Performance and application of the blowing carding

Performance and application of short process blowing carding combine

the production line of short process blowing carding combine produced by Zhengzhou Hongda new textile machinery Co., Ltd. has a high starting point of technology, a high degree of automation and high processing accuracy. Due to the good performance of the single machine and the application of micro electronic technologies such as PLC programmable controller, self leveller and pressure sensor, the short process of "one grasp, one opening, one mixing, one cleaning and one carding" is realized, and the non return, stepless continuous cotton supply and sliver quantitative detection and adjustment are realized. The whole system is stable and reliable

1 advantages of short process blowing carding combine and process flow

1.1 advantages of short process blowing carding combine

(1) roll forming is cancelled, and the backward process of "loosening, pressing and re loosening" is replaced by a reasonable process of gradual loosening, giving full play to the functions of carding machine such as impurity removal, carding and blending, shortening the process flow, and realizing the continuity and automation of blowing carding spinning production

(2) the processes of coil dropping, handling and winding are omitted, which reduces the labor intensity of workers and improves labor productivity

(3) the sticky layer (especially the chemical fiber roll) and the poor joint of the cotton roll during unwinding are eliminated, which affect the card sliver quality and sliver breakage

(4) the rewinding of cotton cleaning is eliminated, the back flower of carding is reduced, and the production rate of blowing carding is improved

(5) due to the short process, the floor area of the machine is saved, which is conducive to the reasonable arrangement of the new machine arrangement for equipment transformation and the capital construction investment of the new plant

1.2 process flow of short process blowing carding combine

fa 006 reciprocating cotton grabber (with tf27 bridge magnet) → amp 2000 Mars Metal two in one detector → TF 30 heavy separator (with a 045b cotton condenser) → FA 103 double axial flow cotton opener → FA 028 six bin cotton mixer (TV 425a cotton conveying fan) → FA 109 three roller cotton cleaner → FA 151 micro dust remover → 119a Mars detector → FA 177a cotton feeder × 7 → FA 221B carding machine × 7。

2 single machine characteristics of short process blowing carding combine

2.1 FA 006 reciprocating gripper (one gripper)

bale stacking length 21.9 M. The control part is composed of imported PLC programmable controller and contact elements, and the executive program has been solidified in PLC. The toothed blade doubles with intermittent descent move back and forth with the turret to grasp the cotton bales in sequence, and the intermittent descent can be adjusted steplessly within the range of 0.1 ~ 19.9 mm/time, so as to achieve "multi bale arrangement and fine cotton grasping". The cotton bales are small and uniform, the average weight of the cotton bales is 300 mg, and the dispersion of the weight of the cotton bales is small, which is conducive to the mixing, loosening and uniform feeding of the next process

2.2 FA 103 double axial flow cotton opener (one opening)

raw cotton is pumped into the beater's room by air flow, and the cotton bundle is free to be hit by two corner nail beaters. The effect is mild and full. The unique design makes only the raw cotton that is completely loosened be pumped out of the machine by air flow; While the cotton bundle rotates 7.3 batches along the beater's axis, the large impurities fall along the beater's tangent direction, and the falling impurities are not disturbed by the size of the air flow, with high impurity removal efficiency; The surrounding angle of the dust stick under each thug is one-third, and the spacing of the dust stick can be adjusted according to the amount of impurities to control the amount of Cotton falling

2.3 FA 028 six bin cotton mixer (first mixing)

from the second bin, a cylinder pull rod push valve is installed, the valve switch is controlled by PLC programmable controller, and the cotton box pressure is set by the controller to ensure that the cotton box filling density is consistent. The raw cotton in each bin is loosened by the six winged toothed beater and then falls onto the cotton conveying curtain. The cotton conveying curtain is directly connected with the cotton cleaner. The speed of the cotton conveying curtain is synchronized with the cotton feeding speed of the cotton cleaner, so as to ensure that the cotton feast fed to the cotton cleaner can achieve extremely high uniformity, achieve full and uniform cotton mixing, and simplify the opening and cleaning process

