Issuu on Google+

Card TC 11


2

Card TC 11

Trützschler Card TC 11: Precision and efficiency


Card TC 11

4 Innovations 16

Carding

38

Control, operation

42 Maintenance 44

Man-made fibre card

48

IDF 2

52

Technical data

3


4

Card TC 11

Trützschler Card TC 11 –  THE NEW SUCCESS FORMULA FOR CARDING INTERACTION OF EFFI­ CIEN­CY, QUALITY AND PRODUCTIVITY

APPROX. 40% ADDITIONAL PRODUCTIVITY AT HIGH­ EST QUALITY LEVEL

The cost pressure in the textile industry grows from year to year. This is also due to the fact that the spinning mills cannot pass on the climbing cotton prices 1:1. At the same time, the quality requirements of the consumers increase. Hence, a future-oriented card must not only set record highs in terms of efficiency and productivity, but also in terms of quality. Of key importance is also the handling of valuable raw material. The TC 11 offers optimal material utilisation.

Trützschler identified the challenges at an early stage and, in response, developed the new card generation TC 11. It meets even highest expectations thanks to characteristics that are unique in high-production carding:  Approx. 40 % more production at same compact space  Highest quality due to longest carding section on the market  Lowest operating costs  Lowest waste quantities

FLEXIBILITY TO ENSURE EVEN MORE EFFICIENCY The TC 11 supports the competitiveness of your spinning mill not only by its excellent productivity and quality, but also by the lowest operating costs. It also features a flexibility that allows quick and frequent lot changes without any problems. Even important, quality-relevant settings such as of the flats, carding segments or mote knife, are completed within minutes. Immediately after restart of the machine, T-Con indicates whether and where there is still a potential for optimisation.


Card TC 11

This result appeals to sober analysts and the quality conscious: Tr端tzschler efficiency = circumference x width of card cylinder

5


6

Card TC 11

Exclusive from Trützschler: 5.3 m2 THE PERFECT SPACE FOR QUALITY AND ECONOMIC EFFICIENCY LONGER CARDING SECTION = MORE QUALITY!

MORE CARDING WIDTH = MORE PRODUCTIVITY?

BALANCE OF QUALITY AND PRODUCTIVITY

A simple formula states: The great­ er the distance covered by the fibres on the cylinder, the b ­ etter the carding quality. With a carding section of more than 2.8 metres, only Trützschler cards offer optimal quality. It is precisely this carding section that – in addition to the ideal number of flats – also ensures a sufficient number of carding segments and cleaning units.

There is a formula for this as well: More width while maintaining roll geometries means generally more productivity. However, the accuracy required in the setting limits the desire for more width. Starting at a certain width, the elements surrounding the cylinder would have to be so massive that the resulting costs would be in no economic relation to productivity.

We have included everything in the TC 11 that Trützschler stands for: More than 120 years of experience, a team of first-class engineers, as well as countless analyses, simulations and field tests. The end result was clear: A working width of 1.28 m represents the perfect balance be­ tween productivity and efficiency. Any occurring forces can be optimally handled up to this width by an intelligent design.


Card TC 11

7


Card TC 11

[1 m card = 100]

Performance/price ratio

8

100 80 60 40 20 0 0.7

1.0

You are searching for optimal efficiency? THE ANSWER IS TC 11 MORE ECONOMICAL THAN ALL ITS PREDECESSORS

LOWER INVESTMENT COSTS*

UP TO 25 % LESS OPERATING COSTS*

The technical qualities of the new TC 11 are impressive. However, it shows its strengths also in terms of efficiency. Compared to its predecessors – which were already very good in this regard – it offers three tangible advantages:  Best performance/price ratio  Lowest operating costs  approx. 40 % more production at same space requirement.

Compared to the predecessor series TC 7, the investment costs for carding are considerably lower for the TC 11. Simply less cards are required. In addition, this allows a smaller building size and smaller filter.

In the end, the life-cycle-costs determine whether an investment was successful from an economic point of view. In case of the TC 11, you do not have to wait very long for a RETURN OF INVESTMENT. Compared to TC 7, your cost advantages in the areas of energy, filter and maintenance result in savings of up to 25 %. This equals roughly 152,000 US$ per year.

*a  pprox. 14 cards, 140 kg/h 8,000 operating hours per year. The raw material use is approx. 15,680 t, purchased at a cotton price of 94 USct./lbs.


Card TC 11

The diagram shows that the best performance to price ratio is reached in the range between 1.25 –1.30 m. With a working width of 1.28 m, the TC 11 is precisely in this range.

Working width [m] 1.5

A fictional „spinning mill example“ produces 1000 kg/h card sliver, carded ring, Ne 20. The calculation is based on costs for cards, filters and building. The spinning mill example is identified on the following pages by this symbol:

2.0

9


10

Card TC 11

Perfection can be measured – WITH T-CON PRODUCTIVITY CANNOT BE INCREASED THROUGH ESTIMATED VALUES Efficient production requires utilisation of the card‘s full potential at all times. The prerequisite for this are optimal settings of the work elements. However, this process is frequently carried out when the card is in cold condition and is usually based on „empirical values“. Changes in ambient temperatures or changes caused by high production quantities are not considered.

THE PERFECT SOLUTION FOR IMPERFECTIONS

NO ROOM FOR SAFETY LAPSES

The patented Trützschler T-Con lowers the number of imperfections by up to 10 %.

With T-Con, across-the-board settings of safety reserves are a thing of the past. T-Con registers even the slightest contact with clothings and shuts down the card long before a damage can occur. This makes it possible to bring productions closer to an ideal line without taking a risk.

For this purpose, the actual distances between cylinder, flats and fixed carding elements are determined. The results appear on the card display and indicate which settings can be improved. There is no easier way to accomplish perfect card settings and thus optimal productivity.


Card TC 11

The optimisation options are clearly shown on the screen. The type of fibre and production level are taken into account.

Considerably lower operating costs with T-Con Experiences with T-Con show that 10 % more production and 10 % less IPI in the yarn are possible, which in case of our spinning mill example equals annual operating costs savings of approx. 280,000 US$.

