Carding Machine Knife Element Segmentation for Fiber Separation
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Solution Overview
Problem
Existing fiber carding technologies have limited separating points on the drum circumference due to the large space required for separating knives and suction channels, leading to increased separation of good fibers and reduced efficiency in separating dirt and short fibers.
Innovation Solution
A card design with a drum divided into zones, featuring carding and separating elements with multiple ejection openings and knife blades that share a common suction channel, allowing for increased separating points and flexible configuration, reducing the separation of good fibers by gentle peeling and optimizing air flow with guiding elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separating knives and suction channels are used, then dirt and short fibers can be removed, but the number of separating points on the drum circumference is limited and good fibers are excessively rejected
Solution Approach 1:
The separating element is divided into multiple segments along the drum circumference, with each segment containing several discharge openings and knife blades. This segmentation allows multiple separating points to be arranged on the drum circumference without requiring large individual components, thereby increasing productivity while maintaining gentle separation that prevents excessive rejection of good fibers.
Solution Approach 2:
The invention transitions from a single large separating element to multiple smaller elements distributed across the drum circumference in different zones (pre-carding, main carding, post-carding, and bottom carding zones). This dimensional distribution increases the number of separating points while reducing the separation intensity at each point, thereby minimizing good fiber rejection.
2Quantity of substance
If the distance between the element in front of the knife blade and the surface of the opposing roller is increased, then the discharge opening can be larger, but the knife blade penetrates deeper into the fiber material and rejects more good fibers
Solution Approach 1:
Instead of using one large discharge opening, the invention divides it into multiple smaller discharge openings arranged in rows. Each opening is associated with its own knife blade, allowing for effective separation while maintaining a smaller overall distance from the drum surface, thus preventing deep penetration and excessive rejection of good fibers.
Solution Approach 2:
Each discharge opening and knife blade combination is optimized locally with appropriate spacing and dimensions. The multiple rows of discharge openings are distributed to create uniform rejection effects across the working width, allowing each local element to be smaller while the collective system achieves the required separation capacity without excessive good fiber rejection.
3Productivity
If multiple discharge openings are created, then more separating points are available, but each opening would require its own suction channel which increases device complexity
Solution Approach 1:
Multiple discharge openings and their associated suction channels are merged into a single common suction channel. The suction channel is designed to collect separated components from multiple discharge openings through strategically positioned collection points, thereby reducing device complexity while maintaining high productivity through multiple separating points.
Solution Approach 2:
The common suction channel serves multiple functions by collecting separated components from multiple discharge openings simultaneously. This universal component replaces what would otherwise be multiple individual suction channels, simplifying the overall device structure while maintaining the capability to handle separation at multiple points along the drum circumference.
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 significantly increases the number of separating points on the drum circumference, improves the separation of dirt and short fibers while minimizing the separation of good fibers, and provides manufacturing advantages through space savings and adjustable knife elements.
Implementation Method 1
a suction channel (25)
Implementation Method 2
at least one air guide element (29) is arranged between the suction channel (25) and the cutting element (26)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a carding machine for processing fibers, comprising a drum (3) with a drum circumference, a drum surface (23), and a working width (A). Opposite the drum surface (23) of the drum (3), which is rotatable about an axis of rotation (4) in a direction of rotation (17), carding elements (12) for parallelizing the fibers and removal elements (13, 14, 15) for removing dirt and short fibers are arranged. The removal elements (13, 14, 15) are provided with a suction channel (25), the drum circumference being divided into a pre-carding zone (9), a main carding zone (5), a post-carding zone (10), and an under-carding zone (11). The carding elements (12) and the removal elements (13, 14, 15) span the entire working width (A).In the post-carding zone (10), the pre-carding zone (9), or the under-carding zone (11), at least one discharge element (13, 14, 15) is provided, comprising a base body (24), a suction channel (25), and a knife element (26). The knife element (26) has a plurality of discharge openings (27) and knife blades (28) associated with the discharge openings (27), and at least one air guide element (29) is arranged between the suction channel (25) and the knife element (26).