2.4 FA 109 three roller cotton cleaner (first cleaning)

the cotton cleaning system is composed of three rollers with the same diameter, which are coarse needle, coarse serration and fine serration in turn, and is equipped with dust removal knife, carding board and continuous suction. The speed of the roller can be adjusted steplessly by frequency conversion according to the grade of raw materials, and the speed is increased by 1:1.7. With the process of gradually accelerating the speed and gradually densifying the needle teeth, the fibers can be gently transferred from one beater to the next, so as to reduce the damage to the fibers. The dust removal knife of the three rollers is equipped with an adjusting plate, which can change the lint content according to the requirements in the production process. The main feature of this machine is fine loosening of raw materials, with high loosening and impurity removal performance, so that the dust and impurities and some short fibers are removed in the opening and cleaning stage. When the impurity content of raw cotton is ≤ 4%, the impurity removal efficiency can reach 60% ～ 70%, which reduces the burden of the carding machine and greatly shortens the whole carding process

2.5 FA 221B carding machine (one carding)

the carding card cloth adopts the imported new card cloth, the pre carding plate is set at the bottom of the pricking roller, and the front three and rear three fixed cover plates and other auxiliary carding elements are set at the front and back of the cylinder, so as to make the fiber carding and mixing more fully. The machine is equipped with two front and two rear cotton cleaners, which can effectively reduce the lint in the sliver and can also be selected and used for fine dust. Using the three roller stripping device, the stripping effect is good and the head breakage rate is low. Equipped with a long and short segment self leveling device, the short segment and long segment unevenness are detected at the feeding roller and the outlet bell respectively, so that the evenness of sliver below 5 m and above 50 ~ 100 m can be effectively controlled, the weight unevenness of sliver can be reduced, and the number of changes of drawing draft change gears that control the final quantity can be reduced. Variable frequency speed regulation is adopted, and the sliver speed is 15 ~ 20 m/min when the head is green. The PLC programmable controller is used to control, and the panel displays various process parameters, and the common process parameters can be directly adjusted on the panel, making the adjustment process more simple and convenient

2.6 FA 151 micro dust remover

the cotton inlet fan sucks the fully loosened fibers into the machine from the rear bench, and under the action of wind, the fibers are sprayed onto the filter plate at high speed to remove fine impurities, micro dust and lint in the fibers. The speed of the cotton outlet fan is stepless adjusted by the frequency converter

2.7 FA 177a cotton feeding box

this machine is installed in the feeding part of the carding machine. It will evenly deliver the cotton after opening, impurity removal and mixing by the cotton cleaner to the carding machine. The compound cotton storage box is connected with closed-circuit circulating air flow, and the cotton feeding roller driven by frequency conversion can ensure the uniformity of the output cotton layer. The continuous cotton feeding device can automatically adjust the cotton feeding speed of the cotton cleaner according to the cotton quantity change (pressure fluctuation) in the cotton box to ensure the continuous cotton feeding process

3 process characteristics of short process blowing carding combine

the process of short process blowing carding combine implements the process route of "multi package arrangement, fine cotton gripping, early dropping and less crushing, gradual loosening, full mixing, combing instead of beating, efficient impurity removal, and High-yield carding"

the division of blowing and carding is reasonable. The opening and cleaning part is equipped with FA 028 six bin cotton mixer and FA 109 three roller cotton cleaner, so that there is only one holding and striking point in the whole process. The sawtooth roller is used to comb instead of beating, and the carding board is used to strengthen the effect of opening, loosening and impurity removal, effectively removing short lint and dust, so as to reduce the burden of carding, ensure the sliver quality, and greatly shorten the whole process

a multi-channel metal removal device and a large impurity removal device are applied in the process to prevent and reduce accidents. The system is equipped with an automatic noil suction device, which avoids the shutdown caused by manual output of noil and ensures the continuous production of the system

using the continuous cotton feeding system device, stepless speed regulation is carried out according to the pressure change of the cotton conveying pipeline, ensuring the continuous supply of the whole system. In the continuous feeding device, PID digital regulator is used for analog control, so that the cotton supply can stably and continuously adapt to the needs of different numbers of carding machines, keep the pipeline pressure within 780 PA ± 50 PA, ensure the uniform density of FA 177a cotton feeding box, and create conditions for the long and short segment self leveling device of carding machine to better control the quantitative fluctuation of sliver

