BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of a flat card which incorporate an apparatus according to the invention;
FIG. 2
a is an operating diagram with drive motors for the flat card, the card feeder and the can coiler according to FIG. 1;
FIG. 2
b is an operating diagram with drive motors for the can coiler according to FIG. 1 and a card drafting mechanism;
FIG. 3 shows a speed-regulated drive motor for the cylinder and a licker-in of a flat card;
FIG. 4 is a block diagram with an electronic machine control and regulation device, electronic motor control and regulation devices and speed-regulated drive motors of the machine;
FIG. 5 shows the power consumption of the motor as a function of time or the loading of the motor as a function of different operational states;
FIG. 6 shows the power consumption of the motor as a function of the amount produced per unit time i.e. the loading of the motor as a function of the production output;
FIG. 7 is a function block diagram of one embodiment of apparatus according to the invention and
FIG. 8 shows the variation of the loading and speed as a function of different operational states.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
With reference to FIG. 1, a flat card, for example, a TC 03 flat card made by Trützschler GmbH & Co. KG of Mönchengladbach, Germany, has a feed roller 1, feed table 2, lickers-in 3a, 3b, 3c, cylinder 4, doffer 5, stripper roller 6, nip rollers 7, 8, web guide element 10, delivery rollers 11, 12, revolving card top 13 with card top guide rollers 13a, 13b and flats 14, can 15 and can coiler 16 with coiler plate 16a. The directions of rotation of the rollers are indicated by curved arrows. Reference letter M denotes the centre point (axis) of the cylinder 4. Reference numeral 4a indicates the clothing and reference numeral 4b indicates the direction of rotation of the cylinder 4. Reference letter C indicates the direction of rotation of the revolving card top 13 in the carding position and reference letter B indicates the return transport direction of the flats 14. Reference numeral 17 denotes a cleaning roller for the stripper roller 6 and reference numeral 18 denotes a card feeder.
FIG. 2
a shows an example of a drive concept. Various drive motors and transmission elements together form the drive solution for the flat card TC 03. Special-purpose servomotors drive cylinder 4 and licker-in 3. Maintenance-free special-purpose belts ensure a long service life. The web take-off in the case of the TC 03 is equipped with a separate, regulatable drive. It is thus possible to select the ideal draft for each speed. Even during acceleration and braking, the draft appropriate for the speed at any particular instant is set by the controller. That results in more uniform slivers from the first to the last metre in the can. The motors for the feed roller 1, doffer 5 and web take-off are special-purpose servo drives. There are no high-maintenance gears, for example in the doffer drive. They are brush-less and therefore totally maintenance-free. They are distinguished by very good dynamic properties and thus a load-independent speed variation. As a result, the short-wave uniformity (Uster value) of the card slivers is improved. In the case of an optimum separate set-up of can coiler and changer (see FIG. 2b), a servo drive is additionally used.
In the arrangement of FIG. 2a, the following rollers are driven by a speed-regulated motor 21, electric drive motor 21, e.g. AC servomotor (AC=alternating current): cylinder 4 by motor 22; lickers-in 3a, 3b, 3c by motor 23; feed roller 1 of the flat card by motor 24; doffer 5, stripper roller 6 and nip rollers 7, 8 by motor 25; delivery rollers 11, 12 by motor 26; rear card top guide roller 13a and cleaning roller 19 by motor 27 and intake roller 39 of the card feeder 18 by motor 31. In the can coiler and changer set-up of FIG. 2b, the rollers are driven as follows: intake and middle roller pair of the card drafting system 32 by motor 28; output roller pair of the card drafting system 32 as well as delivery rollers and coiler plate 16a by motor 29; can rotary plate by motor 30.
According to FIG. 3, the cylinder 4 is driven by a speed-regulated motor 22 and the licker-in 3 is driven by the speed-regulated motor 23. On the shaft of motor 22 there is arranged a belt pulley 35 and on the shaft of cylinder 4 there is arranged a belt pulley 36, around which an endless belt 37 is looped for drive purposes. The outer side of the belt 37 is in engagement with a guide roller 38 and a tensioning roller 39. On the shaft of the motor 23 there is arranged a belt pulley 40 and on the shaft of the licker-in 3 there is arranged a belt pulley 41, around which an endless belt 42 is looped for drive purposes. The regulated motor 23 is connected electronically to an electronic machine control and regulation device 44 (see FIG. 4) by way of an electronic motor control and regulation device 432, and the regulated motor 22 is connected electronically to the electronic machine control and regulation device 44 (see FIG. 4) by way of an electronic motor control and regulation device 431 (see FIG. 4).