11


12

Card TC 11

MAGNOTOP – THIS IS HOW SIMPLE OPTIMAL FLAT TOPS CAN BE SECURE ECONOMIC ­ADVANTAGES DURING EACH CLOTHING CHANGE Maintaining consistent high quality requires regular change of flat tops. For this purpose, Trützschler has developed the patented MAGNOTOP system together with Trützschler Card Clothing. Its clothing strips, which are easy and quick to replace, offer unbeatable economic advantages: Depending on labour costs, savings of 300  – 1100 US$ per card re-clothing can be realised. Investments in a flats workshop (usually 170 – 210,000 US$) are completely eliminated.

UNNECESSARY FEATURES HIGHER ACCURACY WITH­ TRANSLATE INTO SAVINGS OUT INITIAL GRINDING The improved efficiency achieved by the easy replacement of the clothing strips without flats workshop results in an immediate reduction of operating costs. Use of the ­MAGNOTOP system also eliminates the otherwise unavoidable extra costs:  No spare flat sets required  No service costs for re-clothing  No transport costs

With MAGNOTOP, the clothing strips fit perfect from the start. This is due to the reduced toler­ ances; the clothing strips are attached to the flat bar via superstrong neodymium magnets. The usual levelling that compensates deformations caused by assembly can be eliminated. This prolongs the service life by one grinding cycle.


Card TC 11

The perfect points of new flat tops are preserved because levelling after replacement of flat tops is not necessary.

The clothing strips can be easily replaced without any tools.

13


14

Card TC 11

Higher efficiency DUE TO FEWER PROCESS STEPS FEWER STEPS TO REACH THE GOAL The "best" process steps are those that do not exist in the first place. Thus, problems can be avoided, errors ruled out and money saved. A reduction of draw frames is of particular interest in the spinning mill. And this is precisely what the Integrated Draw Frame IDF 2 achieves by direct coupling to the Tr端tzschler

ALSO SHORT SPINNING PROCESS Card TC 11 in the rotor spinning mill. Efficiency is increased by a multiple. Because the Tr端tzschler card/draw frame couplings combine all the advantages of the Card TC 11 with a proven and reliable draw frame technology, the quality is improved as well.

There is no shorter spinning process than feeding the card sliver directly to the OE rotor spinning machine. This requirement is also perfectly met by the Integrated Draw Frame IDF 2.


Card TC 11

Open leveller draw frame unit

For rotor spinning, a sliver with a lower level of parallelisation is of advantage; for this reason, the drafts should be kept small. The 1 zone drafting system of the IDF 2 provides an excellent sliver evenness and a significantly improved yarn evenness. The better quality is evident in the uniform fabric appearance.

15


16

Card TC 11

Features and advantages only offered by Trützschler cards Fully-integrated tuft feeder DIRECTFEED

• High production with even card feeding

Setting Optimiser T-Con

• For maximum utilisation of the TC 11 potential

Flexible Integral Feed Tray SENSOFEED+

•S  hort-wave levelling for a low sliver count variation

Sliver former WEBSPEED

• Completely maintenance-free

Precision Knife Setting System PMS

• Adjustment of waste amount in no time at all

Aluminium flat bars without screw connection

• Quick flat exchange, without tools

Magnet Flat System MAGNOTOP

•R  eplacement of flat tops directly on the machine without tools

Precision Flat Setting System PFS

• Reproducible flat setting in only a few seconds

Flat Measuring System FLATCONTROL

• Objective and very precise flat adjustment

Infinitely variable setting of the flat speed

• Exact adaptation to the fibre quality in only a few seconds

Electronic cylinder brake

• Reduces cleaning and maintenance time

Nep sensor NEPCONTROL

• Online measurement of neps and trash particles

Computer control with touch screen

• Simple operation and targeted maintenance

Digital motor controls

• Maintenance-free and high-precision

Spectrogram monitoring

• Stops the card in case of faults in the spectrogram

Thick place monitoring

•S  tops the card in case of excessive thick places in the sliver

Spectrogram analysis

•A  ssists in finding the cause of spectrogram errors

Management of maintenance and card clothing

• Targeted maintenance support

3-roll WEBFEED Unit

• For gentle pre-opening

WEBFEED with one roll

• For the carding of man-made fibres or ELS cotton

Needle or clothed rolls

• Perfectly tailored to your product

Thick place monitoring and metal detection in the feed area

• For quality assurance and protection of the card

Long- and short-wave levelling system

• For perfect card sliver evenness

Special toothed belts for flat guiding

• Flat replacement without tools

 remium clothings from TCC, made of high-grade P steel for licker-in, main cylinder and doffer

• Extended service life ensures longer maintenance intervals

High-precision aluminium elements with ­super-smooth surfaces

• Gentle material guidance in the fibre-carrying areas

Central safety locking system

• High operational safety

Nearly all the points listed here are protected by international patents to secure the technical and technological lead for all users of Trützschler cards.


Card TC 11

18


19

Card TC 11

Highlights at a glance

Computer control with touch screen

Flexible Integral Feed Tray SENSOFEED+ for perfect clamping and very precise short-term levelling

Fully-integrated Tuft Feeder DIRECTFEED with built-in air volume separator and segmented feed tray

Setting Optimiser T-Con

Precision Flat Setting System PFS

The measuring bar is a precision instrument „Made by Trützschler“

Magnet Flat System MAGNOTOP

Nep Sensor NEPCONTROL TC-NCT

Precision Knife Setting System PMS

MULTI WEBCLEAN – flexible for all applications


Carding

Control / operation

Maintenance


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

SENSOFEED+ and DIRECTFEED: The specialists for optimal feeding More than 20,000 cards delivered with DIRECTFEED The Tuft Feeder DIRECTFEED is an integral part of the Card TC 11. The delivery roll of tuft feeding is identical to the card‘s feed roll. Hence, faulty drafts due to wrong or suboptimal settings have no chance to develop. DIRECTFEED utilises the successful Trützschler double trunk principle: The upper trunk has a significantly larger volume for a 60 –180 % higher material reserve, whereas the special geometry of the lower trunk and the extended material fly form the foundation for excellent sliver CV values. The air outlet comb with direct and permanent suction is positioned right in front of the feed roll. It is only here, just a few centimetres in front of the nip line of the feed roll, that the actual web is formed.

