Needling Machine Needle Position Monitoring
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Solution Overview
Problem
Existing needling machines face challenges in achieving high operational reliability and needle density due to shape and position tolerances, leading to increased risk of needle collisions and wear with hold-down devices and stitch plates.
Innovation Solution
A needling machine equipped with a monitoring device that tracks the positioning of needles relative to hold-down and support devices, allowing for detection and correction of incorrect needle positioning, even at high densities, thereby preventing collisions and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the density of needles is increased to optimize bonded nonwoven properties, then needling performance is improved, but the risk of needle collision with hold-down devices or stitch plates increases
Solution Approach 1:
The patent applies preliminary action by performing alignment checks and positioning adjustments of needles relative to hold-down devices and stitch plates before the needling operation begins. The system pre-establishes correct spatial relationships and detects potential collisions in advance, allowing corrective actions to be taken before actual needling starts, thus preventing needle breakage while maintaining high needle density
Solution Approach 2:
The patent implements feedback mechanisms that continuously monitor the position of needles relative to hold-down devices and stitch plates during operation. Sensors detect deviations in needle positioning and provide real-time feedback to the control system, which then adjusts needle positions or alerts operators to prevent collisions, enabling the system to maintain high needle density while ensuring operational reliability
2Productivity
If the density of needles is increased, then bonded nonwoven properties are optimized, but needle wear increases due to contact with hold-down devices and stitch plates
Solution Approach 1:
The system performs preliminary positioning verification and alignment checks before needling operations begin, ensuring that needles are correctly positioned relative to hold-down devices and stitch plates. This prevents premature contact and wear, extending needle lifespan while maintaining the high needle density required for optimized bonded nonwoven properties
Solution Approach 2:
Real-time monitoring systems track needle positions and detect any deviations that could lead to contact with hold-down devices or stitch plates. The feedback mechanism enables continuous adjustment and correction, minimizing unnecessary contact and wear, thus extending needle operational life while sustaining high productivity through maintained high needle density
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A needle machine (2) according to the invention comprises a needle bar (8) with a plurality of needles (10), a hold-down device (22) for holding down and a support device (26) for supporting the sheet structure (4), as well as a monitoring device (41, 42) which is configured to monitor the positioning of the plurality of needles (10) relative to the hold-down device (22) and/or to the support device (26). Methods according to the invention include monitoring the positioning of the plurality of needles (10) relative to the hold-down device (22) and/or support device (26) by means of a monitoring device (41, 42) after a needle board (12) has been inserted into the needle machine (2) or during operation of the needle machine (2).