Carding Machine Contact Arc for Gap Control
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Solution Overview
Problem
Existing carding machines face challenges in adjusting the carding gap within a large range and reliably transmitting data from a flat bar to a controller, leading to limitations in carding quality and increased risk of collisions due to thermal expansion and uneven fiber processing.
Innovation Solution
A carding machine design featuring a contact element with a contact arc that compensates for distance changes between the flat bar and drum, allowing for adjustment of the carding gap by several millimeters and enabling precise data transmission through resilient or elastic spring elements, which can be retrofitted to existing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the carding gap is set narrow to improve carding quality and reduce nit formation, then the risk of collisions between carding components increases due to thermal expansion
Solution Approach 1:
The patent implements a feedback mechanism where a contact element on the drum makes electrical contact with a contact bar on the traveling cover to detect the actual carding gap. This detected information is fed back to the control system, which automatically adjusts the traveling cover position to maintain the optimal carding gap, thus resolving the contradiction between narrow gap for quality and collision risk
2Reliability
If the carding gap is set wide to avoid collisions, then nit formation in the carded strip increases
Solution Approach 1:
The feedback system continuously monitors the carding gap through electrical contact between the drum and traveling cover, enabling the control system to maintain an optimally narrow gap without excessive safety margins, thereby reducing nit formation while avoiding collisions
3Manufacturing precision
If the carding gap is adjusted during operation to maintain optimal values, then the complexity of the adjustment mechanism increases
Solution Approach 1:
The patent uses a relatively simple electrical contact mechanism between the drum and traveling cover to detect carding gap changes, which is processed by the control system to automatically adjust the gap. This feedback-based automatic adjustment maintains consistent carding gap without requiring complex manual adjustment mechanisms
Solution Approach 2:
The system automatically changes the position parameter of the traveling cover based on detected carding gap variations, maintaining optimal carding conditions through dynamic parameter adjustment rather than fixed settings
4Loss of information
If contact elements are fixed in the flexible bow to transmit data, then the adjustment range of the carding gap is limited to a small range
Solution Approach 1:
The patent positions the contact element on the rotating drum and the contact bar on the traveling cover, allowing their relative positions to change dynamically as the drum rotates and the cover adjusts. This dynamic arrangement enables both data transmission and large-range carding gap adjustment, overcoming the limitation of fixed contact elements in the flexible bow
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
Enables automatic calibration and precise control of the carding gap, reducing the risk of collisions and improving carding quality by allowing for a narrower carding gap, thus minimizing the formation of neps in the card sliver and ensuring reliable data transmission.
Implementation Method 1
the contact element is configured with a contact arc that is designed to compensate for changes in the distance between the carding bar and drum
Implementation Method 2
enabling precise data transmission through resilient or elastic spring elements
Implementation Method 3
The working gap changes depending on operating conditions because the carding components expand unevenly due to thermal expansion
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present invention relates to a carding machine (100) with a drum (4) and a revolving flat (17) with flat bars (20) running around a portion of the circumference of the drum (4), wherein at least one flat bar (20) is designed to transmit current operational data or an electrical contact to a controller of the carding machine (100), wherein the at least one flat bar (20) is designed to match with at least one contact element (22), wherein the contact element (22) is designed to conduct the electrical contacts or data to the controller of the carding machine (100), wherein the at least one contact element (22) is arranged in the region of a flexible arc (27). The invention is characterized in that the at least one contact element (22) has at least one contact arc (23) which is designed to compensate for a change in distance between the flat bar (20) and the drum (4). The invention further relates to a contact element.