The feeding of material slubs leads to a minimal deformation at this point of the tray edge. In the simulation the effective forces are highlighted in colour.

SENSOFEED+ The flexible Integral Feed Tray SENSOFEED+ ensures controlled web feeding to the ­WEBFEED Unit. Its feed table compacts the tuft web and guides it to a knife-shaped feed tray tip. The material at this top allows a partial elastic deformation that occurs when material slubs are fed. This deformation is only a few hundredth of a millimetre and has hardly any influence on the overall deflection of the feed tray. As additional function, the Integral Feed Plate SENSOFEED+ can also include feed monitoring for the card.

1

2

3 4 5 6 7

8

Tuft Feeder DIRECTFEED 1 New high-volume upper trunk 2 Integrated air volume separator 3 Feed roll, electrically coupled to the feed roll of the card 4 Segmented tray for secure clamping 5 Opening roll with gentle needling 6 Closed air circuit with integrated fan 7 Self cleaning air outlet comb 8 Flexible Feed Tray SENSOFEED+

21


22

Card TC 11

Carding

Control / operation

Maintenance

WEBFEED: The plus for gentle but efficient opening The WEBFEED system consists of one large or three opening rolls connected in series. The tufts are opened in a gentler way and to a higher degree than is the case with conventional lickerins. This results in an even and fine web that increases the carding efficiency at the actual main working points (between cylinder and flats/ carding segments) during the transfer to the main cylinder.

Fibre pre-opening is of decisive importance for the carding process. Therefore it makes sense here to precisely adapt to the respective application. In the process, the different versions are flexible and easy to replace:

• 3 rolls – first roll: Needles

e.g. cotton at high production rates

• 3 rolls – first roll: Metallic wires

e.g. cotton/man-made fibre blend yarns

• 1 roll: Needles

e.g. man-made fibres + ELS cotton

For a ten-fold durability compared to metallic wires, the needles are made of special steel.

Tuft size

ed l spe hera Perip ss nene ing fi Cloth

g angle Clothin

Gradual opening for maximum fibre protection (3-roll WEBFEED)


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

PMS: Adjustment in no time at all The main cleaning zone of the TC 11 lies in the area of the first roll of the WEBFEED system. Here, an optimal waste composition requires an accurate mote knife setting. This is exactly what the successful Precision Knife Setting System PMS provides. The knife, which circles around the centre of the needle roll, is infinitely adjustable within seconds. Thus, the distance of the knife point to the needles is exactly the same in every position.

Through the circular adjustment the top edge of the knife always remains at an optimum distance to the needles. 1 Feed roll 2 The adjusting slide moves with the knife on a circular path around the centre of the needle roll 3 With this lever the position of the knife is adjusted in no time 4 The permanent suction keeps the card clean in this area as well

1

2

3

4

There is no need to stop the card, since the setting lever is freely accessible on the left machine side. A glance into the transparent suction ducts immediately shows the success of the readjustment. With this lever the mote knife is adjusted.

PMS with motor: Perfect setting within seconds With this system, a small servo motor is the key to increased user-friendliness and precision: The knife can be circularly adjusted around the centre of the first WEBFEED roll via touch screen – and that even while the machine is running. All values can be stored according to lot. For extremely short transitions from one material to the next, the setting values of the PFS and of the PMS system, as well as the speeds of the cylinder roll and WEBFEED roll, can be stored according to lot in the memory of the control.

This small servomotor adjusts the knife circularly around the centre of the first roll of the WEBFEED.

23


Card TC 11

Carding

Control / operation

Maintenance

3.7 m2: The largest ”active carding area“ in the market ensures maximum productivity

1.28 m

The new width of the Trützschler cards of 1.28 m is the result of an intensive development process. Initial analyses concerning an optimal cylinder width revealed the following: A larger width would make the construction so massive that it would no longer be economically feasible. A smaller width wastes productivity. Based on this concept, production parameters of the predecessor model TC 7 were evaluated with the help of T-Con sensors (see page 38), and the new

design was developed. This also includes new statics and the application of new materials. The level of precision used during manufacturing contributes to the growth in productivity. During countless tests the technical concept was tried out, refined and, last but not least, tested as prototype in customer facilities. The results fully met our expectations.

”active carding area“ 4.0 ”active carding area“ [m2]

24

Pre-carding

1.1

Flat

3.0

3.0 2,4 2.1

2.0

3.7

0.5

0.5

Post-carding

0.6 1.8 0.5

1.5

1.3 1.1

1.0

1.1

0.5

0

0.6 other card manufacturers

0.6

TC 11 


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Card TC 11

Technical data

2.8 m: The longest carding section on the market ensures perfect quality Pre-carding Flat Post-carding

The TrĂźtzschler Card TC 11 features the longest carding section on the market. Carding quality is ensured by optimal distribution over the three carding areas. In this regard, the cylinder area is of particular importance. The main focus is on the revolving flat: With an optimal number of flat bars, it is responsible for cleaning as well as extracting neps and short fibres. To ensure its optimal function, the fibre web must be prepared accordingly.

This job is assigned to the pre-carding area with its cleaning and carding elements. The higher the pre-opening, the more intense the carding, which in turn results in increased production. The large post-carding area takes care of the rest, thus ensuring even cleaner sliver and higher fibre parallelism.

Carding section Carding section [m]

3.5

Pre-carding 2.8

3.0

0.8

2.4 2.1

2.0

0.5

0.5 1.3 1.1

2.0 0.4

1.2

1.2

1.0 0.8 0.5

0.6 0.4

0 other card manufacturers

TC 11 

Flat Post-carding

Of importance is the proper balance between pre- and post-carding zone and the flat

25


26

Card TC 11

Carding

Control / operation

Maintenance

MAGNOTOP flat tops: Magnetic attraction of quality

In the past, each one of the 84 flat bars had to be manually handled six times during the replacement of flat tops. With MAGNOTOP this is only necessary once – which reduces the approximately 14 hours spent by personnel to less than 2 hours.

