2.2 Analysis of new technological innovation of cotton feeding box
2.2.1 The design of the exhaust device of the cotton storage room of the upper cotton box
The raw material is input into the cotton storage room of the cotton box with the air flow through the cotton head, and the cotton storage room is provided with exhaust mesh panels on all sides, on the one hand, it is to control the air flow rate of the system, and ensure that the multiple feeding boxes that are connected together can obtain the uniform amount of raw materials; On the other hand, during the exhaust process, some of the linters and fine dust in the raw materials can be taken away, which can effectively improve the quality of the output cotton.
The new technology of cotton feeding box mostly adopts the method of increasing width, reducing height, shortening the conveying process and increasing the cotton storage capacity of the upper cotton box, so as to help improve the yield and ensure the uniform stability of the cotton feast; It adopts the form of cotton box filter screen + mesh exhaust air, which can ensure the stable airflow of the upper cotton box.
2.2.2 Design of the structure for cotton rollers
The traditional design is to reverse feed the cotton to the cotton board, pressurize the elasticity of the cotton board, and strengthen the control of the cotton layer; The forward feeding of the cotton feeding board improved the transfer rate, reduced the fiber damage, and reduced the linter rate. Double roller cotton feeding reduces the control strength of the cotton layer, reduces the phenomenon of winding and backflowering, and reduces fiber damage. The new technology of the cotton feeding box adopts the form of air flow to feed the cotton, relying on centrifugal force and fiber self-weight feeding, canceling the feeding roller, and realizing barrier-free transportation.
2.2.3 Comb type opening roller design
The beating form of the traditional cleaning and carding combined feeding box is four rows of opening roller card clothing arranged in a straight row or spiral arrangement, which opens delicately and softly, and has little damage to the fiber.
With the continuous improvement of the output of the cleaning and carding combination, the new technology of the feeding box adopts the method of increasing the number of comb needle rows to 6-10 rows, and partially adopts the method of full carding needle beater, and at the same time reducing the opening path of the opening beater, so as to use the centrifugal force generated during high-speed operation to transport raw materials or eliminate dust impurities, less fiber damage, and lower growth rate of neps, which is conducive to improving the quality and output of products. The specific comparison is shown in Figure 6 and Figure 7.
Fig.6 Four rows of spiral comb needle beaters
Fig.7. Full comb needle beater
2.2.4 Design of the position of the fan for collecting cotton and supplying air
The traditional design is to set up a small fan blowing device on the cotton feeding box, so that the raw materials can smoothly fall into the cotton passage of the lower cotton box, and at the same time, the raw materials accumulated in the cotton passage can form a relatively stable density under the action of blowing pressure, and are basically uniform in the transverse and longitudinal directions.
The new technology of the cotton feeding box is to set the position of the small fan air outlet at the cotton outlet of the opening roller, and the nozzle is facing down and forming a tangential direction with the opening roller, which is conducive to preventing the phenomenon of returning flowers and entanglement of the opening roller. The small fan is supplemented by the air outside the machine, and the air volume adjustment plate is provided at the air inlet, and the air volume of the small fan blowing system can be adjusted to meet the requirements of different outputs.
2.2.5 The design of the cotton passage and return airflow
The traditional cotton feeding box is provided with a vibrating grid on the inner side of the cotton passage of the lower cotton box, which is composed of a deceleration motor, an eccentric shaft of the vibrating rod and a breathable grid, and the main function is to let the air in the raw materials be released through the breathable grid, and take away some dust, and output to the dust filter system through the static pressure box. After the output of the carding system is increased, this design form can not effectively increase the amount of cotton conveyance, and can not meet the requirements of high-speed production of the cleaning and carding system.
The new technology of feeding the cotton box adopts the design idea of double roller feeding or no roller feeding, and the PID adjustment of the cotton box pressure can ensure the stability of the lower cotton box pressure, and at the same time, the internal circulation return air is used to always keep the cotton collection in a negative pressure state, ensure the uniformity of the cotton layer, and improve the stability of the feeding cotton layer; There are also design schemes that increase the negative pressure of the lower cotton box, adjust the internal circulation return air according to the accumulation of cotton flow, and partially discharge it into the dust removal unit, so that the working state of the air flow is always stable. The comb board of the lower cotton box adopts a comb needle structure, the cotton is smooth, no flowers, the air flow is smooth, the positive pressure distribution cotton flow in the cotton box, and the negative pressure gathers the cotton flow. The comparison of different comb plates is shown in Figure 8 and Figure 9.
