Crosslapper Buffer Belt Layout for Constant Lap Output Speed
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Solution Overview
Problem
The output speed of a lap from a crosslapper varies over time, causing potential damage to the fragile lap structure due to vertical back-and-forth movements, especially during the production of lightweight laps, which can lead to defects at the edge.
Innovation Solution
A buffer device with a lower and upper endless belt system that turns the lap 180° twice in opposite directions around turning rollers, using movable rollers to adjust the speed of the lower belt to match the input speed of a further processing device, ensuring the lap is protected and maintained at a constant quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If vertical back-and-forth movements are used to adapt the output speed of the crosslapper, then the speed adaptation is achieved, but the lap structure is damaged due to harmful forces
Solution Approach 1:
Instead of moving the lap vertically to adapt speed (conventional approach), the patent inverts the approach by using horizontal back-and-forth movements of the belts. The belts move horizontally to create speed variation, while the lap remains horizontally transported and sandwiched between belts, avoiding vertical acceleration forces that damage the lap structure.
Solution Approach 2:
The patent introduces intermediate belts (upper and lower belts) as mediators between the crosslapper output and the further processing device input. These belts act as a buffer that absorbs speed variations through horizontal movements, protecting the lap from direct harmful forces while still achieving speed adaptation.
2Object-affected harmful factors
If the output speed of the crosslapper is made constant, then the lap structure is protected, but the speed cannot be adapted to the input speed of the further processing device
Solution Approach 1:
The patent applies dynamics by making the belt system movable and adjustable. The belts can vary their speed dynamically to match the crosslapper's variable output speed while maintaining a constant speed for the further processing device. This dynamic adjustment is achieved through the horizontal back-and-forth movement capability of the belts, allowing speed adaptation without compromising lap integrity.
3Quantity of substance
If lightweight laps are produced to reduce material usage, then resource efficiency is improved, but the lap becomes more fragile and susceptible to damage during speed adaptation
Solution Approach 1:
The patent inverts the conventional vertical speed adaptation approach and uses horizontal belt movements instead. This inversion eliminates the vertical acceleration forces that particularly damage lightweight laps, allowing thin laps (less than 150 g/m2) to be processed without edge defects or structural damage during speed adaptation.
Data Source
AI summary
Crosslapper, in particular arranged at the outlet from a carding device producing a web of fibers, in particular nonwoven fibers, comprising a front belt carrying the web of fibers in the crosslapper to an infeed or accumulator carriage, a rear belt carrying the accumulated web to a layering carriage and an apron on an upper strand (2′; 2″; 2′″) of which the layering carriage deposits the web accumulated by the accumulator carriage alternately on the bias in one direction and in the other direction to form a lap (N) moving at a speed V1(t) that varies as a function of time, in particular in a periodic manner, the crosslapper also comprising an output belt strand (20′; 20″; 20″′) on which the lap (N) leaves the crosslapper at a speed V2(t) that is different from the speed V1(t), in particular at a constant speed, the lap (N) undergoing at least one turn between the upper strand (2′; 2″; 2′″) and the output belt strand (20′; 20″; 20′″), in particular through 180°, around a roller (3.2′; 4.1″; 3.7′″) mounted such that it can move in translation along the output belt strand (20′; 20″; 20′″), the lap (N) being sandwiched between another strand, turned in the opposite direction to the upper strand (2′), of the apron and the output belt strand (20′) and/or between another strand, turned in the opposite direction to the upper strand (2″; 2′″), of the apron and an upper strand of an intermediate apron (30″; 30′″) and/or between a lower strand of an intermediate apron (30″; 30′″) and the output belt strand (20″; 20′″).