. The second rotary drive 58 can further adjust the second phase angle of the second crank section 54 of the second shaft 26 via the first reversing gear 44. Since, in this embodiment, the first crank section 52 and the second crank section 54 can be driven even when the first coupling 50 is disengaged, phase difference adjustment is also possible during the operation of the needle-tipping machine 2.

[0085] The embodiment according to [Fig.5] differs from the embodiment according to [Fig.4], firstly in that the first rotational drive 56 is coupled with the first transmission part 46 of the first shaft 22. In addition, the first drive arrangement 20 preferably includes a second reversing gear 60 which couples another transmission part 62 of the first shaft 22 with another transmission part 64 of the second shaft 26. The second reversing gear 60 is also preferably designed as a single-stage cylindrical gear, which transmits torque, at a constant number of revolutions, by reversing the direction of rotation. The first crank part 52 of the first shaft 22 and the second crank part 54 of the second shaft 26 are preferably arranged between the first reversing gear 44 and the second reversing gear 60, so that a closed ring of shafts is formed.

[0086] In this embodiment, the first drive arrangement 20 further comprises a second switchable coupling 66 that separably connects the second crank portion 54 and the other transmission portion 64 of the second shaft 26. Similar to the first coupling 50, the second coupling 66 can be switched between a coupled and an uncoupled state. If the first coupling 50 and the second coupling 66 are coupled, the first rotary drive 56 and the second rotary drive 58 will synchronously generate a torque to drive the shafts 22, 26.If the first coupling 50 and the second coupling 66 are uncoupled, the first drive 56 will be able to adjust the second phase angle or completely brake the second shaft 26 via the first reversing gear 44 and the second drive 58 will be able to adjust the first phase angle or completely brake the first shaft 22 via the second reversing gear 60.

[0087] As shown in [Fig. 4] and 5, the needle-tipping machine 2 may further include a control device 68. The control device 68 may, in particular, be arranged to control and regulate the first rotary drive 56 and, if present, the second rotary drive 58. It is also advantageous for the first drive arrangement 20 to include a first rotary angle encoder 70 for detecting a first angular position of the first shaft 22 and a second rotary angle encoder 72 for detecting a second angular position of the second shaft 26. The first and second rotary angle encoders 70, 72 are preferably connected in communication with the control device 68 and provide it with an output signal characterizing the respective angular position.

[0088] The control device 68 is therefore able to control, on the basis of a setpoint value of the first horizontal stroke component, the first and / or second rotation drives 56, 58 so that the set phase angles of the first and second shafts 22, 26 have a phase difference which influences this setpoint value of the first horizontal stroke component.

[0089] In summary, a needle-cutting machine 2 and a method for operating such a needle-cutting machine are proposed, which, by superimposing two horizontal stroke components, make it possible to obtain a resulting horizontal stroke that is greater than a horizontal stroke that can be produced by the drive arrangements 20 and 30 alone. The application range of the needle-cutting machine can be broadened by means of a simple and economical assembly of the machine and the use of standard components. Other embodiments of the present invention will be obvious to those skilled in the art, based on the description of detailed examples.

Claims

1. Demands A method for operating a needle-punching machine (2) comprising an arrangement of needle bars (4) for needle-punching a flat textile structure (2), wherein the arrangement of needle bars (4) has at least one needle bar (8, 10) with a plurality of needles (12), and the method comprises: the production of a vertical stroke (V) of the needle bar arrangement (4) by means of a first drive arrangement (20) which includes a first shaft (22), a second shaft (26), a first connecting rod (24) and a second connecting rod (28), in which the first connecting rod (24) and the second connecting rod (28) are respectively articulated coupled with the needle bar arrangement (4), the first connecting rod (24) is eccentrically mounted on the first shaft (22) and the second connecting rod (28) is eccentrically mounted on the second shaft (26), and in which the first shaft (22) and the second shaft (26) are driven in rotation in opposite directions; the production of a first horizontal stroke component of needle tips of the plurality of needles (12) by means of the first drive arrangement (20), the first shaft (22) and the second shaft (26) having a phase difference; the production of a second horizontal stroke component of the needle tips of the plurality of needles (12) by means of a second drive arrangement (30) which includes a third connecting rod (34) which is articulatedly coupled with the needle bar arrangement (4) and has a horizontal motion component (T) which it transmits to the needle bar arrangement (4); in which the first horizontal stroke component and the second horizontal stroke component overlap and thus produce a predetermined horizontal stroke (H) whose value is both greater than a value of the first horizontal stroke component and greater than a value of the second horizontal stroke component, in which the first horizontal stroke component and the second horizontal stroke component overlap such that the value of the first horizontal stroke component and the value of the second horizontal stroke components are added together to give the predetermined value of the horizontal stroke (H).

2. Method according to claim 1, characterized in that the vertical stroke (V) and the horizontal stroke (H) overlap and produce an essentially elliptical path of movement of the needle tips of the plurality of needles (12).

3. Method according to claim 1 or 2, characterized in that the first horizontal stroke component and the second horizontal stroke component are oriented parallel to each other and parallel to a transport direction (F) of the flat textile structure (2) through the needle-punching machine (2).

4. A method according to any one of the preceding claims, characterized in that the value of the first horizontal stroke component is variable.

5. Method according to claim 4, characterized in that the method further comprises: adjusting the phase difference and thus the value of the first horizontal stroke component.

