Revolving Flat Card Drum Geometry for Fiber Processing
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Solution Overview
Problem
Revolving flat cards face challenges in achieving a low overall height while maximizing processing time and minimizing fiber damage, as existing designs result in large overall height and limited under-carding zones, leading to aggressive fiber processing and increased waste.
Innovation Solution
A revolving flat card design with a licker-in and doffer arranged on the drum circumference, forming a carding length of over 3,100 mm by optimizing the drum diameter and angle between the licker-in and doffer planes, with a drum diameter of 1150 to 1250 mm and an angle of more than 305°, and utilizing pre-carding and post-carding zones for gentle fiber treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the licker-in and doffer are arranged to achieve high productivity, then the processing speed is improved, but the overall height of the card increases and the fiber transport path is limited
Solution Approach 1:
The patent transitions from a conventional horizontal arrangement to a vertical arrangement of the carding machine. The drum is positioned vertically with the licker-in at the top and doffer at the bottom, utilizing the vertical dimension to achieve a compact horizontal footprint while maintaining high productivity. This dimensional change allows the fiber transport path to wrap around the drum circumference multiple times within a limited vertical space.
2Length of stationary object
If the drum diameter is reduced to lower overall height, then the machine compactness is improved, but the under-carding zone is limited
Solution Approach 1:
The patent ensures continuous fiber processing by arranging the licker-in, drum, and doffer in sequence along the vertical axis, with the fiber transport path forming a continuous loop around the drum. The fiber feed channel directs fibers continuously from the licker-in onto the drum surface, which then transports them through multiple circumferential revolutions to the doffer, maximizing the utilization of the available under-carding zone.
3Length of stationary object
If the fiber transport path is shortened to reduce overall height, then the machine compactness is improved, but fiber damage increases due to aggressive processing
Solution Approach 1:
The patent utilizes the curved circumferential path of the drum to gently transport fibers through the carding zone. The revolving flats follow the curved drum surface, providing gradual and continuous carding action rather than abrupt linear processing. This curved path allows fibers to be processed gently over an extended distance, reducing mechanical stress and fiber damage while maintaining compact dimensions.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a traveling carding machine (1) for processing fibers, comprising a drum (4) with a drum axis (21), a drum diameter (20), a drum surface (28), and a drum direction of rotation (29). A pre-tearer (7) with a pre-tearer axis (23) and a pre-tearer diameter (22), a take-up unit (9) with a take-up axis (25) and a take-up diameter (24), and a traveling card assembly (6) are arranged around the circumference of the drum (4). A fiber transport direction (30) is determined by the drum direction of rotation (29) in the direction from the pre-tearer (7) to the take-up unit (9). The traveling card assembly (6) is arranged between the pre-tearer (7) and the take-up unit (9) and, viewed in the fiber transport direction (30), downstream of the pre-tearer (7). Between the pre-carder (7) and the moving cover unit (6) a pre-carding zone (31) is formed and between the moving cover unit (6) and the take-up unit (9) a post-carding zone (32) is formed.The drum axis (21) and the feeder axis (23) lie in a feeder plane (26), and the drum axis (21) and the take-off axis (25) lie in a take-off plane (27). A carding length is defined by a partial circumference of the drum surface (28) between the feeder plane (26) and the take-off plane (27) in the fiber transport direction (30). The feeder plane (26) and the take-off plane (27), viewed from the feeder plane (26) in the fiber transport direction (30), form an angle (α) of more than 305°.