FIG. 4 shows a control arrangement with an electronic controller 44, frequency converter 43 and motors 22 to 25. According to FIG. 4, a plurality of motor control and regulation devices 431, 432, 433, 434, for example servo axle regulators, are present. A drive motor, for example motors 22, 23, 24, 25, is connected to each servo axle regulator 431, 432, 433, 434, respectively. The servo axle regulators 431, 432, 433, 434 are connected to the electronic machine control and regulation device 44, for example TMS 2 made by Trüutzschler GmbH & Co. KG. Reference numeral 45 denotes an operating and display unit which is connected to the machine control and regulation device 44.
The speed-regulating device is an integral component of the control and regulation system. Particularly the speed-regulating function of the motor control and regulation devices is employed for the invention.
It is possible for commercially available speed-regulating devices to be used. It is also possible to use servo regulating devices specially matched to the machine. The servo regulating devices can be actuated directly by digital signals via a bus system, for example CANbus. It is operated with feedback of the actual speed value.
FIG. 5 shows the variation in loading and the pre-set loading limits for different operational states. The graph shows diagrammatically the power consumption I (A) over time t (sec). The region with a positive gradient represents the acceleration period, the middle constant region represents operation and the region with a negative gradient represents the run-down period. Reference letter a denotes the desired value, reference letter b denotes a lower limit and reference letter c denotes an upper limit. The limits for the desired loading values are calculated and pre-set as a function of the particular operational state of the machine.
FIG. 6 shows the loading and the associated loading limits as a function of the production rate of a machine. The values for a production rate of 80 kg/h are shown by way of example. The graph shows diagrammatically the power consumption I (A) over production rate (kg/h). Reference letter d denotes the desired value, reference letter e denotes a lower limit and reference letter f denotes an upper limit. The limits for the desired loading values are calculated and pre-set as a function of the particular production rate of the machine.
In the embodiment of the invention shown in FIG. 7, the operating and display device 45, a switching device 49, for example a switch-off device, and the motor control and regulation device 431 (servo axle regulator) are connected to the electronic machine control and regulation device 44. The motor control and regulation device 431 comprises a speed-regulating or setting device 48, downstream of which there are arranged a power amplifier 46 and a load sensor 47. The load sensor 47 is connected to the motor 22, to the speed-regulating or setting device 48 and the electronic machine control and regulation device 44.
The motor 22 is connected (in a manner not shown) to three phases (L1, L2, L3). The graph I/t according to FIG. 5 shows the power consumption over time. The power consumption I, for example in a supply line, is transformed downwards in a transformer (not shown) and by means of coils. A load sensor 47 converts the input current into a voltage. The varying voltage corresponds to the loading (actual value). The voltage is fed to the speed-regulating or setting device 48 and to the machine control and regulation device 44. In the speed-regulating and setting device 48, the actual value of the loading is compared with the desired value of the loading, which is pre-set by the machine control and regulation device 44. In that way, there is created, in the form of the load sensor 47, a device for automatically determining the loading of the drive motors 21; 22 to 31 during operation, which is connected to the device, in the form of the speed-regulating or setting device 48, for comparison with pre-set values (desired values/limit values) for the loading.
When electric motors 22 to 31 are operated with speed-setting or regulating devices and the output data of motor and device do not exactly correspond, in some cases considerable overloading of the motors can occur. The fact that the output data do not exactly correspond can be quite intentional, and even necessary.
EXAMPLE
A motor is designed for a maximum power output of 7.5 KW. That corresponds to a nominal current of 16 A. It is operated with a frequency converter which can deliver 30 A. If the motor then consumes more power (e.g. 25 A), for example as a result of sluggishness in the drive system, the frequency converter delivers that current without anything being noticed. The consequence would be, however, considerable overloading of the motor. It would become too hot. Accordingly that could possibly even result in permanent damage and ultimately in failure. Those disadvantages are avoided with the apparatus according to the invention.
The regulation and control device can be configured so that it can assume the monitoring of the motor loading independently and in dependence upon operating situation in question. For that purpose, it has suitable means for communication with the electronic control unit of the machine. The speed-setting or regulating device as well as the electronic control unit of the machine can also be configured so that they are independently capable of influencing the permissible loading limits for the motor in dependence upon empirical data.
FIG. 8 shows in two graphs the variation in loading and speed as a function of different operational states. The Figure shows inter alia the optional possibility of switching off the monitoring. In certain situations, the monitoring can be switched off for a short period, for example during a braking operation. The monitoring is switched on in region I, switched off in region II and switched on in region III.
The apparatus according to the invention gives rise inter alia to the following advantages:
- 1. No additional apparatus or modules are required for implementing a system according to the invention.
- 2. Overloading and the resulting damage to the motors are reliably preventable.
- 3. Wear or other defects in bearings of the motors or other drive elements connected thereto can be recognised and reported or displayed.
- 4. Sluggishness can be determined and reported or displayed.
- 5. When the pre-set lower limits are passed, this indicates, for example, belt breakage or a similar defect.
- 6. When a problem is recognised, the drive or the entire machine can be brought to a standstill.
Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims.
Patent Application
20070273318
