Carding Machine Movable Comber Cylinder Thickness Control
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Solution Overview
Problem
Existing carding machines have limited processing intervals, restricting the range of product thicknesses they can produce, leading to increased production costs, longer processing times, and higher defect rates, especially for small thickness products and those requiring specific filtering features.
Innovation Solution
A carding machine with a carding unit and comber cylinder that can interlace and adjust fiber thickness, featuring movable components and conveyor belts to adapt processing paths, allowing for a wide range of thicknesses from 10 g/m² to 1500 g/m², and capable of producing single or double layers with controlled fiber orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prior art carding machines are used, then standard processing is achieved, but the processing interval is limited and product thickness range is restricted
Solution Approach 1:
The carding machine is designed with a movable comber cylinder that can be positioned in different locations (first position for standard processing, second position for extended processing). This allows a single machine to handle a wide range of product thicknesses from 10 g/m² to 1500 g/m², eliminating the need for multiple dedicated machines for different product types.
Solution Approach 2:
The comber cylinder is made movable rather than fixed, allowing dynamic adjustment of its position during operation. This dynamic configuration enables the machine to adapt between different processing modes (standard and extended) and produce varying product thicknesses, directly resolving the contradiction between versatility and device complexity.
2Manufacturing precision
If fibers are processed through multiple machines to achieve small thickness products, then processing is completed, but the quality deteriorates and defect rate increases
Solution Approach 1:
The invention combines carding and combing operations into a single integrated machine with a movable comber cylinder. By merging multiple processing functions into one machine, fibers can be processed through a single extended path rather than multiple separate machines, maintaining quality while improving productivity.
3Reliability
If dedicated machines are produced for specific product types, then processing specialization is achieved, but production costs increase
Solution Approach 1:
The carding machine with movable comber cylinder serves as a universal machine capable of producing various product types and thicknesses. This multi-functionality eliminates the need for multiple dedicated machines, reducing production costs while maintaining reliable specialized processing for different product requirements.
4Quantity of substance
If extended processing is performed for thick products, then product thickness is increased, but processing time increases
Solution Approach 1:
The movable comber cylinder enables dynamic selection of processing paths. For thick products requiring extended processing, the cylinder moves to the second position, allowing fibers to pass through the carding unit multiple times in a single continuous operation, thereby achieving increased thickness without proportionally increasing total processing time.
Data Source
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Figure 3A
AI summary
Described is a carding machine for one layer (F) of fibres comprising a carding unit (3) designed to interlace the fibres of the layer (F, F') of fibres and to adjust the thickness of the layer (F) of fibres, and a comber cylinder (4) located downstream of the carding unit (3) and designed to comb the fibres of the layer (F, F'') of fibres.