Segmented Pull-Off Rollers for Low-Torsion Combing Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing combing machines face issues with high energy consumption, significant vibrations, and inaccuracies due to the complex drive system of stripping rollers, which are subjected to torsional forces and require powerful motors, leading to inefficiencies and increased manufacturing costs.
Innovation Solution
The combing machine design includes tear-off rollers driven from both sides with separate segments, allowing independent operation in different directions of rotation, reducing torque imbalances and energy consumption, and simplifying assembly through a floating bearing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the stripping rollers are driven by a single motor-gearbox combination from one side, then the drive system is simple, but the shafts experience high torsion leading to delivery inaccuracies and the system cannot handle high combing cycles
Solution Approach 1:
The tear-off roller is divided into multiple segments (at least two) that can be independently driven. Each segment is connected to its own drive motor, allowing independent rotation control. This segmentation eliminates the torsion problem in long shafts by replacing the single long shaft with multiple shorter, independently driven segments, thereby improving delivery accuracy while maintaining manageable device complexity.
2Productivity
If the number of comb heads is increased to achieve higher productivity, then the output increases, but the torsion in the drive shafts increases significantly
Solution Approach 1:
By dividing the tear-off roller into segments that can be independently driven, the system can accommodate more comb heads without proportionally increasing shaft torsion. Each segment serves a specific zone of comb heads, allowing the system to scale productivity while maintaining acceptable stress levels in each individual shaft segment.
Solution Approach 2:
The drive system transitions from a single-sided drive to a dual-sided drive configuration, where tear-off rollers are driven from both ends of the combing machine. This dimensional change in the drive architecture allows for better torque distribution and reduced shaft torsion when multiple comb heads are operated simultaneously.
3Productivity
If the stripping rollers perform reciprocating stepping motion with frequent direction changes, then the combing cycle can be completed, but energy consumption increases and significant power losses occur
Solution Approach 1:
The system utilizes periodic reciprocating motion of the tear-off rollers, where each roller is driven forward during the combing stroke and returned during the return stroke. By independently controlling each segment's periodic action, the system optimizes energy usage by allowing free return motion or reduced-power return strokes, significantly lowering overall energy consumption compared to forced reciprocating motion in traditional single-sided drive systems.
4Stress or pressure
If separate drive motors are used for each tear-off roller segment, then independent rotation is achieved reducing shaft torsion, but the device complexity increases
Solution Approach 1:
The tear-off roller is segmented into multiple independently driven sections, each with its own motor. This segmentation directly addresses the shaft torsion problem by eliminating long, heavily loaded shafts. While it does increase device complexity, the modular nature of the segments makes the system more maintainable and allows for incremental implementation, balancing the trade-off between reduced torsion and increased complexity.
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
the invention relates to a combing machine, designed for producing combed fibres, comprising at least one combing head (20) with a feed device, wherein the combing head (20) has at least one feed cylinder (7), which is designed to supply fibres that are connected to one another from the feed device to a nipper assembly (5), which is designed to clamp the interconnected fibres, as well as comprising at least one pair of pull-off rollers (10, 12; 11, 13) which is designed to pull the clamped fibres out of the nipper assembly (5), wherein each pair of pull-off rollers (10, 12; 11, 13) has a pull-off roller (10, 11) that is driven from both sides by a drive, wherein the pull-off roller (10, 11) that is driven from both sides has a separation point (35) or the pull-off roller (10, 11) is formed by two separate segments, such that the pull-off roller (10, 11) can be driven on both sides in a different rotational direction. The invention is characterised in that the separation point (35) is formed in the region of a mounting point, or in that the two separate segments are mounted together in the region of a mounting point.