Fig.8 Traditional comb board form
Fig.9. New roller comb board form
2.2.6 Output the design of the roller
In order to make the raw materials accumulated in the cotton passage of the lower cotton box can be fed into the carding machine smoothly, the traditional cotton feeding box is equipped with a pair of output rollers at the outlet part, and through the chain drive connected with the cotton roller of the carding machine, the appropriate drafting ratio is selected to keep the operation synchronized, so as to realize the smooth feeding of the cotton layer into the carding machine. However, the friction resistance between the raw materials and the cotton guide plate output in this form is large, and it is easy to cause the phenomenon of poor cotton feeding. The vibrating plate Garola cotton is not suitable for high-yield cleaning and carding, and has been eliminated.
The new technology of the cotton feeding box adopts the forms of equal diameter roller cotton transportation, different diameter roller cotton transportation, fiber self-weight non-roller cotton transportation, etc. The diameter of the equal roller adopts double roller output, which has strong ability to control fibers and stable output, as shown in Figure 10; Different diameter roller cotton conveying adopts a small front and a large rear configuration to avoid the arching of the cotton layer and the accidental drafting phenomenon, see Figure 11; The cotton out part of the lower cotton box adopts double-sided comb needle exhaust, which makes the cotton fall more smooth, ensures the uniformity of the cotton feast, further improves the quality of the cotton fed into the carding machine, and ensures the uniform and stable weight of the horizontal cotton layer of the cotton layer CV%.
Fig.10 Working form of double roller with the same diameter
Fig.11 Different working forms of cotton rollers
2.2.7 The integration of cotton boxes reduces the cotton transportation process
The traditional cotton feeding box adopts double-section cotton feeding, which is divided into upper and lower cotton boxes and conveying cotton road, etc., and the cotton flow is long, and the cotton flow is long at the same time, and the cotton flow congestion is caused by the control of roller, which can not adapt to high speed and high yield.
The new integrated cotton box technology combines the output roller at the lower end of the cotton box with the feeding roller of the carding machine, which solves the accidental drafting between the output roller and the carding machine to the cotton roller. Self-leveling adopts multi-dimensional leveling control technology for integrated centralized control, integrating cotton box pressure detection, carding machine length and short segment detection, cotton box and carding machine cotton feeding control and other technologies in one, barrier-free cotton flow, can effectively reduce the phenomenon of entanglement, has the advantages of high control accuracy, good stability, simple operation, etc., the unevenness rate of the green strip of the high-yield carding machine is ≤1%, see Figure 12.
Fig.12. Integrated cotton box
2.2.8 The cotton box is actively fed into the fan cotton collection system
After the raw materials of the traditional cotton box collection system are accumulated after blowing, they rely on the airflow grid or mesh board to leak the cotton to collect the cotton, which is prone to problems such as uneven airflow distribution and cotton layer accumulation.
Under the new technology of cotton feeding box, the cotton box adopts active suction and cotton collection, the internal airflow is stable, and the full carding needle opening roller is soft and open, which reduces the neps; The service life of the cardbed needle punch roller card clothing is longer, the machine parking time is reduced, the cotton layer structure is uniform, the weight CV value is stable, the traditional photoelectric control is replaced by the pressure control of the feeding box, the weight of the cotton is accurately controlled when feeding the cotton, and the uneven weight of the cotton is minimized. See Figure 13 and Figure 14.
Fig.13. Positive fan cotton collection device
Fig.14 The whole carded needle has less damage to the fiber
Third, the development trend of cleaning and feeding into cotton boxes
3.1 The cotton feeding box and the thorn roller are integrated and intelligent
Digitalization, high speed, high yield and continuity of cotton feeding system are the development directions. At present, the cotton box plays a more obvious role in the cleaning and carding mixing ring leveling system, with multiple detection points such as the thickness of the input signal for the cotton basket, the speed of the output signal feeding the cotton roller, and the output signal for the cotton roller, which is the entry point for the development of intelligent cotton boxes. Through communication control, monitoring and coordination and adjustment system, the cleaning and carding feeding cotton box monitors the signals of the suction system and compressed air system, and combines special sensors to achieve seamless quality monitoring, monitors the thick point of the cotton net and metal foreign bodies when feeding the cotton, continuously monitors the quality of the green strip, and the centralized intelligent control system detects the state of the cotton box feeding the cotton layer at all times, and at the same time detects the quality of the cotton net, identifies the interference and displays the best raw material preparation, and realizes intelligent production, see Figure 15.
