BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a carding machine with a saw-tooth clothing according to the invention;
FIG. 2 is a section through a carding segment and a portion of a side panel with a clearance between carding segment clothing and cylinder clothing;
FIG. 2
a is a detailed view of the carding elements of FIG. 2;
FIG. 3 is a schematic side view of a 4-roller cleaner with a saw-tooth wire according to the invention;
FIG. 4 shows schematically in side view a first method of manufacture of saw-tooth wire according to the invention, in which the laser beam is guided corresponding to the contour of the teeth;
FIG. 4
a shows a cut-out part;
FIG. 5 shows schematically in side view a second method of manufacture of saw-tooth wire according to the invention, in which the profiled wire is guided corresponding to the contour of the teeth;
FIG. 6 shows schematically in side view a third method of manufacture of saw-tooth wire according to the invention, in which the laser beam is in the shape of the contour of the gullet;
FIG. 7 is a perspective view of the association of a device for laser beam fusion cutting with a profiled wire during manufacture;
FIG. 8 is a side view of the saw-tooth wire with hardened edge regions;
FIG. 9 is a side view of a rig for manufacturing a saw-tooth wire according to the invention with a laser device;
FIG. 10 is a side view of a displacement device;
FIGS. 11
a and 11b show a side view (FIG. 11a) and sectional view (FIG. 11b) of a profiled wire before cutting; and
FIGS. 12
a and 12b are, respectively, a side view (FIG. 12a) and sectional view (FIG. 12b) of a saw-tooth wire manufactured according to the invention.
DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
With reference to FIG. 1, a flat card, for example, a card TC 03 made by Trüttzschler GmbH & Co. KG of Mönchengladbach, Germany, has a feed roller 1, feed table 2, lickerins 3a, 3b, 3c, cylinder 4, doffer 5, stripping roller 6, squeezing rollers 7, 8, web-guide element 9, web funnel 10, take-off rollers 11, 12, revolving flat 13 with flat guide rollers 13a, 13b and flat bars 14, can 15 and can coiler 16. The directions of rotation of the rollers are shown by respective curved arrows. The letter M denotes the midpoint (axis) of the cylinder 4. The reference numeral 4a denotes the clothing and reference numeral 4b denotes the direction of rotation of the cylinder 4. The letter A denotes the work direction. The curved arrows drawn in the rollers denote the direction of rotation of the rollers. Between the lickerin 3c and the rear flat guide roller 13a and between the doffer 5 and the front flat guide roller 13b a plurality of stationary carding elements 20I and 20II (see FIG. 2) are arranged facing the cylinder 4.
In the course of drawing on the wire, the saw-tooth wire SD according to the invention is unwound from a supply reel mounted on a bearing block, then passed through a braking device and wound as carding clothing 4a onto the outer periphery of the cylinder 4. After the winding-on procedure, the carding clothing 4a runs helically on the outer periphery of the cylinder 4.
The feed roller 1, the lickerins 3a, 3b, 3c, the doffer 5 (doffer clothing 5a), the stripping roller 6 and the flat bars 14 of the flat card can also be clothed with the saw-tooth wire SD according to the invention.
Referring to FIG. 2, on each side of the card an approximately semi-circular, rigid side panel 18 is secured laterally to the machine frame (not shown); cast concentrically onto its outer side in the region of the periphery thereof there is a curved, rigid bearing element 19, which has a convex outer surface 19a as its support surface and an underside 19b. A stationary carding segment 20I has bearing surfaces at both ends, which lie on the convex outer surface 19a of the bearing element (for example, an extension bend). Carding elements 20a, 20b with clothing strips 20aI, 20bI, (carding clothings 24a, 24b) are mounted on the undersurface of the stationary carding segment 20I. The reference number 21 denotes the tip circle of the clothings 20aI, 20bI. The cylinder 4 has on its periphery the cylinder clothing 4a, (saw-tooth wire SD). The reference numeral 22 denotes the tip circle of the cylinder clothing 4a. The distance between the tip circle 21 and the tip circle 22 is denoted by the letter a, and is, for example, 0.20 mm. The clearance between the convex outer surface 19a and the tip circle 22 is denoted by the letter b. The radius of the convex outer surface 19a is denoted by r1 and the radius of the tip circle 22 is denoted by r2. The radii r1 and r2 intersect at the mid-point M of the cylinder 4. The carding segment 20, shown in FIG. 2 consists of a support 23 and two carding elements 20a, 20b, which are arranged in succession in the direction of rotation (arrow 4b) of the cylinder 4, the clothings 20aI, 20bI, of the carding elements 20a, 20b and the clothing 4a of the cylinder 4 lying facing each other. The carrier body 23 consists of an aluminium hollow profiled member and has continuous hollow spaces. The clothing strips 20aI, 20bI, are fitted with a plurality of sections of the saw-tooth wire SD according to the invention as clothing sections 24a, 24b, which—viewed across the width of the machine and along the length of the stationary carding segments 20I, 20II—are arranged in close proximity to one another.
