Carding Machine Flat Top Height Measurement Device
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Solution Overview
Problem
Existing carding machines face challenges in accurately measuring the height of flat tops, leading to excessive grinding and reduced card clothing life due to the lack of precise height data, resulting in prolonged machine downtime and uneven wire surfaces.
Innovation Solution
A device with a support mechanism, including a guide track and digital dial indicator, measures the height of flat tops on a carding machine, allowing for precise data collection and transmission to a processor for analysis, enabling informed grinding decisions and simultaneous cleaning and grinding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement of flat top height is used, then measurement process is simple, but measurement precision is poor leading to excessive grinding
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated measurement system comprising a transducer, amplifier, and digital display. The transducer converts mechanical height variations into electrical signals, which are then amplified and displayed digitally, eliminating manual measurement errors and providing precise automated height measurement of flat tops.
Solution Approach 2:
The measurement system automatically measures and displays flat top heights without requiring operator intervention. The transducer self-adjusts to contact the flat top surface, the amplifier automatically processes the signal, and the digital display presents the measurement, enabling continuous automated monitoring during carding machine operation.
2Productivity
If flat tops are taken out for measurement and resharpening, then measurement accuracy can be ensured, but machine downtime increases
Solution Approach 1:
The measurement system continuously monitors flat top heights during normal carding machine operation, detecting height variations before they become excessive. This preliminary detection allows for timely resharpening interventions, preventing the need for complete flat top removal and extensive downtime for maintenance.
Solution Approach 2:
The carding machine continues to operate continuously while the measurement system monitors flat top heights in real-time. The transducer and amplifier system works continuously alongside the carding process, eliminating interruptions and maintaining productive action without stopping the machine for routine measurements.
3Manufacturing precision
If excessive grinding is applied to ensure even height, then manufacturing precision is maintained, but card clothing life is reduced
Solution Approach 1:
The measurement system provides continuous feedback on flat top heights through the digital display. This feedback mechanism allows operators to monitor height variations and perform minimal, precise resharpening only when necessary, rather than applying excessive grinding to all flat tops. The feedback loop enables data-driven maintenance decisions that preserve card clothing life while maintaining adequate height uniformity.
Data Source
Figure 1
Figure 1A~1B
Figure 2
AI summary
A device for measuring height of revolving flat wire on card comprises a support mechanism has two supporting bracket (15, 16) fitted on right and left side bends of a carding machine,a guide track (8) parallel to the revolving flat of carding machine is supporting a carriage(10) which is moved along the length of flat tops. The carriage (10) supporting a dial indicator (9) has a support bracket or stem (9c) supporting an anvil (9d) which presses on the tops of wire points and reading is shown in dial indicator. The carriage and dial indicator is moved up and down by precision slide and reading is set to zero when ends of flat tops is adjusted to same value. Further carriage measures the height at five points by sensor. The recorded reading is transmitted to a processor for analysis and storage and the exact amount of grinding cutting the flat tops is fed to the motor by precision feeding system. The carriage has differential speed while moving from one end to other end and a sensor is provided at each end of guide track by which reversal movement is controlled. Further carriage supporting a motor holding bracket (21) to mount a motor either with grinding or cleaning wheel. Exact amount of grinding cut is provided by means of rotation of cam controlled by the processor. Alternatively, the precision feeding system bracket 29 on which guide 33 is mounted whereby guide slide 31 is being moved on guide 33 by ball screw arrangement driven by a belt drive through a servo or stepper motor