JYF ball screw with the highest accuracy o - Ⅲ - 8 honeycomb dust filtering equipment is selected in the process. The dust filtering system adopts PLC programmable controller, which has stable and reliable operation and high filtering efficiency, meeting the process requirements of the blowing carding unit and ensuring the normal operation of the blowing carding unit

4 spinning test and problems needing attention in production of short process blowing carding combined machine

under the condition of optimizing the process of each single machine in the process, test the blowing noil and impurity removal efficiency, sliver quality, and then use the sliver produced by the short process blowing carding combined machine to undergo two passes of drawing and roving, and then spin it into C 28 tex yarn, and test the quality of semi-finished products and yarn

4.1 raw cotton performance

grade 3, length 29 mm, single fiber strength 3.22 CN, impurity content 1.7%, neps 42/10g, seed chips 49/10g, moisture regain 8.7%

4.2 main process parameters of single machine

(1) FA 006 reciprocating cotton grabber

the speed of cotton grabbing beater is 1250 R/min, the reciprocating speed of trolley is 10 m/min, and the decline of beater is 2 mm/time

(2) FA 103 double axial flow cotton opener

the speed of the first beater is 420 R/min, the speed of the second beater is 424 R/min, and the speed of the trash removal beater is 11 R/min

(3) FA 028 six bin cotton mixer

the beater speed is 576 R/min, the bin changing pressure is 250 PA, and the cotton conveying fan speed is 1400 R/min

(4) FA 109 three roller cotton cleaner

the speeds of the first, second and third rollers are 843, 1479 and 2400 r/min respectively

(5) FA 177a cotton feeding box

beater speed 784 R/min, circulating fan speed 2800 R/min, cotton box pressure 250 PA

(6) FA 221B carding machine

sliver dry weight 22 g/5 m. The speed of licker roll, cylinder and doffer is 810, 350 and 33.6 R/min. The spacing of each part (1/1000 ″) is as follows:

pre carding plate - take-up roller: 22

tin - licker roll: 7

tin cover plate: 8, 7, 7, 6

tin - rear fixed cover plate: 22

tin - front fixed cover plate: 9

tin doff: 5

4.3 quality index test

4.3.1 blowing noil and impurity removal efficiency (Table 1) table 1 blowing noil and impurity removal efficiency

when the raw cotton contains 1.5% ～ 2.0% impurities, the cleaning and impurity removal efficiency can only reach 35% ～ 45%, while the cleaning and impurity removal efficiency of the short process blowing carding combine can reach 55.86%. The non blowing carding combine process generally requires that the control range of sliver impurity content should not exceed 0.2%, while the short process blowing carding combine has high carding efficiency, and the sliver impurity content is only 0.0265%

4.3.2 sliver quality

(1) the weight unevenness of sliver quality

produced by non blowing carding combine is generally required to be controlled below 4%

according to the raw cotton condition and yarn quality requirements, the NEP impurity range in the sliver is self-determined. Generally, the NEP impurity in the sliver is about 60 ~ 110 grains/g, of which the NEP is about 15 ~ 50 grains/g

the CV value of the stem should be controlled in the range of 4.1% ～ 5%

(2) sliver quality produced by short process blowing carding combine (Table 2) table 2 sliver quality

weight unevenness is 1.33%

79 neps/g in total, including 17 neps/g

the CV value of the stem is 3.52%

the head breakage rate of the carding machine is also very low, only 0.24 times/shift

it can be seen that the sliver quality produced by the short process blowing carding combine is significantly better than that of the non blowing carding combine

4.3.3 drawing and roving quality

the evenness CV value of medium and special yarn is generally controlled at 4.1% ～ 4.3%, and the evenness CV value of roving is generally controlled at 6.5% ～ 9.1%. The sliver produced by the short process blowing carding combine has a sliver dry CV value of 3.57% and a roving sliver dry CV value of 6.34%. Relatively visible, short