FIG. 3 shows a cleaner, for example, a CL-C4 made by Trützschler GmbH & Co. KG, with four rollers 31, 32, 33 and 34 arranged in succession, the directions of rotation of which are indicated by I, II, II and IV. At the end of the roller 34 there is a pneumatic extraction device 35 for the fibre material (arrow F). The diameter of the rollers 31 and 34 is the same. The circumferential speed of each successive roller is greater than the circumferential speed of the respective preceding roller. The fibre material to be cleaned, especially cotton, is fed in tuft form to the cleaning device arranged in a closed housing. This is carried out, for example, through a hopper (not shown), by a conveyor belt or the like. The lap is fed by means of two feed rollers 36, 37 in engagement with a spiked roller 31 (diameter 150 to 300 mm, e.g. 250 mm), which is rotatably mounted in the housing and rotates anticlockwise (arrow I). A clothed roller 32 is arranged downstream of the spiked roller 31. The clothed roller 32 is covered with a saw-tooth clothing comprising saw-tooth wire 32a, the clothed roller 33 is covered with a saw-tooth clothing comprising saw-tooth wire 33a, and the clothed roller 34 is covered with a saw-tooth clothing comprising saw-tooth wire 34a, and all have a diameter of about 150 mm to 300 mm, e.g. 250 mm. The roller 31 has a circumferential speed of approximately 10 to 21 m/sec, e.g. 15 m/sec, the roller 32 has a circumferential speed of approximately 15 to 25 m/sec, the roller 33 has a circumferential speed of approximately 30 to 35 m/sec, e.g. 32 m/sec, and the roller 34 has a circumferential speed of approximately 40 to 50 m/sec, e.g. 46 m/sec. Associated with the spiked roller 31 is a separation opening 38 for egress of impurities in the fibre, the size of the opening being adapted or adaptable to the degree of contamination of the cotton. A separation edge 39, e.g. a knife, is associated with the separation opening 38. In the direction of the arrow I, a further separation opening and a separation edge are provided at the roller 31. The numerals 42 and 43 denote stationary carding elements, which are clothed with saw-tooth wires according to the invention 42a and 42b respectively. Separation openings and separation edges 44, 45, 46 are likewise associated with the clothings of the clothed rollers 32, 33, 34 with the saw-tooth wire 32a, 33a and 34a respectively. The rollers 31 to 34 are enclosed by covering elements 53a, 53b. The numerals 68a and 68d denote adjustable guide elements.
The mode of operation is as follows: The lap comprising fibre tufts is fed by the feed rollers 36, 37 in engagement with the spiked roller 31, which combs through the fibre material and picks up clusters of fibres on its spikes. As the roller 31 passes the separation opening, in accordance with the circumferential speed and curvature of this roller and the size of the separation opening matched to this first separation stage, short fibres and coarse impurities fly out of the fibre material owing to centrifugal force and after passing through the separation opening enter a waste box in the extraction housing 47. The fibre material pre-cleaned in this way is removed from the first roller 31 by the clothing points 32a of the clothed roller 32, thus undergoing further loosening. As the roller 32 passes the separation edge 44, further impurities fly out of the fibre sliver owing to centrifugal force. The fibre material is subsequently removed by the clothing points 33a of the clothed roller 33, from there is removed by the clothing points 34a of the clothed roller 34 and finally discharged through the duct 35. The clothed rollers 32, 33 and 34 are clothed with the saw-tooth wire according to the invention, 32a, 33a, and 34a respectively. The point density of the clothings (pps—points per square inch) increases from the clothed rolled 32 through the clothed roller 33 to the clothed roller 34.
To produce the saw-tooth wire SD according to the invention (see FIGS. 12a, 12b), a specially shaped profile band, a profiled wire PD (see FIGS. 11a, 11b) is used, in which teeth 27 are made by laser treatment. Profiling of the one-piece profiled wire PD is generally produced by non-cutting shaping, e.g. by rollers, by drawing, or the like. Three methods of saw-tooth wire SD manufacture are illustrated in FIGS. 4 to 6.