14 h

Up to now, replacement of flat tops required much time and expenditure. Now MAGNOTOP provides increased speed and cost efficiency. The system uses so-called neodymium magnets, which are considered to be the strongest permanent magnets ever: One neodymium magnet, smaller than a cigarette pack, can easily hold or lift a weight of 100 kg. Another decisive advantage: The expensive alloy made of iron, neodymium and boron, retains its magnetic force for many decades.

2h MAGNOTOP-change of flat tops 1.  Pick up set of new MAGNOTOP clothing strips and unpack. 2.  Take one flat bar each from the card, remove clothing strip by hand, attach new clothing strip and put flat bar back into card. 3. Perform basic settings. 4. Discard old clothing strips.

Quick change of flat tops, entirely without tools The flat bars of the innovate MAGNOTOP system for attaching flat tops are equipped with neodymium high energy magnets in form of strips. On the back of the clothing strips there is a matching thin, flexible metal strip. Once positioned on the flat bar, the clothing strips remain securely in place, because the magnetic forces exceed the developing carding forces by a multiple. Thus, the fastening is 100 % reliable; on the other hand, the clothing strips can simply be „peeled off“ from the side and removed with little effort.

The MAGNOTOP system was developed in cooperation between clothing specialists from Trützschler Card Clothing and Trützschler card developers.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

Lower costs, higher quality

With MAGNOTOP, there is no longer a need for inhouse flats workshop, additional space, special machines, service, maintenance and according specialists. This corresponds to savings in investment costs between 170,000 and 210,000 US$. Operating costs are eliminated entirely. Another advantage is the quick and easy testing of new types of flat tops. The previous set of MAGNOTOP clothing strips can be reused at any time. The patented MAGNOTOP fastening system also compensates tolerances. This simplifies precision setting of flat tops even more, which in turn improves the carding results and leads to less neps in the yarn. The direct way to increased time and cost efficiency Today, replacement of cylinder and doffer clothings directly on site is a matter of course. In contrast, in the past flat bars had to be laboriously removed and transported to a special workshop where they were replaced. MAGNOTOP allows complete flat top service directly at the card.

MAGNOTOP-Advantages at a glance • Improved yarn quality through higher precision • Elimination of investments in a flats workshop, operating costs, etc. • Elimination of providers‘ service costs. • Elimination of investment for one or several spare flat bar sets • No storing of flat sets • No grinding of flat tops after re-clothing • No transport costs, instead simplified logistics

The clothing strips can be replaced without any effort and without any tools.

3 4 3

5 2

1

1

2

2

Conventional system with clips

MAGNOTOP system

1 Aluminium flat bar 2 Clothing strips 3 A  dhesive and compensation layer 4 Neodymium magnet 5 Thin metal strip

27


Card TC 11

Carding

Control / operation

Maintenance

Changing flat bars: 1 hour, 0 tools

300

Time [min]

28

240

180

120

60

0

Conventional highproduction card

TC 11

Setting of flat bars Replacement of flat bars

Via remote control it is possible to move the flat for service-purposes also while card is at a standstill.

Replacement of flat bars requires one person to work only approx. one hour.

Each individual MAGNOTOP flat bar is made of high-strength aluminium profiles, which are lightweight and extremely stable. The flat bars are directly connected via a cam to two toothed belts that ensure perfect guidance. The hard metal pins at the ends of the flat bar glide across

a special plastic strip. This arrangement has the advantage that a complete flat replacement can be performed by just one person without tools in less than one hour.

1

3 4

5

Trßtzschler MAGNOTOP flat bar – proven millions of times 2 1 Optimised, lightweight aluminium profile 2 Flat top 3 Wear-resistant hard metal gliding pins 4 Plastic support 5 The cleaning felt keeps the sliding plastic clean


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Card TC 11

Technical data

Automatically faster: Flat setting Trützschler developed the Precision Flat Setting System PFS for central adjustment of the whole flat to the cylinder. It performs precision flat setting – during production – within just a few seconds. After the initial setting, the PFS system can help maintain precise distances throughout the entire service life of a clothing set. The basic setting is further facilitated by the use of the Flat Measuring System FLATCONTROL TC-FCT.

4

1

2

3

Precision Flat Setting System PFS

The flat bars can be inserted into the cams of the toothed belt easily without tools.

After the basic setting is performed, only a handle needs to be turned on each side of the card to increase or decrease the distance of all flat bars in working position to the cylinder. A scale shows the current setting in relation to the basic setting.

5

6

1 Metal flexible bend 2 Wear-resistant special plastic slide rail 3 Setting lever 4 High-precision aluminium flat bars 5 Cam toothed belt for the flat drive 6 The distance setting can be read directly from a scale

PFS with motor: Centrally controlled precision This system performs the motorised adjustment of the flat setting system in a precise, reproducible manner within seconds. From a central control it ensures that the distance of all flat bars in working position to the cylinder in­creases or decreases. All that is required to select the respective adjustment on the display of the machine control. The adjustment is indicated accordingly and, same as all other settings, can be managed in the lot memory.

A servo motor performs the flat setting on both sides of the card.

29


30

Card TC 11

Carding

Control / operation

Maintenance

MULTI WEBCLEAN: The tailor-made solution for each application Cleaning element This element consists of a mote knife with a hood under permanent suction. It is designed to separate tiny dirt particles, seed coat fragments, dust particles, and fibre fragments.

Carding element The carding element consists of two clothing strips in a support (TWIN TOP), which can be equipped with a number of different clothing types and finenesses, depending on application area and raw material.

To ensure optimal carding conditions for each application, they must be adjusted to raw material, production volume and targeted quality. For precisely this purpose Trützschler developed the MULTI WEBCLEAN system.

Cover element If none of the elements described above is used on one of the eight variable positions in the pre-carding and post-carding area, a cover element is mounted.

