FIELD OF THE INVENTION

The present invention relates to the spinning preparatory machine. More particularly the invention relates to the revolving flat bars along with guide roller arrangement for guiding the revolving flats in a textile carding machine.

BACKGROUND OF THE INVENTION

Textile spinning preparatory machine like carding machine includes the objective of separating the flocks into individual fibres. Additionally carding results in parallelisation, cleaning, reduction of neps, aligning, blending and elimination of some short fibres and sliver formation.

Carding machine is provided with a feed arrangement, in which the fibre lap from the chute is pushed into the working zone of the feed roller to licker-in area to open the fibre tufts and the fibres are transferred from the licker-in to main cylinder. Then fibres are transferred to cylinder-revolving flat zone and opened up into individual fibers. Said cylinder-flat zone is provided with wire points in face to face arrangement to remove the neps. The said revolving flat assembly comprises number of individual carding flat bars connected sequentially to form a closed - loop structure disposed adjacent to the carding main cylinder. The fibres come out of carding region in the form of a very thin web. The weight of carding web depends upon the setting of flats v/s cylinder, carding speed, type of wire clothing used on both cylinder and flats. The formed web is stripped from the main cylinder by another roller called doffer. Said doffer roller rotates at a very low surface speed when compared to the main cylinder. Thus the opened fibers are condensed at the doffer to form a web, which is then transferred to the condense roller with a workable draft.
The web is then passed through a pair of squeezing or crushing rolls before it is finally stored in the form of fibre stand or sliver form in sliver can.

In the context of the above, one of the most important function of a carding machine is to separate the individual fibres from fibre flock which is performed between the main cylinder and flats of revolving flat arrangement. Intensity of separation depends on spacing of the main cylinder from the flats, sharpness of the clothing, number of working flats with respect to the main cylinder, the tooth density of the clothing, and clothing life.

The existing flats of revolving flat arrangement, are made of aluminum material provided with T-shaped cross section. Said flat bars comprises an extruded hollow metallic body as top portion and a metallic clothing with plurality of sharp tooth arranged as bottom portion. The plurality of the said flat bars are linked together with the chain like arrangement to form a closed loop structure on the top of the main cylinder of the carding machine.

To increase the production output in carding machines, all the known arrangements were directed to increase the operating width of the said carding machines from 1m to 1.5m or more combined with higher operating speeds and such carding machine is described in US6219885. The problem arising due to the increased operating width combined with higher operating speeds is rapid increase in temperatures during the machine running conditions. Existing flat bars configuration were compromised by flat shape, size, height, width and stability to withstand the thermal deflection due to higher temperatures. Said thermal deflections were unavoidable particularly when the height of the flat bars were below 100mm. The increase in operating temperatures causes improper carding gap thereby affecting the quality of the
fibres being processed. Also in known arrangements, diameter of guide rollers for driving the revolving flat arrangement were smaller and below 195mm, which causes the flat bars to slide in higher speeds at the entry and exit of the flat bars on the main cylinder. The said higher sliding speed increases the pulling force acting on the fibre materials at the entry and exit of the revolving flat arrangement. Higher operating temperatures along with increased pulling force acting on the fibre materials between the revolving flat arrangement and main cylinder results in improper hook removal, insufficient dirt separation, insufficient nep removal and damages to the fibres being processed which in turn, affects the overall production efficiency of the carding machines

Therefore, there remains a need for a carding machine with a new revolving flat arrangement with high stability flat bars along with improved guide rollers arrangement to increase the production capacity in carding machine that would overcome the limitations and disadvantages present in the existing machines.

OBJECTS OF THE INVENTION

The main object of the present invention is to provide a revolving flat arrangement of the carding machine with higher production.

Another object of the present invention is to provide a revolving flat arrangement with improved guiding arrangements for higher production.

Yet another object of the present invention is to provide a revolving flat arrangement with higher thermal stability and higher thermal deflection point for withstanding higher temperatures during running conditions.

SUMMARY OF THE INVENTION

According to the present invention, the carding machine is provided with at least one revolving flat arrangement. The said revolving flat arrangement comprises plurality of individual flat bars connected sequentially forming a closed- loop structure disposed adjacent to main cylinder of the carding machine. Flat bars are made of cast iron / aluminum and have a T-shaped cross section. Each flat bars comprise an extruded hollow metallic body as top portion and a metallic clothing with plurality of sharp tooth arranged as bottom portion.