In the embodiment of FIG. 4, a profiled wire PD is moved in direction C. At the same time, a laser beam 53 is moved in the direction of the contour 27I of the teeth 27. The laser beam 53 moves corresponding to the example illustrated in FIG. 4 in direction D along the contour 27I of the back of a tooth 27. The laser beam 53 acts on the blade 26 of the profiled wire PD and leaves behind a kerf 54, whereby a gullet 28 is cut out of the blade 26. By means of a multi-axially controllable machine tool (not shown), a laser is controlled by software so that it travels along the contour 27I of the tooth geometry and thus “burns out” the clothing. Each new clothing can then be manufactured by modifying the software. The laser travels along the contour 27I and cuts out the tooth geometry. The profiled wire PD moves in one direction C. The movements in directions C and D are program-controlled.
In the embodiment of FIG. 5, the profiled wire PD is moved in direction C and at the same time alternately in directions E and F. The laser beam 53 is, in contrast to FIG. 4, stationary. In this way, two mechanical axes in the directions E and F are provided. The movements in directions C, E and F are program-controlled. The formation of the saw-tooth wire SD by cutting the teeth 27 out of the blade 26 otherwise corresponds substantially to the example according to FIG. 4.
The movements in the directions C, D, E and F in FIGS. 4 and 5 are continuous.
In the embodiment of FIG. 6, the profiled wire PD is moved in direction C. Movement can be by increments or continuous. The laser beam 55 is in the shape of the contour of the gullet 28. The laser beam 55 is in the particular shape that it is to cut out of the blade 26, i.e. the gap (gullet 28) between two successive teeth 27. This can be done using a template that imparts the corresponding shape to the laser beam 55. It is also possible, by simply exchanging the template, to produce a predetermined tooth shape. Using mirrors and prisms it is possible to burn out a plurality of gullets 28.
A cut-out part 67 (see FIG. 4a) is cut out of the blade 26, as shown in any of FIGS. 4 to 6. The cut-out part 67 is removed. This produces a cut-out in the blade 26. By further cut-outs in direction C the teeth 27 are formed in the blade 26. Between two successive teeth 271, 272 there is a gullet 28 in the blade 26. The size of the gullet 28 corresponds to the size of the cut-out part 67 plus the width (breadth) of the cutting slot of the kerf 54. The cutting slot width of the kerf 54 must be taken into account in the production of the finished size of the teeth 27 and the gullets 28. The external shape of the teeth 27 is produced by the cutting out process.
The relative movement between the laser beam 53 and the blade 26 of the profiled wire PD required to produce a continuous kerf 54 can be achieved in different ways. For laser cutting, the profiled wire PD can be moved below the stationary laser beam 53, for example, by means of an X/Y co-ordinate displacement means (see FIG. 10). In addition, for laser cutting either the laser source including the cutting head can be moved over the profiled wire PD (see FIG. 4), or a movable mirror system can be guided together with the cutting head (“flying optics” system) between the stationary laser device and the profiled wire PD.
One suitable arrangement for laser cutting of a saw-tooth wire is shown in FIG. 7. During laser beam fusion cutting by means of a laser device 56, a laser beam 53I that is generated by means of gases (gas laser) or crystals (solid-state laser) serves for cutting, and is focused (bunched) by at least one lens 57 onto a very small area of the surface of the blade 26 of the profiled wire PD. The steel of the profiled wire PD fuses or evaporates and is blown out of the kerf 54 by a gas jet 58 (see FIGS. 4 and 5). The cutting gas 59 is an inert gas, usually nitrogen or argon, and is introduced into the cutting nozzle 60 through an inlet.
The laser beam 53 can operate in free space or can be guided through a medium, such as oil or water. The laser power and the cutting speed need to be adapted to the type of material (steel) and material thickness of the profiled wire PD. For example: the material can be Remanit (X 5 Cr Ni18-10), thickness 0.7 mm, maximum feed rate 16.0 m/min, cutting gas nitrogen.
In the embodiment shown in FIG. 8, the case depth of the saw-tooth wire is denoted by the numeral 60. Since high temperatures are generated during lasing, but can be exactly determined, the energy should be applied in metered amounts so that in parallel with the cutting-out operation a hardening process occurs at the surface of the tooth 27. Since the temperature of the laser is always exactly the same, a constant hardness or case depth is ensured from tooth 27 to tooth 27. The hardness is thus limited purely to the part of the tooth 27 that engages with the fibre material during carding or cleaning. The flexibility of the tooth base 25, which is needed for winding the saw-tooth wire SD onto the roller, e.g. the cylinder 4, is thus ensured.