It allows the individual attachment of ten special elements each in the pre- and post-carding area of the cylinder. Only the first and last element are specified; the remaining eight elements can be flexibly selected according to the required production task. The three elements of the modular system • Cleaning element • Carding element • Cover element


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

Depending on application, the MULTI WEBCLEAN consists of the cleaning, carding and cover elements.

Replacement within minutes Once the elements are precisely adjusted, they can be mounted and dismounted without the need for readjustment due to specially developed fixing elements.

In principle, any element can be mounted to each of the 16 positions. The card is delivered in a configuration that has been individually specified in advance.

TC-MWC 3: The solution for torn materials The recycling fibre set offered by Tr端tzschler is a version of the MULTI WEBCLEAN system, intended especially for processing of torn fibres in cards of the TC series. In addition to the two cleaning elements, seven carding elements are applied in the pre-carding area. The post-carding area is equipped with six carding and two cleaning elements.

MULTI WEBCLEAN for carding of recycling fibres

31


Card TC 11

Carding

Control / operation

Maintenance

Continuous suction ensures carding quality and efficiency A permanent suction of all points is standard on Trützschler cards, ensuring increased clean­ liness, cost effectiveness and efficient dust removal. The main reason for the efficiency of the per­ manent suction is the low operating subpressure and the low air requirement. At -740 Pa or 4200 m3/h (in relation to a card with 1 m width, this is only 3230 m³/h), the values are clearly below those of other systems. This can be attributed to the flow optimisation of each individual duct element – an advantage that is obvious not only on paper but also on the machine: Transparent duct parts provide an insight into the suction hoods, even while card is in operation.

Lower energy consumption of the card filter Reduced exhaust air and less negative pressures lower the ­operating costs of the filter. Based on our spinning mill example, this results in annual savings of US$ 29,050. Energy costs US$/year

32

50,000 47,250 42,000 35,000 8000 h/year – 0.112 US$ / kWh

28,000 21,000

The suction ducts are fastened entirely without tools. They are pulled off and put on with the SNAPLOCK Quick-Change System.

18,200 14,000 7,000 0 Other cards TC 11

In comparison: Other cards: TC 11:

[m3/h] [m3/h] Exhaust air volume 60006000

5500 m3/h at -1250 Pa 4200 m3/h at -740 Pa

Operating subpressure

[Pa] [Pa] -1500 -1500

5500

-1250

-1200 -1200 4200

-900 -900

40004000

-740

-600 -600

20002000

-300 -300

0

0

0 Other cards

0

TC 11

Low exhaust air volumes and operating subpressures reduce the operating costs considerably.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Card TC 11

Technical data

TC-C: A can changer as it should be

The can changer TC-C stands freely in front of the card, without mechanical connection. A service aisle between can changer and card reduces the distances.

Can changer for 500 m/min The can changer TC-C is an alternative to the can coiler that is standard on the TrĂźtzschler Card TC 11. It is designed for cans up to 1500 mm height and 1000 mm diameter. All can changers of the TC-C series are new developments designed for the high delivery speeds of the TC 11. Optimal accessibility and operation The can changer stands freely in front of the card, thus it is optimally accessible from all sides. A service aisle between can changer and card results in shorter distances between the cards. The separate drive allows very fine draft adjustments between card and changer via the card‘s touch screen. Faulty drafts and sliver breaks due to excessive tension draft are no longer possible. Another plus for user-friendliness is provided by the automatic sliver separation during can changing.

The free arrangement saves space and reduces operating time. 1 A centre distance of only 3.5 m is possible 2 The service aisle cuts the distance from card to card

1

2

33


34

Card TC 11

Carding

Control / operation

Maintenance

A quality control that does not miss a thing

With TC 11, every metre of card sliver is checked prior to its deposit in the can. This is made possible by extensive, integrated quality monitoring during which the sensor data for all relevant areas are gathered: • Sliver count • Sliver evenness • Spectrogram • Frequency of thick places The data is evaluated by the card control, and the results appear in form of a diagram on the touch screen. If predefined limits are exceeded, the card shuts down automatically. This type of production control of every metre of card sliver

Display of thick place evaluation

is clearly superior to random laboratory checks because it is performed permanently and online. Thick places are also reliably detected. Upon request, the quality management can also be supported by additional systems and tools:  he online Nep Sensor NEPCONTROL TC-NCT T permanently records the number of neps, dirt particles and seed coat fragments (option)


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

The evenness of fed material, card sliver and draft deviation is clearly displayed on the same timeline.

Pictures or diagrams provide visual information, which often is superior to text messages (e.g. in case of fault messages)

With the virtual roll bars below the continuously calculated spectrograms, the error sources can be located more quickly.

The error source calculated by the automatic spectrogram analysis is shown directly in the gearing diagram.

Maintenance and clothing management benefit from concrete additional information.

Production parameters can simply and quickly be entered via touch screen.

Card TC 11

35


36

Card TC 11

Carding

Control / operation

Maintenance

NEPCONTROL TC-NCT: The web always in sight

With the nep sensor NEPCONTROL TC-NCT, Tr端tzschler offers a unique solution for permanent quality control: TC-NCT monitors the card web during production and provides concrete information on quality. In the process, every single metre of card sliver is tested. Focus on nep level A camera takes approx. 20 pictures per second of the web under the take-off roll. In doing so, the camera moves about the whole working width of the card in a special, fully closed profile. This optical principle copies the visual percep足 tion of a person, and is thus superior to indirect measuring methods. A high-performance computer directly attached to the profile evaluates the pictures with a special software, distinguish足 ing between neps, trash particles and seed coat fragments. With NEPCONTROL TC-NCT it is also possible to establish a distribution profile of the nep and particle level over the working width. Possible clothing damage becomes immediately visible this way.

The camera view of the web with trash particles (neps, seed-coat fragments, trash parts).