According to the present invention, the carding machine is provided with revolving flat arrangement comprising number of individual flat bars connected sequentially to form a closed-loop structure and is driven by at least one or more guide rollers. The total height of the said individual flat bar is at least 115mm to 150mm. The diameter of the said guide roller is in between the range of 150mm to 450mm, preferably in the range of 210mm to 360mm, The increased flat height provides a better stability and higher thermal deflection for the individual flat bars, during running conditions. The increased diameter of the guide rollers ensures less pulling force acting on the fibre material between the entry and exit region between the flat bars and the main cylinder, for eliminating the fibre hooks and neps.

According to an embodiment of the present invention, the carding machine is provided with a revolving flat arrangement with number of individual flat bars connected in sequential manner to form a closed- loop structure, and driven by at least one or more guide rollers. The said diameter of the guide roller is at least 1.3 to 3 times the total height of the individual flat bar.
According to another embodiment of the present invention, the carding machine is provided with a revolving flat arrangement with a total number of at least 95 to 150 individual flat bars connected in sequential manner to form closed- loop structure. The said revolving flat arrangement is driven by at least one or more number of guide rollers. The total number of guide rollers is at least 4 to 20. The at least one of said guide roller is provided with a drive roller shaft. The said drive roller shaft of the guide roller is suitably connected to the drive elements such as electric motor. The said drive elements can be connected to either one of the drive roller shaft of 4 to 20 guide rollers or can be connected to plurality of more than one of the drive roller shaft of 4 to 20 guide rollers for purpose of driving the revolving flat arrangement. The gap between the drive roller shaft of the guide roller and the flat bar top is at least 5mm to 80mm, when the flat bars guides over the guide roller. At least one of the guide rollers is provided with 65 to 120 number of teeth for guiding the flat bars anywhere in the closed loop of revolving flat arrangement.

According to an alternate embodiment of the present invention, the carding machine is provided with a revolving flat arrangement. The said revolving flat arrangement is driven by one or more guide rollers and also by at least one redirecting roller. The said redirecting roller can be provided at either one or both ends of entry or exit of the revolving flat arrangement and guides the individual flat bars in non circular path at entry and / or exit, in proximity to the main cylinder.

According to yet another embodiment of the present invention, the carding machine comprising a revolving flat arrangement is driven by at least one or more guide rollers and / or by at least one redirecting roller and is additionallyguided by a guiding element, at either one or both ends of entry and exit of the revolving flat arrangement for guiding the flat bars in non circular path and / or at exit in proximity to the main cylinder.

The new revolving flat arrangement with increased height for flat bars along with increased diameter for guide roller increases the dimensional and thermal stability of flat bars, which ensures the enhanced carding action between the revolving flat arrangement and main cylinder at entry and exit of flat bars in proximity to main cylinder. Also higher production is obtained without any deterioration in the quality of the fibre materials being produced.

Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Figure 1 illustrates the side view of the textile carding machine with revolving flat arrangement according to the invention.

Figure 2 illustrates the textile carding machine with revolving flat arrangement with re-directing rollers according to the invention.

Figure 3a illustrates the textile carding machine revolving flat arrangement with flat guiding element at the fibre exit region according to one of the embodiment of the invention.

Figure 3b illustrates the textile carding machine revolving flat arrangement with flat guiding element at the fibre entry region according to one. of the embodiment of the invention.
Figure 3c illustrates the flat guiding element at the fibre exit region according to figure 3a.

DETAILED DESCRIPTION OF THE INVENTION

The carding machine (1) of the present invention is provided with at least one revolving flat arrangement (2) as shown in figures 1 to 3c. The said revolving flat arrangement (2) comprises a plurality of individual flat bars (3) connected sequentially forming a closed- loop structure disposed adjacent to carding main cylinder (4) of the carding machine (1). Flat bars (3) are made of cast iron / aluminum and have a T-shaped cross section. Each flat bars (3) comprises an extruded hollow metallic body as top portion and a metallic clothing with plurality of sharp tooth arranged as bottom portion. The revolving flat arrangement (2) forms a closed loop structure and disposed adjacent to the carding main cylinder (4) having 300mm to 1300mm diameter forming a carding area. At least 36 flat bars (3) of plurality of flats forms the working flats and makes contact to the carding main cylinder (4) to form a carding area. The revolving flat arrangement (2) is provided with at least one or more guide rollers (5a, 5b, 5c, 5d) for driving the said revolving flat arrangement (2).'

