Dual Cleaning System for Combing Cylinder Wear Reduction
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Solution Overview
Problem
Current combing machines face challenges in maintaining consistent combing quality due to inadequate cleaning of the combing set, especially with high numbers of comb cycles, as existing cleaning methods fail to effectively remove material deposited between combing sets, leading to increased wear and reduced productivity.
Innovation Solution
The implementation of a dual cleaning system, comprising a mechanical cleaning brush and a pneumatic suction channel, arranged in the enveloping circle of the combing segment, where the suction channel is connected to a vacuum source and positioned to complement the brush roller's cleaning effect, ensuring thorough removal of combed-out components and maintaining optimal combing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the speed of the brush roller is increased during cleaning intervals to improve cleaning effectiveness, then the cleaning effect is improved, but the wear of the bristles increases
Solution Approach 1:
The cleaning function is segmented into two distinct mechanisms: a brush roller for mechanical cleaning and a suction device for pneumatic removal. This segmentation allows each component to operate at optimized speeds - the brush roller at lower speeds reducing wear, while the suction device operates independently to remove loosened contaminants without requiring high brush speeds.
Solution Approach 2:
The suction device acts as an intermediary that removes contaminants after they are loosened by the brush roller. This intermediary mechanism enables the brush roller to operate at lower speeds since it only needs to loosen contaminants, not remove them entirely, thereby reducing bristle wear while maintaining cleaning effectiveness.
2Manufacturing precision
If the radial distance between the circular comb and brush roller is readjusted frequently to maintain cleaning quality, then the cleaning precision is improved, but the productivity decreases
Solution Approach 1:
The combination of brush roller and suction device creates a continuous cleaning action that maintains consistent cleaning quality throughout operation. The suction device continuously removes contaminants as they are loosened, ensuring the brush roller operates in a consistently clean environment without requiring frequent radial distance adjustments, thus maintaining productivity.
Solution Approach 2:
The suction device partially replaces the mechanical adjustment system by providing a non-contact method for contaminant removal. This substitution eliminates the need for frequent mechanical readjustment of the radial distance between the circular comb and brush roller, maintaining cleaning quality while preserving productivity.
3Reliability
If special cleaning intervals with lower comb cycles are implemented to clean the combing set, then the cleaning effect is improved, but the productivity is reduced
Solution Approach 1:
The dual cleaning system enables continuous cleaning action during normal combing operations without requiring special cleaning intervals. The brush roller continuously loosens contaminants while the suction device simultaneously removes them, maintaining combing quality consistency throughout production and eliminating the need for productivity-reducing cleaning stops.
Solution Approach 2:
The suction device serves as an intermediary that handles contaminant removal during normal operation, allowing the brush roller to focus on loosening contaminants at standard combing speeds. This division of labor eliminates the need for special cleaning intervals with reduced comb cycles, maintaining both cleaning effectiveness and overall productivity.
4Device complexity
If a single brush roller is used for cleaning the combing set, then the device complexity is low, but the cleaning effectiveness becomes insufficient with high comb cycles
Solution Approach 1:
The cleaning system is segmented into two functional components: a brush roller for contaminant loosening and a suction device for contaminant removal. This segmentation provides comprehensive cleaning coverage for the entire combing set, ensuring effectiveness even at high comb cycle frequencies while maintaining relatively simple overall system structure.
Solution Approach 2:
The brush roller and suction device are merged into a coordinated cleaning system where both components work together on the combing set. This combination provides superior cleaning effectiveness compared to a single brush roller, handling both the loosening and removal of contaminants, while the integrated design keeps the added complexity minimal.
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 dual cleaning approach enhances the cleaning effectiveness, allowing for constant combing performance over a long period, even with high comb cycles, by dividing the cleaning workload between mechanical and pneumatic elements and optimizing the suction process, thereby preventing material buildup and reducing wear on the brush roller.
Implementation Method 1
The suction channel, which is connected to a vacuum source, is connected to a housing in which the brush roller is rotatably mounted. The applied negative pressure thus acts up to the area above the circular comb and supports the drawing of the fiber tuft into the combing set during the combing process.
Implementation Method 2
About the bristles of the brush roller located in the combing combed components are stripped and discharged under the influence of suction to a suction channel.
Implementation Method 3
The brush roller is rotatably mounted below the circular comb in a housing in which the circular comb is also located. The direction of rotation of the brush roller is generally the same as the direction of rotation of the circular comb in the above-mentioned range, with the peripheral speed of the brush roller being greater than that of the circular comb.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a cleaning device for a combing segment (7), which consists of comb fittings (6), of a combing machine round comb (4), which is rotatably mounted by means of a shaft (5) and which combs a tuft (FB) protruding from a clamping point (KS) of a clamping assembly (1). The cleaning device comprises at least one cleaning element (44), which is arranged in the region of the enveloping circle (HK) of the combing segment (7) of the round comb (4), for cleaning the comb fittings (6) of the combing segment (7) during a comb operation. The aim of the invention is to improve the cleaning effect for the combing segment of the round comb. This is achieved in that at least one additional cleaning element (60) is arranged in the region of the enveloping circle (HK) of the combing segment (7) of the round comb (4).