This is how the evaluation of neps and trash particles appears on the monitor of the card.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

FLATCONTROL TC-FCT: The fast flat setting

When it comes to fast and accurate calculation of the distance between cylinder and flat, the Measuring System FLATCONTROL TC-FCT from Trützschler offers numerous benefits: • Better card sliver quality due to smaller setting tolerances • Extended service life of clothing • Quick flat setting • Reproducible, objectively verifiable settings • Independent of personal influences Basic settings reproducible at any time When performing basic flat settings with ­FLATCONTROL TC-FCT, first the measuring flat is moved to the corresponding setting position via remote control. The colour monitor of the computer shows a diagram of the current distance to the cylinder. The technician can now adjust the distance of flat to cylinder within seconds – considerably more accurate than with feeler gauges. Measurement covering the entire flat area Taking the place of three regular flat bars, the sensors of the FLATCONTROL measuring flat record the distance to the cylinder clothing. All measurement values are automatically saved, wirelessly transferred to a notebook and displayed in form of a diagram.

Scope of delivery of Flat Measuring System FLATCONTROL • Measuring flat • Notebook PC with accessories • Calibration device • Solid metal case for transport and safekeeping • Service carriage for transport within the spinning mill

For the time of the measurement, three normal flat bars are replaced by a measuring flat.

Targeted quality optimisation FLATCONTROL TC-FCT is a measuring system that efficiently prevents losses caused by too widely set revolving flats. The setting variation within one card group can also be systematically reduced with FLATCONTROL TC-FCT. The result: Each card works within an optimal range, thus significantly increasing the quality level.

The screen shows the current condition of the flat settings. To perform the setting, the technician just needs to take one look at the screen.

37


38

Card TC 11

Control / operation

Carding

Maintenance

T-Con: Because card setting must be optimal at all times The distances of the carding elements to each other are the most important settings at the card. They significantly influence the carding and therefore the yarn quality. The setting is made on the standing, i.e. relatively cold machine. Up to now, dynamic changes during operation such as centrifugal forces or increases in temperature are not taken into consideration. In the process, they change the card settings during operation. The actual settings during carding have therefore been unknown so far. This has changed fundamentally with the Setting Optimiser T-Con. Its latest version is applied in the Trützschler Card TC 11. The fields highlighted in blue show the recommended optimisations determined by T-Con.

The five T-Con functions • T-Con ACTUAL

Display of the most important process variable for carding quality

• T-Con contact monitoring

Maximum safety against clothing contact

• T-Con distance optimisation

Optimal yarn quality due to correct setting parameters

• T-Con operating status analysis Prerequisite for controlled setting • T-Con-Spacer

Fast, accurate, reproducible settings

Information evaluated by T-Con: Contacts Temperatures Rotational speeds Setting

T-Con

PMS Setting PFS Setting

Sliver count

Production

Material

Delivery speed


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

For determining exact carding settings and recommending optimisations The optimisation tool T-Con is a software pack­ age integrated in the card control. It uses special sensors to obtain measured values, e.g. current temperatures or speeds of carding elements, and carries out a permanent analysis of the operating conditions. On the screen of the card control T-Con displays the current distances and recommends possible optimisations, depending on the fibres that are being processed at the time. Fast and efficient setting optimisation The flat distance can now be changed within seconds, e.g. via the Precision Flat Setting System PFS, even during production. T-Con determines and displays the new operating condition immediately. The setting of the fixed carding segments can also be optimised within minutes without measuring tools. To do so, only the T-Con Spacers – precise colour-coded distance elements – have to be replaced.

This sensor determines contacts between the carding elements.

No chance for clothing damage T-Con also protects the clothings; if the setting is too narrow, a warning appears. In case the metallic wires of two carding elements actually make contact, the card will be stopped immediately before any damage can occur.

Operating costs are considerably lowered with T-Con Experiences with T-Con show that 10 % more production and 10 % less IPI values in the yarn are possible, which in case of our spinning mill example equals annual savings in operating costs of approx. 280,000 US$.

The T-Con Spacers can easily be replaced in just a few simple steps and thus enable a reproducible setting of the carding segments.

This sensor monitors the cylinder temperature.

39


40

Card TC 11

Carding

Control / operation

Maintenance

Reliable and user-friendly – this is how a control should be The Trützschler card control uses a robust industrial computer that records all sensor data and issues according control commands, e.g. to the drive and servo motors. A large colour touch screen facilitates trouble-free control for operators, maintenance specialists and quality managers.

Operating level: Machine personnel

Operating level: Servicing personnel

A few simple diagrams and symbols, independent of language, inform the operator about the status of the machine.

Here a variety of password-protected settings can be performed, among other things limit values for all quality shut-downs.

Operating level: Plant manager / Quality manager

Operating level: Trützschler service technician

Here persons with special access authorisation have the possibility to change, among other things, machine configurations and customerspecific data.

Trützschler specialists are able to call up specific data, to perform the service call in a fast and effective manner.

Easy to understand and individually configurable The most important advantage of monitor control is the largely language-independent operation via generally comprehensible symbols, diagrams and pictures. At the same time it is possible to display only those operating functions that are currently necessary or useful. In the event of a malfunction, the point of failure is clearly classified and precisely identified by means of a detailed picture or diagram. Continuous quality and production monitoring The control of the Card TC 11 gathers and monitors all machine-relevant data ranging from tuft feeding, card, can changer all the way to Integrated Draw Frame IDF 2.

TC-VSD: Infinitely variable setting, without compromises With this method, infinitely variable setting of the required cylinder speed, and thus the WEBFEED speeds, is achieved via a frequency converter at the cylinder's drive motor. The control is carried out directly on the screen of the card, which significantly simplifies frequent material changes. Furthermore, the infinitely variable rotary speed setting TC-VSD can be used to compensate the wear of the cylinder clothing by a slightly higher cylinder speed, thus maintaining a stable nep level. With TC-VSD, the speeds of cylinder and WEBFEED can be set infinitely variable on the screen.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Card TC 11

Technical data

Perfect interaction of the individual levelling systems For the production of an even card sliver, a number of measures must interact perfectly: Variation coefficient

1. Card feeding In Trützschler installations, already the material flow to the card is continuously controlled via the CONTIFEED System. Thus, the production requirements of all cards of a line determine the current production of the last machine in the blowroom. The result is a continuous card feeding that forms the basis for an even sliver.