One illustrative embodiment of an apparatus for manufacturing, and subsequently winding, a saw-tooth wire is shown in FIG. 9. A take-off reel 61 of profiled wire PD is provided, which is mounted on a stationary frame 62 so as to rotate in direction G. The profiled wire PD is supplied continuously in direction I to the laser device 56. The saw-tooth wire SD formed by treating the profiled wire PD with the laser device 56 moves in direction I to the driven take-up reel 63, which is mounted on a stationary frame 64 to rotate in direction H.
As already mentioned, FIG. 10 shows a displacement device which, for carrying out a manufacturing process of the kind shown in FIG. 5, effects displacement in the direction of the arrows E and F—perpendicular to direction C. For that purpose, displacement devices 65 and 66 are provided at a distance before and after the laser device for example the laser device 56 shown in FIG. 9. Each displacement device comprises two bottom rollers 65a, 65b and 66a, 66b respectively and one top roller 65c and 66c respectively. The displacement in directions EI, FI and EII, FII corresponds to the tooth depth h6 (see FIG. 12a) and can be, for example, in the case of a fine cylinder clothing 4a, 1 mm and less.
FIGS. 11
a and 11b show in side view and in section respectively a profiled wire PD, which comprises a foot 25 and blade 26 in one piece, and is suitable for use in the method of the invention to make a saw-tooth wire.
FIGS. 12
a and 12ba show in side view and in section respectively an illustrative embodiment of saw-tooth wire SD, which comprises a foot 25 and a blade 26 in one piece. The following are marked in FIG. 12a:
|
Symbol
Term
Definition
|
|
α
Front angle
Angle between front face and the
|
vertical axis to the wire base
|
β
Wedge angle
Angle between front angle δ and back
|
angle γ of the tooth
|
γ
Back angle
Angle between back face and the wire
|
base
|
δ
Front angle
Angle between front face and the wire
|
base
|
ε
Opening
Corresponds to the wedge angle (ε = γ)
|
angle
|
h6
Tooth depth
Depth of the gullet cut-out, measured
|
from the tooth tip
|
p
Tooth
Distance between successive tooth
|
spacing
tips, measured on the drawn wire.
|
|
The following are marked in FIG. 12b:
|
Symbol
Term
Definition
|
|
h1
Overall height
Distance from the base to the
|
of wire
wire tip
|
h2
Base height
Height of the foot measured from
|
the base
|
b1
Base width
Width of the foot at the wire
|
base
|
b2
Blade width at
Width of the blade, measured at
|
foot
the foot
|
b3
Blade width at
Width of the blade, measured at
|
tip
the tip
|
|
The blade height is denoted by h3, which is obtained from the difference h1−h2. b4 denotes the blade width at the point of the deepest gullet cut-out.
The following is an example of saw-tooth wire dimensions for a clothing 5a of a doffer 5 of the flat card TC 03 (see FIG. 1), which clothing is manufactured by Trützschler Card Clothing GmbH, D-75387 Neubulach, Germany, and could expediently be manufactured using a method according to the invention:
T 40 30 100 0295 28 FGRZ
T=Trützschler wire
40=total height ( 1/10 mm) h1
30=front angle (°) α
100=base width ( 1/100 mm) b1
0295=point density (points per square inch)
28=working height (110 mm) h1−h2
FGRZ=surface treatment.
The following is an example of saw-tooth wire dimensions for a clothing 4a of a cylinder 4 of the flat card TC 03, which clothing is manufactured by Trützschler Card Clothing GmbH, D-75387 Neubulach, Germany, and could expediently be manufactured using a method according to the invention:
X 6338
b1=0.39 mm
b2=0.16 mm
b3=0.07 mm
b4=0.13 mm
h1=1.98 mm
h2=1.23 mm
h3=0.75 mm
h6=0.44 mm.
The invention relates to a saw-tooth wire SD for the manufacture of saw-tooth all-steel clothing for a rotating roller or a stationary carding element of a spinning room machine, having a base part 25 and adjoining the same—either by way of a base shoulder or directly without a base shoulder, as specified in DIN ISO 5334—a blade part 26, the blade part 26 comprising saw teeth 27 formed by tooth incisions 28 starting from the edge of the blade part 26 remote from the foot base 25.
Since slight burring at the edge of the tooth 27 may in some circumstances occur during lasing, the clothing wire (saw-tooth wire SD) has to be drawn through two grinding discs after burning, so that the teeth 27 have an absolutely clean contour.
The advantages of the method according to the invention are inter alia:
- No different tools
- No tool wear, tolerances thus maintained for all teeth
- Easy change-over to new clothing forms
- Lasing and hardening in one production step
- Exact case depth observed
- Reproducible operation during lasing and hardening
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
20080000053
