Three-Level Carding Roller for Asynchronous Fiber Blending
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Solution Overview
Problem
Existing rotor spinning technologies cannot effectively blend two or more fibers in any proportion while maintaining invariable linear density and blending ratio, leading to inadequate fiber breakdown, yarn defects, and unsatisfactory color blending.
Innovation Solution
A rotor spinning device with a three-level carding roller and combined feeding roller system, driven by a servo motor, allows asynchronous feeding and carding of fibers, enabling dynamic control of yarn density and blending ratio through a computer-controlled PLC system, which includes a fiber transport channel and winding mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional single carding roller is used to feed three slivers, then the structure is simple, but the fiber breakdown is inadequate causing blocking and yarn defects
Solution Approach 1:
The single carding roller is divided into three separate carding rollers (first, second, and third carding rollers), each responsible for processing one sliver. This segmentation allows independent optimization of each roller's parameters and improves overall fiber breakdown quality while preventing blocking.
2Device complexity
If three slivers are fed at the same time with a single carding roller, then the feeding mechanism is simple, but the color blending effect is unsatisfactory due to short carding area
Solution Approach 1:
The patent extends the carding process from a single-stage to a multi-stage configuration, adding temporal and spatial dimensions to the carding area. The three carding rollers are arranged in sequence, creating an extended carding path that significantly increases the mixing distance and improves color blending quality.
3Stability of the object's composition
If coupling and feeding methods are used to maintain invariable linear density, then the linear density is stable, but the blending ratio cannot be adjusted
Solution Approach 1:
The patent introduces independent speed control for each carding roller through a servo motor control system. This dynamic control allows the feeding speeds of different slivers to be independently adjusted, enabling blending ratio modification while maintaining stable linear density through coordinated control of all three rollers.
4Adaptability or versatility
If asynchronous feeding with different speeds is implemented, then blending ratio can be changed, but the feeding control system becomes complex
Solution Approach 1:
The patent replaces traditional mechanical coupling mechanisms with an electronic servo motor control system. Each carding roller is driven by an independent servo motor controlled by a PLC, enabling precise asynchronous speed control and blending ratio adjustment through electronic control rather than complex mechanical linkages.
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 solution allows for the production of yarns with variable linear density and blending ratio, enhancing fiber mixing, reducing yarn defects, and achieving flexible and efficient color blending, including gradient-color and segment-color yarns.
Implementation Method 1
With the centrifugal force of the rapidly rotating rotor, the fibers in the collection groove are further piled up and mixed
Implementation Method 2
Under the action of air flow, the fiber flows into the rotor through the fiber transport channel
Data Source
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Figure 3a~3b
AI summary
Disclosed is a device for a rotor spinning method using multi-level carding. The device includes a spinning system and a computer control system. The spinning system includes a feeding and carding mechanism, a collecting and twisting mechanism, and a winding mechanism. The feeding and carding mechanism includes a combined feeding roller (2-1, 2-2) with two rotational freedom degrees and a multi-level carding roller (2-6, 2-7, 2-8), the speed ratio of two rollers of the combined feeding roller (2-1, 2-2) with two rotational freedom degrees is adjustable, and therefore the linear density and blending ratio of rotor spun yarn can be regulated and controlled freely. A rotor spinning method using two-cotton-sliver asynchronous inputting and three-level carding is also disclosed.