Fleece Profile Control via Segmented Basis Weight Measurement
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Solution Overview
Problem
Existing methods for producing fiber webs struggle to achieve uniformity across the width and length of the fiber tuft mat, leading to inconsistent basis weights and profiles, which affects the quality of the final fleece or fiber flock mat.
Innovation Solution
A device comprising a material delivery system, a transport mechanism, a measuring device for weight per unit area analysis, and a profile changing device that adjusts fiber distribution based on real-time measurements to ensure uniformity or create specific profiles by feeding or removing fibers from targeted areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a belt weigher is used to measure the average mass of the fiber flock mat, then the feed speed of the pile producer can be controlled to achieve rough equalization of fiber flow, but the basis weight distribution across the width of the fiber tuft mat remains non-uniform
Solution Approach 1:
The invention divides the measurement function into multiple independent measuring elements arranged across the width of the fiber tuft mat. Each measuring element measures the basis weight at a specific transverse position, enabling localized detection of non-uniformities. This segmentation allows the system to identify and correct width-wise variations that a single average measurement cannot detect.
Solution Approach 2:
The invention transitions from one-dimensional average mass measurement (along the transport direction) to two-dimensional basis weight measurement (across the width and along the transport direction). By arranging multiple measuring elements transversely across the mat width, the system captures the basis weight distribution in both dimensions, enabling precise identification of local thin and thick areas.
2Manufacturing precision
If various station-internal settings and design details are adjusted to improve fiber distribution uniformity, then the fiber tuft mat can be delivered more evenly, but the results remain insufficient for achieving high uniformity or desired profiles
Solution Approach 1:
The invention implements a closed-loop feedback system where the measuring elements continuously monitor the basis weight distribution of the fiber tuft mat, and the control device adjusts the material delivery device in real-time based on these measurements. This feedback mechanism enables dynamic correction of non-uniformities and allows the system to achieve both high uniformity and desired transverse/longitudinal profiles by responding to actual measured conditions.
Solution Approach 2:
The invention enables independent control of material delivery parameters at different transverse positions and along the transport direction. The control device can adjust feeding rates, material distribution, and other parameters dynamically based on measured basis weight variations, allowing the system to adapt to different uniformity requirements and create specific transverse or longitudinal profiles as needed.
3Productivity
If the feed speed of the pile producer is controlled based on belt weigher measurements, then the amount of fiber material reaching the pile producer can be equalized over time, but only the average mass is controlled while width-wise distribution remains unaffected
Solution Approach 1:
The invention segments the material delivery control into multiple independent zones corresponding to different transverse positions across the fiber tuft mat width. Each measuring element is paired with control capabilities for its specific zone, enabling localized adjustment of fiber distribution. This segmentation allows the system to maintain overall productivity while simultaneously correcting transverse basis weight variations that affect local quality.
Data Source
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AI summary
The feed device (2) has a scattering section (20) in which a driven feed roller and a driven opening roller are arranged. A dispensing device stores and dispenses a fiber sliver or a fiber fleece strip assigned to the feed roller, such that the feed roller pulls in the fiber sliver or the fiber fleece strip provided by the dispensing device. The feed roller is fed with the fiber sliver or the fiber fleece strip. The opening roller is arranged to open up the fiber sliver or fiber fleece strip pulled in by the feed roller to form and scatter the individual fibers or fiber flocks. An independent claim is included for a fleece-forming system.