6. Method according to claim 5, characterized in that the first drive arrangement (20) comprises a first reversing gear (44) between the first shaft (22) and the second shaft (26) and the phase difference adjustment further comprises: the decoupling of a rotation of the first shaft (22) with respect to a rotation of the second shaft (26), and the rotation of the first shaft (22) or of the second shaft (26) by means of a rotation drive (56).

7. Method according to claim 6, characterized in that the method further comprises: determining a setpoint value for the first horizontal stroke component; determining a setpoint phase difference based on the setpoint value for the first horizontal stroke component; rotating the first shaft (22) or the second shaft (26) by means of the rotation drive (56) so that an actual phase difference corresponds to the setpoint phase difference.

8. A method according to any one of the preceding claims, characterized in that the maximum value of the first horizontal stroke component is between 5 mm and 20 mm, preferably between 8 mm and 15 mm.

9. A method according to any one of the preceding claims, characterized in that the value of the first horizontal stroke component and the value of the second horizontal stroke component constitute respectively half of the value of the horizontal stroke (H).

10. A method according to any one of the preceding claims, characterized in that the value of the second horizontal stroke component is constant.

11. A method according to any one of the preceding claims, characterized in that the value of the second horizontal stroke component is between 5 mm and 40 mm, preferably between 10 mm and 30 mm.

12. A method according to any one of the preceding claims, characterized in that the second drive arrangement (30) comprises a third shaft (32), in which the third connecting rod (34) is mounted eccentrically on the third shaft (32) and in which the third shaft (32) is in constant rotation.

13. Needle-punching machine (2) for needle-punching a flat textile structure (2), in which the needle-punching machine comprises: a first arrangement of needle bars (4) which has at least one needle bar (8, 10) with a plurality of needles (12);a first drive arrangement (20) which is arranged to produce a vertical stroke (V) of the needle bar arrangement (4) and a first horizontal stroke component of the needle tips of the plurality of needles (12), in which the first drive arrangement (20) comprises a first shaft (22), a second shaft (26), a first connecting rod (24), a second connecting rod (28) and a first reversing gear (44), in which the first connecting rod (24) and the second connecting rod (28) are respectively articulatedly coupled with the needle bar arrangement (4), the first connecting rod (24) is eccentrically mounted in a first crank portion (52) of the first shaft (22) and the second connecting rod (28) is eccentrically mounted in a second crank portion (54) of the second shaft (26); and; a second drive arrangement (30) which is arranged to produce a second horizontal stroke component of the needle points of the plurality of needles (12), in which the second drive arrangement (30) includes a third connecting rod (34) which is articulatedally coupled with the needle bar arrangement (4); in which the first reversing gear (44) couples a first transmission part (46) of the first shaft (22) with a second transmission part (48) of the second shaft (26) and the first shaft (22) and the second shaft (26) have a phase difference; in which the first drive arrangement (20) includes a first switchable coupling (50) which separably connects the first crank part (52) and the first transmission part (46).

14. Needle-making machine (2) according to claim 13, characterized in that the first coupling (50) in a coupled state connects together the first crank part (52) and the first transmission part (46), and in an uncoupled state separates the first crank part (52) and the first transmission part (46) from each other.

15. Needle-making machine (2) according to any one of claims 13 to 14, characterized in that the first drive arrangement (20) comprises a first rotational drive (56) which is coupled with one of the first crank part (52) and the first transmission part (46).

16. Needle-making machine (2) according to claim 15, characterized in that the first drive arrangement (20) comprises a second rotational drive (58) which is coupled with the other among the first transmission part (46) and the first crank part (52).

17. Needle-making machine (2) according to claim 15, characterized in that the first drive arrangement (20) comprises a second rotational drive (58) which is coupled with the second transmission part (48) or the second crank part (54).

18. A switch-setting machine (2) according to any one of claims 16 to 17, characterized in that the switch-setting machine (2) comprises a control device (68) which is arranged, based on a setpoint value of the first horizontal stroke component, to drive the first rotation drive (56) so that a phase difference between the first shaft (22) and the second shaft (26) influences the setpoint value of the first horizontal stroke component.

19. Needle-tapping machine (2) according to any one of claims 13 to 18, characterized in that the first drive arrangement (20) comprises at least one rotary angle encoder (70, 72) which is arranged to detect an angular position of the first crank part (52) of the first shaft (22) and / or an angular position of the second crank part (54) of the second shaft (26).

20. Needle-making machine (2) according to any one of claims 13 to 19, characterized in that the first drive arrangement (20) comprises a second reversing gear (60), which couples another transmission part of the first shaft (22) with another transmission part (64) of the second shaft (26), and a second switchable coupling (66), which separably connects the second crank part (54) and the other transmission part (64) of the second shaft (26).

21. Needle-making machine (2) according to any one of claims 13 to 20, characterized in that the second drive arrangement (30) comprises a third shaft (32), in which the third connecting rod (34) is mounted eccentrically on the third shaft (32), in which the second drive arrangement (30) comprises a third rotational drive to drive the third shaft (32).

22. Needle-making machine (2) according to any one of claims 13 to 20, characterized in that the second drive arrangement (30) comprises a third shaft (32), in which the third connecting rod (34) is mounted eccentrically on the third shaft (32), in which the second drive arrangement (30) is coupled with the first drive arrangement (20).

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