The carding machine (1) is provided with revolving flat arrangement (2) with number of individual flat bars (3) connected sequentially to form a closed-loop structure and is driven by at least one of the guide rollers (5a, 5b, 5c, 5d), in which the total height (H) of the said individual flat bar (3) is at least 115mm to 150mm. The diameter of the said guide roller (5a, 5b, 5c, 5d) is in between the range of 150mm to 450mm, preferably in the range of 210mm to 360mm. The • increased flat height provides a better stability and higher thermal deflection for the individual flat bars, during running conditions. The increased diameter of the guide rollers (5a, 5b, 5c, 5d) ensures less pulling force acting
on the fibre material between the entry and exit region of the flat bars on the main cylinder, for eliminating the fibre hooks and neps.

The carding machine (1) as an embodiment comprises a revolving flat arrangement (2) driven by at least one or more guide rollers (5a, 5b, 5c, 5d). The said diameter of the guide rollers (5a, 5b, 5c, 5d) is at least 1.3 to 3 times the total height (H) of the individual flat bar (3).

The carding machine (1) according to another embodiment is provided with a revolving flat arrangement (2) with a total number of at least 95 to 150 individual flat bars (3) connected in sequential manner to form closed- loop structure. The said revolving flat arrangement is driven by at least one or more number of guide rollers (5a, 5b, 5c, 5d). The total number of guide rollers (5a, 5b, 5c, 5d) is at least 4 to 20. The at least one of said guide roller (5a, 5b, 5c, 5d) is provided with a drive roller shaft (6). The said drive roller shaft (6) of the guide roller is suitably connected to the drive elements such as electric motor (not shown), for driving the revolving flat arrangement (2). The said drive elements can be connected to either one of the drive roller shaft of guide roller (5a, 5b, 5c, 5d) or can be connected to plurality of more than one of the drive roller shaft of guide rollers (5a, 5b, 5c, 5d) for purpose of driving the revolving flat arrangement (2). The gap (A) between the drive roller shaft (6) and the flat bar top (3) is at least 5mm to 80mm, when the flat bars (3) are guiding over the guide roller (5a, 5b, 5c, 5d). At least one of the guide rollers (5a, 5b, 5c, 5d) is provided with 65 to 120 number of teeth for guiding the flat bars (3) anywhere in the closed loop of revolving flat arrangement.

The carding machine (1) as an embodiment comprises a revolving flat arrangement (2) driven by one or more guide rollers (5a, 5b, 5c, 5d) and alsoby at least one redirecting roller (7a, 7b). The said redirecting rollers (7a, 7b) can be provided at either one or both ends of entry or exit of the revolving flat arrangement (2) and guides the individual flat bars (3) in non circular path at either entry and / or exit in proximity to the main cylinder (4).

The carding machine (1) as an additional embodiment, comprises a revolving flat arrangement (2) driven by at least one or more guide rollers and / or by at least one redirecting roller (7a, 7b) and is additionally guided by a guiding element (8a, 8b), at either one or both sides of the fibre exit as shown in Figures 3a & 3c or in fibre entry side of revolving flat arrangement (2) as shown in Figure 3b for guiding the said flat bars (3) in non circular path at entry and / or exit in proximity to the main cylinder (4).

The new revolving flat arrangement (2) with increased height for flat bars (3) and with increased diameter for guide roller (5a, 5b, 5c, 5d) increases the dimensional and thermal stability of flat, which ensures enhanced carding action between the revolving flat arrangement and main cylinder at entry and exit of flat bars proximity to main cylinder. Also higher production is obtained without any deterioration in the quality of the fibre materials being produced.

In view of the present disclosure which describes the present invention, all changes, modifications and variations within the meaning and range of equivalency are considered within the scope and spirit of the invention. It is to be understood that the aspects and embodiment of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiment may be combined together to form a further embodiment of the disclosure.