The TC 11 guarantees excellent values concerning evenness over the entire length spectrum.

3.00 2.50 2.00 1.50 1.00 0.50 0 1

2

5

10

20

50

100

Cutting length

2. Card feeding Additional homogenisation is made possible by the double trunk principle of the tuft feeder. Its continuous, pressure-controlled feeding of the upper and lower trunk prevents unevenness of the card sliver, which for instance can occur during start up and shutdown of the card. In such cases the speed of the tuft feeder‘s feed roll is automatically adjusted to the respective card production. 3. Long-wave levelling Analogous to the sliver mass measurement performed by the sensor in the card‘s sliver trumpet, the feed roll speed is measured and controlled via a single sensor. It covers the entire spectrum of the regular card sliver counts.

without levelling

TC 11

4. Short-wave levelling The Card TC 11 is also equipped with a shortwave sliver count regulation. This system, which is already effective for a sliver length of less than 1 m, considerably improves card sliver evenness. While the thickness of the tuft web is constantly scanned by the Integral Feed Tray SENSOFEED+, the card control calculates a possible adjustment of the feed roll speed from the incoming values.

Four levelling systems adapted to each other guarantee a perfectly constant sliver fineness and an excellent evenness.

Controlled Card feeding Unit CONTIFEED (e.g. feed roll of SP-FP)

Integrated tuft feeder levelling

Diagram of short-wave levelling

Long-wave levelling

41


42

Card TC 11

Carding

Control / operation

Maintenance

Better access than ever for efficient maintenance

After removal of the doors, all areas of the card are optimally accessible.

The TC 11 sets benchmarks in terms of maintenance-friendliness. Thus, the doors can be disassembled without tools in just a few minutes. The drives are concentrated on the right side of the machine. The operators are protected by a central safety locking system. Conventional drive covers that can obstruct maintenance work are completely eliminated. Replacement of the WEBFEED Unit is also very simple because it can be replaced in one part. The same applies to the Integral Feed Tray SENSOFEED+. It is also possible to disassemble the complete flat cleaning device and the web doffing within shortest time. And, since the can changer has no mechanical connection to the card, cleaning work is simplified in addition to operation.

Targeted maintenance management The card control is a valuable tool for the service technician during maintenance tasks, like clothing care or regular lubrication. Example clothing change: The card control shows this early enough on the screen. Example error detection and recovery: The control offers special tools for this as well. Example operating conditions: In addition to the distances of the card elements as determined by the Setting Optimiser T-Con, for instance rotational speeds, speeds or negative pressures are also displayed.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

Maintenance efficiency due to digitally controlled servo drives Costs for energy consumption (example 130 kg/h) Compared to cards that operate without individual drives, Trützschler cards allow for significant energy savings. In our spinning mill example, this equals more than 43,000 US$/year. Energy costs US$/year

Meanwhile more than 25,000 Trützschler cards are equipped with completely maintenance-free servo motors as standard feature. They are used for doffer, web doffing unit and can changer. Another advantage of the digital servo drives is their high efficiency, which reduces electrical power losses. Furthermore, they provide a maximum of speed and control accuracy at low speeds, which results in improved sliver CV values. The control of the digital servo drives communicates directly with the card control.

300,000 302,400

291,530 247,919

252,000 201,600 151,200 100,800

130 kg/h – 8000 h/year – 0.112 US$ / kWh

50,400 0 Other cards TC 11

Completely maintenance-free: The digitally controlled servo drive has neither carbon, brushes nor fans, and is completely enclosed.

other cards: TC 11:

Installed power consumed power approx. Installed power consumed power approx.

42 kVA = 24 kW 17 kWh 36 kVA = 21 kW 15 kWh

Assembly of the digital motor control takes place at Trützschler in Mönchengladbach, Germany.

43


44

Card TC 11

Carding

Control / operation

TC 11-S: The best man-made fibre card ever

The spinning mill example Our fictional „spinning mill example“ for manmade fibres clearly shows the savings potentials that can be achieved with Trützschler technology. It features more than 10 man-made fibre cards, with an annual production of 160 kg/h per card during 8,000 operating hours. This equals a raw material use of approx. 12,800 t. The following preinvestment analyses are in reference to this „spinning mill example“

Maintenance


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Usually card development focused primarily on cotton processing. Hence, it came as no surprise that the production capacity of cotton increased significantly from card generation to card generation: In the coarser yarn segment, the 100 kg/h limit was quickly exceeded. The productivity of man-made fibre carding, however, stagnated. This is exactly the reason why Tr端tzschler chose another path: From the beginning, the current card generation was developed simultaneously for cotton and man-made fibres. The Card TC 11-S is the result for man-made fibre processing. 12-fold difference: Differences between man-made fibre card and cotton card 1 Stainless steel comb instead of screen fabric 2 Stainless steel cleaning flap

Card TC 11

Technical data

Extremely resistant: The fibre-guiding elements The reviving agent used for many man-made fibres has an aggressive effect on paint and base metals. As a result, paint may peel off and metal surfaces may become sticky, thus impairing optimal fibre flow in the card. This leads to production limits and frequent production interruptions in cleaning work. On the Tr端tzschler Card TC 11-S, all plates in the tuft feeder and in the transfer section to the card are made of stainless steel. All covering elements relating to cylinder and doffer consist of high-precision aluminium elements. An anodizing process protects these parts from the aggressiveness of man-made fibres. In the can changer, hosepipe and coiling plate made of stainless steel ensure gentle sliver guidance and sliver coiling.

3 Stainless steel reserve trunk 4 Segmented feed tray 5 Special opening rolls for higher speeds 6 Stainless steel reserve trunk 7 More carding and less cleaning elements 8 WEBFEED with a large needle roll

1

9 Man-made fibre T-Con 10 Special sliver trumpet 11 Additional deflection roll

2

12 New doffer clothing TCC NovoDoff 30 1) 1)

protected by patent

3

9 4 5 7 The differences between man-made fibres card and cotton card are significant.

