DESC:FIELD OF THE INVENTION
The present invention relates to a textile carding machine. Particularly the present invention relates to the guide element for fiber transfer in carding machine.
BACKGROUND OF THE INVENTION
Carding is a mechanical process that opens, removes trash and neps, breaks up flocks and unorganized clumps of fiber and then aligns the individual fibers so that they are more or less parallel with each other. Finally, converts the mixed and fluffed-up form of textile material into a soft, untwisted thin rope of sliver form. The fiber mat fed to the carding machine should be of a high degree of uniformity to ensure consistent opening and carding. This uniformity is achieved using the chute feed system, which aims at feeding a fiber sheet of a uniform packing density and uniform linear density to the carding machine.
Fibers that are opened and cleaned by licker-in system are transferred to the main cylinder by stripping action. Fibers stripped by the cylinder from the licker-in are transferred to the carding zone, which is the area between the main cylinder and the flats. In principle, a carding action is accomplished when the wire of the two surfaces are inclined in opposite directions and the direction and the rates of motion are such that one surface passes the other, point against point. The flats are wired clothed bars rotating at a very slow speed against the high speed cylinder.
Fibers that are coming out of the carding zone form a very thin web. The weight of the web is determined by extent of carding such as flats or cylinder settings, the relative carding speed, and the type of cloth on both cylinder and the flats. The web is extracted from the main cylinder by another cylinder called a doffer. The substantial reduction of the surface speed of the doffer as compared to that of the cylinder results in a condensation effect. The fiber web is stripped from the doffer using a stripper roller or redirecting roller. It is then passed through a pair of squeeze or crush rolls before it is finally accumulated width wise into a fiber strand form. The calender rolls compress the fiber strand to provide better integrity and stable flow of material. The fiber strand or the card sliver proceeds upward over guide pulleys to enter the coiler system. This consists of a trumpet guide and a second pair of calender rolls that delivers the carded sliver through a revolving tube into the card sliver can. The condensed slivers are then stored in the sliver can by means of coiler arrangement.
In the above arrangement, there always a space or gap exists between the said stripper roller or redirecting roller and pair of crush rollers. This due to the diameter difference of said redirecting roller and top crush rollers as illustrated in Fig.1 of the known arrangement disclosed in European patent application EP1057905A1. Especially the said gap plays a negative effect on fiber web while setting a distance of 0.1 to 0.2mm between redirecting roller and crush rollers. Normally it lead to fiber transfer or escape through above said gap and it creates fiber transfer fly between redirecting roller and top crush roller. Also the fibers stuck on the outer surface of redirecting roller are not completely transferred out from it and goes as waste when it pass through brush roller and brush roller suction. Sometime, those fibers released from redirecting roller are carried by brush roller suction through the gap. This is an undesirable effect which increases wastage of good fiber and affects the fiber web transfer efficiency.
There has thus been a need to develop a fiber transfer between RD roller and top crush roller for high production with desirable quality that would overcome the disadvantages present in the existing machines.
OBJECT OF THE INVENTION
The main object of the invention is to effectively guide the fibers in between redirecting roller and crush roller pair in a textile carding machine.
Another object of the present invention is to avoid returning of good fiber material to brush roller in a carding machine.
One more object of the present invention is to reduce fiber wastage and sliver breaks due to web accumulation which increases the efficiency of the carding machine.
SUMMARY OF THE INVENTION
According to the present invention, the carding machine is provided with chute feeding arrangement, licker-in roller; main cylinder; revolving flats; doffer roller, redirecting roller, pair of crush roller; delivery area include coiler unit with a sliver depositing can. The fibers come out from carding zone (doffer exit) in the form of very thin web transferred through the redirecting roller and a pair of crush rollers. Further the fiber web is condensed into a sliver by passing it through condenser and calender rollers arrangement.
In order to effectively directing the fiber web, a web guide element is provided in between said redirecting roller and top crush roller. Said guide element act as a guide for fiber transfer and also offers better transferring efficiency of fiber from redirecting roller to top crush roller. Thus, the said guide element fills the gap between the said rollers and avoids returning of good fiber material to brush roller suction.
According to the primary aspect of the present invention, said web guide have uniform or decreasing/increasing gap from front with redirecting roller and top crush roller and located below of the top crush roller axis.
Bottom surface of web guide will have uniform gap with respect to redirecting roller under cover.
According to further aspect of the present invention, the web guide element have uniform gap or decreasing/increasing gap from front with redirecting roller and top crush roller and located above of the top crush roller axis.
In one aspect of the present invention, a carding machine is provided. The carding machine includes a doffer roller to doff the fiber web from the main cylinder, a top crush roller, a bottom crush roller disposed below the top crush roller, a redirecting roller which redirects the fiber from doffer roller to the crush rollers, and a brush roller to strip accumulated fibers on a surface of the redirecting roller. The carding machine also includes at least one guide element positioned between the redirecting roller and the top crush roller to reduce a space between the redirecting roller and the top crush roller thereby providing a closer gap with respect to the redirecting roller and the top crush roller.
According to the present invention, the guide element is positioned between the redirecting roller and the top crush roller at lower position.
