High-speed carding machine: How to significantly improve web flatness and carding efficiency in nonwoven production?

The precise mechanical design of a high-speed carding machine is the key to its efficient operation. From the overall structure of the equipment to the layout of each combing element, everything has been carefully calculated and tested to ensure that the fiber raw materials can be fully stretched, separated and arranged in parallel during the combing process.

The structural design of the high-speed carding machine fully considers the physical properties and process requirements of fiber carding. For example, the diameter, rotation speed and arrangement of key components such as the cylinder, doffer and licker-in roller are strictly calculated to ensure that the fibers are subjected to uniform and moderate force during the carding process. High-strength, wear-resistant materials are used to manufacture these components, which extends the service life of the equipment and reduces maintenance costs.

The combing element is the core component of the high-speed carding machine, and its configuration directly affects the combing effect of the fiber. Modern high-speed carding machines usually use a multi-row card clothing structure. The density, inclination angle and shape of the needle teeth in each row of card clothing are carefully designed to maximize the separation efficiency and parallel arrangement of the fibers. The material of the card clothing has also been specially treated to improve its wear resistance and corrosion resistance, ensuring the stability and reliability of the equipment in long-term operation.

In addition to the sophisticated mechanical design, the high-speed carding machine also achieves significant improvements in cotton web flatness and carding efficiency by optimizing the carding process.

Before the fibers enter the high-speed carding machine, they usually go through pre-treatment processes such as opening, mixing and removing impurities. These pretreatment processes can remove impurities from the fibers, improve the fiber's bulk and uniformity, and lay a good foundation for the subsequent combing process. By precisely controlling the parameters of the pretreatment process, it is possible to ensure that the fibers have consistent morphology and properties when they enter the carding area, thereby improving carding efficiency and quality.

The carding zone of a high-speed card is where the fibers receive the main carding action. In this area, the fiber raw materials are combed and stretched multiple times by components such as the cylinder, doffer and licker-in roller, gradually forming a parallel and evenly distributed fiber web. In order to further improve the combing efficiency and quality, modern high-speed combing machines usually adopt a multi-stage combing structure, that is, a combination of multiple combing elements is arranged in the combing area to achieve multiple combing and parallel arrangement of fibers. By adjusting the rotation speed and arrangement of the combing elements, the degree of fiber combing and the thickness of the fiber web can be precisely controlled to meet the production needs of different nonwoven products.

The flatness and uniformity of the fiber web formed after the carding area has an important impact on the subsequent processing steps and the quality of the final product. High-speed carding machines are usually equipped with precise web quality control devices, such as thickness sensors, tension controllers, etc., to monitor and adjust the thickness and tension of the fiber web in real time. These devices can ensure that the fiber web maintains a stable shape and properties during the conveying process, providing high-quality fiber web materials for subsequent processing steps. By optimizing the carding process parameters and the carding element configuration, the strength and uniformity of the fiber web can be further improved, thereby enhancing the overall performance of the nonwoven fabric.

In order to verify the actual effect of the high-speed carding machine in improving the flatness and carding efficiency of the cotton web, a non-woven fabric manufacturer upgraded the high-speed carding machine on its production line. The remodeled carding machine adopts a more sophisticated mechanical design and optimized carding element configuration, while the carding process is comprehensively optimized. After actual production testing, the modified carding machine has achieved significant improvements in cotton web flatness and carding efficiency. The flatness of the cotton web is improved by about 30% and the carding efficiency is improved by about 25%. This achievement not only improves the quality and uniformity of non-woven products, but also reduces production costs and energy consumption, bringing significant economic benefits to the company.