Fig.15 Schematic diagram of the homogenization of intelligent cotton boxes
3.2 Continuous feeding of cotton soft and open integration
The continuous feeding of the cleaning and carding is controlled by PID computer, which realizes stable feeding under the action of air flow pressure, and at the same time opens the roller to achieve soft opening, reduces the damage of the linting, and obtains a small fiber bundle and a more uniform cotton layer structure, which is the development direction of the cleaning and carding feeding box.
3.3 The opening and pre-carding function of the feeding box is integrated
After feeding the cotton box, the volume of impurities and cotton blocks directly affects the carding quality and homogenization effect of the carding, so the opening roller of the cotton box adopts carding configuration, increases the working angle of the carding needle, improves the opening effect, or adopts the sawtooth card cloth and moderately reduces the speed of the opening roller, increases the function of opening and precarding, and realizes the integration of opening and precarding, which is also one of the development trends in the future.
Fourth, the use of new technology of cotton feeding box to optimize the traditional cotton feeding box
4.1 Improve the number of beater comb needles and improve the quality of opening
The opening beater of the traditional cotton feeding box is planted with four rows of spiral arranged corner nails, which is currently developed into 6-10 rows of spiral beaters, and at the same time, the rotation speed is high, and the fiber is fully opened. In practice, the four-row structure was changed to an eight-row structure, and the opening capacity of the cotton tufts was increased, and the yarn cutting defect rate was reduced by 15%, which effectively improved the carding quality.
4.2 Increase the speed of the beater and increase the opening effect
The development trend of the beating speed of the new cotton feeding box is to achieve pre-carding through high speed and improve the opening effect. In the case of increasing the output and quality requirements, the modern cleaning and carding union appropriately improves the beating speed of the traditional cotton box, increases the opening effect of the fiber, and has an obvious effect on improving the yarn quality and eliminating impurities. In practice, in view of the high impurities and many short lints in machine-picked cotton, the beating speed of the cotton box was increased from 630r/min to 810r/min, and the yarn quality of C18.2tex was significantly improved. See Table 2 for the specific comparison indicators.
Table 2 Comparison of the effect of increasing the speed of the beater in the feeding box
4.3 The comprehensive utilization of the cotton box feeding and opening output system needs to be improved
For the continuously fed pneumatic cotton box, airflow control and convenient detection are the direction of development, but the basic data source of the negative pressure detection of the cotton-to-gas ratio needs to be further designed to reduce the instability of the feeding cotton layer.
It is necessary to strengthen the research on the grabbing of the cotton layer, the uneven opening and the size of the raw material volume after feeding, so as to reduce the volume of the carding and feeding raw material block as much as possible to reduce the carding load at the rear of the carding machine.
In the opening part of the cotton box, the cotton, cotton flow distribution, improve the degree of opening as a whole, the current output part of the positive air flow cotton collection is relatively stable, but the quality of the cotton bundle of the opening and the cotton part needs to be further studied, as far as possible to ensure that the longitudinal and horizontal cotton layer is evenly fed, the opening is sufficient, the output is uniform, and the cotton collection is stable.
4.4 Increase the amount of cotton to improve the distribution of raw materials in cotton boxes
When using the traditional vibrating cotton box to process chemical fibers, it is easy to appear that the fiber layer is transversely uneven, and the height of the raw materials in the cotton box is inconsistent.
V. Conclusion
The innovation of the cotton feeding technology is mainly to ensure that the cotton roller is evenly held, the form of the beating hand ensures the opening effect, the upper and lower cotton box cotton road reduces the output cotton channel, controls the nep caused by kneading, and the output roller ensures that the cotton is fed evenly and is not winded, and the cotton collection method adopts active cotton collection, and the air flow and return air of the lower cotton box are optimized and innovated, so as to achieve the purpose of uniform cotton feeding and stable quality.
At the same time, improving the carding effect, increasing impurity removal, system uniformity and intelligence, and the integration of cotton box carding and feeding will show an integrated development trend to meet the development needs of efficient and intelligent cleaning and carding.
Source: Chen Yufeng, Guangshan White Shark Card Clothing Co., Ltd
Editor: China Yarn Network New Media Team
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