According to the present invention, the guide element is positioned between the redirecting roller and the top crush roller at upper position.
According to the present invention, the closer gap is a uniform gap.
According to the present invention, the closer gap is a converging gap.
According to the present invention, the closer gap is a diverging gap.
In another aspect of the present invention, a guide element for a carding machine is provided. The guide element includes at least one long edge. The guide element also includes at least one short edge disposed opposite to the long edge. The guide element further includes a first curved edge disposed adjacent to the long edge and the short edge. The guide element includes a second curved edge opposite to the first curved edge and disposed adjacent to the long edge and the short edge. The guide element is positioned between a redirecting roller of the carding machine and a top crush roller of the carding machine in such a manner that the first curved edge is disposed in a close vicinity of the redirecting roller and the second curved edge is disposed in a close vicinity of the top crush roller to reduce a space between the redirecting roller and the top crush roller thereby providing a closer gap with respect to the redirecting roller and the top crush rollers. At least one edge of the guide element prevents entry of fiber between the redirecting roller and the top crush roller in the upward direction.
According to the present invention, the closer gap is a uniform gap.
According to the present invention, the closer gap is a converging gap.
According to the present invention, the closer gap is a diverging gap.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure - 1 illustrates a textile carding machine according to the present invention.
Figure - 2 & 2a illustrates conventional fiber transfer between redirecting roller and crush roller of the carding machine.
Figure - 3a & 3b illustrates fiber web guide element provided between redirecting roller and top crush roller of the carding machine according to one of the preferred embodiments of the present invention.
Figure - 3c illustrates an upper stationary guide between redirecting roller and top crush roller of the carding machine according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A textile carding machine according to the present invention is shown in Figure-1. Carding is the subsequent process of blow room. The carding machine (A) is equipped with chute feed (1), feeding arrangement (2), licker-in roller (3); Main cylinder (4); revolving flats (5); doffer roller (6), redirecting roller (7), pair of crush rollers (8); delivery area (9) include coiler unit with a sliver deposit can (not shown in fig).
The fiber tuft from the blow room line is the feed material which is in the form of fiber web or sheet to the carding machine (A). The chute feed (1) maintains a continuous and uniform fiber web feeding to said carding machine (A). The fiber web coming out from chute (1) is supplied to carding system with help of feeding arrangement (2) comprising feed roller and feed plate arrangement (not illustrated). The fed fiber web moves subsequently to licker-in roller (3) of said carding machine. The licker-in roller (3) periphery is wrapped with saw-toothed wire clothing, which removes impurities like heavy trash particles and seed from fiber web. Opened and cleaned fiber web from licker-in roller (3) is transferred then to main carding zone. Now these cleaned fiber web passed between main cylinder (4) and revolving flat (5) of main carding zone. Carding action takes place between these main cylinder and revolving flat system. The direction of rotation of said revolving flat and main cylinder is shown by arrow in Fig. The fibers come out from the carding zone is in the form of very thin web or fleece, which enter into doffer roller (6) for further cleaning. Then fiber web or fleece is taken up by the redirecting roller (7) and passes through a pair of crush rollers (8). Above redirecting roller (7), a brush roller (10) is provided to clean or strip the accumulated / stuck fibers from the surface of said redirecting roller (7). Also a suction arrangement is provided above the said brush roller (10) to remove the fiber waste deposited on the said brush roller surface. Further the fiber web travel to the subsequent carding element of web delivery area (9) comprising a web condenser, pair of calender roller and coiler unit. The thin web condensed into a sliver in web condenser and passing through pair of calender rollers and then coiler unit. Finally condensed sliver deposited or stored in sliver can for moving to further subsequent processing machine such as draw frame.
Figure - 2 & 2a illustrates conventional fiber transfer between redirecting roller and crush roller of the carding machine. After carding action, normally the fiber web transferred from main carding zone which comprises main cylinder (4), revolving flat assembly (5) and doffer roller (6). Then the thin fiber web or fleece transferred through redirecting roller (7) and pair of crush rollers (8). During this action, the said web or fleece is guided by redirecting roller undercover or guide sheet (11). The brush roller (10) is arranged above the redirecting roller (7). The suction arrangement (16) with a suction duct above the brush roller (10) is used to remove off the return waste material from crush roller stripper and brush roller (10). Due to the diameter difference between redirecting roller (7) and top crush roller (8a), certain gap or space (17) always exists in between said redirecting roller and top crush roller. Hence the fibers stuck on the outer surface of redirecting roller are not completely transferred through pair of crush rollers (8a, 8b) and sometimes it goes as waste (13) (shown in dotted line) and then it passes to brush roller (10). Moreover, these fibers released from redirecting roller carried by brush roller suction (16) through the said gap or space (17). A normal fiber transfer between redirecting roller (7) and crush roller pair (8a, 8b) is shown as solid line (12) in Figure-2a.
Due to above said gap or space (17) between redirecting roller (7) and top crush roller (8a) some amount of good fibers carried away by the redirecting roller (7), and then transferred to brush roller suction (16). This good fiber material loss through the said gap or space (17) affects the fiber transfer efficiency of redirecting roller.
