Carding Machine Compression Roller Diameter
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Solution Overview
Problem
Existing carding machines for producing nonwovens face challenges in achieving high carding performance and even compression of multiple fiber web layers, leading to increased machine length and complexity.
Innovation Solution
The carding machine design incorporates a compression roller with a diameter of at least 600 mm, operatively connected to multiple take-off rollers, allowing for separate compression and doubling of fiber web layers before transfer, reducing machine length and centrifugal forces, and enabling up to six take-off rollers with different diameters to connect effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rollers and take-up devices are arranged in succession for each fiber pile layer, then the carding machine achieves proper compression and transfer of fiber layers, but the overall length and complexity of the machine increases
Solution Approach 1:
The patent combines multiple compression functions into a single compression roller with diameter of at least 600 mm. This single roller receives multiple fiber web layers from multiple take-off rollers and performs compression and doubling of all layers simultaneously, eliminating the need for separate compression rollers for each layer and reducing the machine length while maintaining reliable compression and transfer of fiber layers
Solution Approach 2:
The compression roller serves multiple functions: it acts as a compression device for all fiber layers, a doubling device that combines multiple layers into a single web, and a transfer point for the processed web to the take-up device. This multi-functionality consolidates what would traditionally require multiple separate devices into one universal component
2Object-generated harmful factors
If the compression roller has a large diameter of at least 600 mm, then centrifugal forces decrease and fiber fly is reduced, but the machine requires more space for the larger roller
Solution Approach 1:
By merging multiple compression functions into one large-diameter compression roller, the patent eliminates the need for multiple smaller rollers and associated take-up devices. The space saved by removing these additional components compensates for the space occupied by the large compression roller, resulting in no net increase in machine footprint while achieving reduced fiber fly through lower centrifugal forces
3Adaptability or versatility
If multiple take-off rollers with differently graduated diameters are used, then flexibility in handling different fiber web layers is improved, but the complexity of synchronizing the rollers increases
Solution Approach 1:
The single compression roller with diameter of at least 600 mm serves as a universal receiving point for multiple take-off rollers with differently graduated diameters. This universal design simplifies synchronization because all take-off rollers feed into one common compression roller rather than requiring coordination between multiple compression rollers, reducing control complexity while maintaining adaptability to handle different fiber web layers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the machine operation, reduces fiber fly, and increases productivity with high carding quality by minimizing the number of rollers and removal devices, while allowing for variable density control through adjustable peripheral speeds.
Implementation Method 1
each of the at least two layers of fiber web is separately compressed by means of the compression roller and brought together on the compression roller to form a single layer of fiber web
Implementation Method 2
the compression roller has a diameter of at least 600 mm. Because the peripheral speed of the compression roller is also lower than the peripheral speed of the lower and upper take-up rollers, the at least two layers of fiber fleece are compressed and doubled before the take-up device within the carding machine. Normally, increasing the roller diameter would increase the overall length of the carding machine. Surprisingly, it has been found that increasing the roller diameter offers several advantages. Firstly, space was created to transfer multiple layers of fiber fleece to the compression roller using several larger take-up rollers. Consequently, at least one roller and one or two additional take-up devices could be omitted, thus reducing the overall length of the carding machine.This also eliminates bearings, drives and the associated synchronization, which simplifies the operation of the carding machines, especially with regard to control. Another advantage is that, due to the increased diameter of the compression roller to at least 600 mm, its peripheral speed and thus the centrifugal forces decrease, so that fiber flight can be reduced.
Data Source
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AI summary
The invention relates to a carding machine for producing fleece from fiber material, comprising at least one tambour (2), having at least two doffing rollers arranged one after the other in the working direction and having a compressing roller (8), which is operatively connected to all doffing rollers downstream of the tambour (2), wherein the carding machine (1) is designed to transfer at least two layers of card web (20) by means of at least two doffing rollers to a compressing roller (8), wherein each of the at least two layers of card web are compressed separately by means of the compressing roller (8) and are joined on the compressing roller (8) into a single layer of card web (20) and said layer of card web (20) is removed, by means of a transfer roller (9), on an outlet side of the carding machine for further processing. The invention is characterized in that the compressing roller (8) has a diameter of at least 600 mm.