Carding Machine Fiber Orientation Control
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Solution Overview
Problem
Current carding systems face challenges in quickly and automatically adjusting fiber orientation and basis weight, leading to inefficiencies in producing fabrics with tailored mechanical properties, as manual adjustments are time-consuming and material-intensive, and require expensive compensating stackers for achieving balanced isotropy ratios.
Innovation Solution
A method and device that use actuators and sensors to automatically adjust fiber orientation and basis weight by measuring fiber orientation and weight per unit area in real-time, using CCD cameras and radiometric/optical measuring devices, with a controller employing fuzzy logic to react to disturbances and adjust settings dynamically, allowing for quick changes during production without affecting downstream processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of fiber orientation is performed by machine operators, then subjective observation and iteration steps are used, but the adjustment process becomes very time-consuming and material-intensive
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated optical measurement and control system. CCD cameras capture fiber orientation images, which are processed by a controller to automatically determine orientation parameters. This substitution eliminates subjective human observation and enables rapid, objective, and repeatable adjustments without material waste from iterative trial-and-error processes.
Solution Approach 2:
The patent implements a closed-loop feedback system where fiber orientation is continuously measured by CCD cameras, compared against target values by the controller, and automatically adjusted by actuating relevant components. This feedback mechanism enables real-time correction and optimization of fiber orientation, dramatically reducing adjustment time and eliminating the need for time-consuming intermediate laboratory analysis.
2Strength
If compression process is used to counteract longitudinal fiber orientation, then fiber alignment is improved, but the basis weight of the fleece increases and production speed decreases
Solution Approach 1:
The patent dynamically adjusts compression parameters based on real-time fiber orientation measurements. Instead of applying fixed compression that increases basis weight, the system uses variable compression forces applied selectively based on measured orientation deviations. This dynamic approach achieves the required fiber alignment while minimizing unnecessary compression that would increase basis weight and reduce production speed.
Solution Approach 2:
The patent changes compression parameters (force, duration, distribution) based on feedback from fiber orientation measurements. The controller adjusts compression settings to achieve optimal fiber alignment with minimal basis weight increase. By varying compression parameters rather than applying constant compression, the system maintains production speed while achieving the required fiber orientation for product strength.
3Strength
If expensive compensating stackers are used to layer fiber webs rotated by 90° for higher strength fabrics, then fabric strength and basis weight are improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for expensive compensating stackers by implementing fiber orientation control directly at the carding process. Instead of adding complex post-processing equipment to layer and rotate fiber webs, the system achieves the required orientation control upstream during fiber web formation. This extraction of the orientation control function from downstream processing simplifies the overall system while maintaining fabric strength requirements.
Solution Approach 2:
The patent performs fiber orientation adjustment preliminarily during the carding process itself, before the fiber webs reach the stacking stage. By controlling fiber orientation at the source rather than correcting it later with complex stackers, the system achieves the desired fabric properties with simpler equipment. The preliminary action of orientation control during web formation eliminates the need for subsequent mechanical manipulation and layering devices.
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 rapid, automated adjustment of fiber orientation and production speed, ensuring consistent product quality and reducing material waste and production costs by allowing continuous monitoring and correction of process deviations, thus optimizing fabric properties and production efficiency.
Implementation Method 1
CCD cameras which are suitable for determining the orientation of the fibers
Implementation Method 2
CCD cameras which are suitable for determining the orientation of the fibers
Implementation Method 3
the second measuring element can be designed as a radiometric or optical measuring device
Implementation Method 4
the second measuring element can be designed as a radiometric or optical measuring device
Data Source
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AI summary
The invention relates to a method and a device for adjusting the fiber orientation on carding machines, wherein, in the transport direction of the fiber pile (20) at an exit side (1b) of the carding machine (1), the fiber orientation of the fiber pile (20) is determined and a first control variable (13a) is generated, wherein, subsequently, in the transport direction of the fiber pile (20), the basis weight of the fiber pile (20) is determined and generated as a second control variable (14a), wherein the first and second control variables (13a, 14a) are compared with the associated reference variables (16, 17), and that, in the event of deviations of the control variables (13a, 14a) from the reference variables (16, 17), at least one actuator for changing the fiber orientation (19, 19', 19", 19"') and/or at least one actuator for changing the basis weight (18) can be actuated by means of a signal.