Figure - 3a & 3b of the drawings illustrates a fiber web guide provided between redirecting roller and top crush roller of the carding machine according to one of the preferred embodiment of the present invention. To avoid fiber return in upward direction through redirecting roller (7) gap or space (17), a fiber web guide element (14) is provided between redirecting roller (7) and pair of crush rollers (8a, 8b). Said guide element (14) also supports the web at upper side while the machine running at higher speeds.
Said fiber guide element (14) have curved shape at the juxtaposed surfaces of redirecting roller (7) and top crush roller (8a). A uniform or diverging/converging closer gap (18) is therefore maintained by the said guide element (14) with respect to redirecting roller (7) and top crush roller (8a).
Figure - 3c illustrates a stationary guide element (15) is provided between redirecting roller and top crush roller of the carding machine according to another embodiment of the present invention. Said stationary guide element (15) have uniform or diverging/converging closer gap (18) with redirecting roller (7) and top crush roller (8a) and located above the top crush roller (8a). When the return fiber material is carried upwards by the redirecting roller (7), the bottom edge of said stationary guide element (15) stops the further entry of fiber in between redirecting roller and guide element (15). Thus it strips the fiber from surface of said redirecting roller (7) and makes them to drop over the running web (12) and carried forward in the actual direction.
The guide element (14, 15) is a metallic or metal alloy or non metallic or composite material which extends over the entire width of the said redirecting roller (7). Both extreme ends of the guide element (14, 15) is supported by means of suitable connecting components or fixtures to machine frame or may slide through sideways. Said guide element (14, 15) can also be easily removable for maintenance or replacement.
Since the returning of good fiber material to brush roller suction (16) is eliminated using aforesaid guide elements (14, 15), an effective fiber transfer is achieved by the redirecting roller (7). This also reduces fiber wastage and sliver breaks due to web accumulation which also increases the efficiency of the carding machine.
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.
Reference Numerals
A-Carding machine, 1-Chute feed, 2-Feeding arrangement, 3-Licker-in roller, 4-Main cylinder, 5-Revolving flats, 6-Doffer roller, 7-Redirecting roller, 8-Pair of crush roller, 8a-Top crush roller, 8b-Bottom crush roller, 9-Delivery area, 10-Brush roller, 11-Redirecting roller under cover or guide sheet, 12-Normal fiber transfer flow, 13-Return material to brush roller, 14-Fiber web guide element, 15-Stationary guide element, 16-Brush roller suction, 17-Space, 18-Closer gap.
,CLAIMS:
1. A carding machine (A) comprising:
a doffer roller (6) to doff a fiber web from a cylinder (4);
a top crush roller (8a);
a bottom crush roller (8b) disposed below the top crush roller (8a);
a redirecting roller (7) which redirects the fiber from the doffer roller (6) to the crush rollers (8a, 8b);
a brush roller (10) to strip accumulated fibers on a surface of the redirecting roller (7); and
at least one guide element (14, 15) positioned between the redirecting roller (7) and the top crush roller (8a) to reduce a space (17) between the redirecting roller (7) and the top crush roller (8a) thereby providing a closer gap (18) with respect to the redirecting roller (7) and the top crush roller (8a).
2. The carding machine (A) as claimed in claim 1, wherein the guide element (14) is positioned between the redirecting roller (7) and the top crush roller (8a) at lower position.
3. The carding machine (A) as claimed in claim 1, wherein the guide element (15) is positioned between the redirecting roller (7) and the top crush roller (8a) at upper position.
4. The carding machine (A) as claimed in preceding claims 1 to 3, wherein the closer gap (18) is a uniform gap.
5. The carding machine (A) as claimed in preceding claims 1 to 3, wherein the closer gap (18) is a converging gap.
6. The carding machine (A) as claimed in preceding claims 1 to 3, wherein the closer gap (18) is a diverging gap.
7. A guide element (14, 15) for a carding machine (A), the guide element (14, 15) comprising:
at least one long edge;
at least one short edge disposed opposite to the long edge;
a first curved edge disposed adjacent to the long edge and the short edge; and
a second curved edge opposite to the first curved edge and disposed adjacent to the long edge and the short edge,
the guide element (14, 15) is positioned between a redirecting roller (7) of the carding machine (A) and a top crush roller (8a) of the carding machine (A) in such a manner that the first curved edge is disposed in a close vicinity of the redirecting roller (7) and the second curved edge is disposed in a close vicinity of the crush roller (8a) to reduce a space (17) between the redirecting roller (7) and the top crush roller (8a) thereby providing a closer gap (18) with respect to the redirecting roller (7) and the top crush roller (8a), at least one edge of the guide element (14, 15) prevents entry of fiber between the redirecting roller (7) and the top crush roller (8a) in the upward direction.
8. The guide element (14, 15) as claimed in claim 7, wherein the closer gap (18) is a uniform gap.
9. The guide element (14, 15) as claimed in claim 7, wherein the closer gap (18) is a converging gap.

10. The guide element (14, 15) as claimed in claim 7, wherein the closer gap (18) is a diverging gap.