7 6

10 11

8 12

45


Card TC 11

Carding

Control / operation

Maintenance

Modified WEBFEED: Higher efficiency, quality and service life The enhanced WEBFEED system for the TC11-S is substantially different from the cotton card. For high production application of cotton, a preopener system with three rolls is essential. For processing man-made fibres there is another solution: A newly developed WEBFEED with only one large single roll, featuring a 50 % larger diameter, special needling and a novel surface finish. These measures combined contribute to the significant production increases. Simultaneously, the WEBFEED system results in improved yarn quality with an average of 30 % less imperfections. Another advantage of the especially for manmade fibre processing developed needle roll is its significantly longer service life. It is approximately ten times that of a clothing roll, thus with greatly improved efficiency. The fibre-guiding elements, as in this case the feed trunk, are made of stainless steel.

Service cost comparison of lickerin In the course of 10 years, the clothings in our spinning mill example must be re-clothed about 20 times per card. During the same time frame, a needle roll is maintenance free. Service costs /10 years [US$]

46

50,000 40,000 30,000 20,000

High wage country

10,000 0

Clothing

Needle

Needled TrĂźtzschler pre-opening rolls have a special surface finish.


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

T-Con for TC 11-S: The right chemistry

Comparison of carding costs The high productivity of the Trützschler man-made fibre card TC 11-S significantly reduces production costs. In our example, annual savings of 216,000 US$ are possible even in a low-wage country. 50 70 50

[US$/ t]

Obviously thermal influences affect the carding of man-made fibres different than processing of cotton. Without the systematic evaluation of T-Con data during extensive trials this would not have been discovered. For instance, the rule “the tighter the flat setting, the better the result”, does not apply to man-made fibres. On the contrary; here it is essential to maintain a certain minimum distance. It prevents electrostatic charges that have a negative effect on carding quality and subsequently also on yarn quality. Hence, the T-Con system for man-made fibre carding uses new algorithms and thus provides the basis for precise setting recommendations. The result is a clearly increased production.

Miscellaneous

4060 40 50 30 30 40

Waste

2030 20

Capital

Wage Energy

20 10 10 10 0 00 Standard card

TC 11-S

TC-MMF: Application set for tuft blending and cards with changing fibres There are many blends of cotton with man-made fibres, be it with polyester, viscose or polyacrylic. With the Optional Set TC-MMF, they all can be processed on the Trützschler Card TC 11. The TC-MMF features stainless steel surfaces that take the particular fibre-metal friction values into account. Its clothings are specifically designed for cotton/man-made fibre blends, thus eliminating the settling of finishing. An important distinguishing feature is also the number and type of carding segments of the MULTI WEBCLEAN system. Because the carding of a blend containing polyacrylic requires, for instance, more segments than the carding of cotton/viscose.

The clear quality advantages can be confirmed in the laboratory.

The Optional Set TC-MMF: • The fibre-guiding elements in the tuft feeder are made of stainless steel • Additional carding elements from 90 to 640 points/inch2 • Special clothings for cylinder, doffer and flat

Card TC 11

47


48

Card TC 11

Carding

Control / operation

Maintenance

The integrated draw frame: Concept with savings potential The Integrated Draw Frame IDF 2 with automatic can changer

The production-related and economic advantages that can be achieved with the Integrated Draw Frame IDF 2 are enormous: • requires less space, • requires less cans, • simplifies can transport, • lowers power consumption and • reduces personnel and operating costs. Due to increased sliver adhesion and adapted fiber orientation, the slivers have a better running behaviour in downstream processing than draw frame slivers.

Opening Cleaning Blending

Short fibers, waste, regenerated fibers Cotton-rotor-spun yarn coarser, approx. Ne 24 (25 tex)

The strength of the IDF 2 system is also apparent in its design. Thanks to the space-saving arrangement of the draw frame unit above the can changer, it requires no more space than a regular can changer. The IDF 2 allows processing of all fibers common in rotor spinning. For coarse and mediumfine high-quality OE yarns up to Ne 24 we recommend the combination of TC 11 and IDF 2. This solution offers improved yarn quality and increased economic efficiency.

Card TC 11 with Integrated Draw Frame IDF 2

Rotor spinning

Opening Cleaning Blending

Rotor-spun yarns finer, approx. Ne 24 (25 tex)

Card TC 11

Draw Frame TD 8


Integrated Draw Frame IDF 2

Man-Made Fibre Card TC 11-S

Comparisons of direct spinning IDF 2 with one and two draw frame passages for OE yarn NE 20

In our example, the combination of TC 11 and IDF 2, at a production rate of 180 kg/h and 8400 production hours per year, results in annual energy savings of more than 84,000 US$.

2.8 2.4

The low value has a positive impact on the fabric appearance, particularly on knitted fabrics

È

2.0

Energy costs US$/year

CVm% 10m

3.2

Card TC 11

Lower energy costs

4.0 3.6

Technical data

1.6 1.2 0.8

360,000 323,936

240,000

239,187

0.4 0.0

TC 11 + IDF 2

TC 11 + TD 7

TC 11 + TD 7 + TD 8

120,000

Yarn count variations

180 kg/h – 8400 h/year – 0,112 US$ / kWh 0

CV %

13.8 13.6

other spinning mill with direct drawing

13.4

Example spinning mill with TC 11 and IDF 2

13.2 13.0 12.8 12.6 TC 11 + IDF 2

TC 11 + TD 7

TC 11 + TD 7 + TD 8

Yarn evenness Neps +280% Thick places + 50% Thin places – 50%

1/ km

60 50

Can changer The can changer for the IDF 2 is largely identical to the one of Draw Frame TD 8, and designed for the standard can diameters. The can height ranges between 900 and 1525 mm. The sliver is automatically separated during can change.

40 30 20 10 0

TC 11 + IDF 2

TC 11 + TD 7

TC 11 + TD 7 + TD 8

TC 11 + TD 7

TC 11 + TD 7 + TD 8

Yarn imperfections

cN/tex

14.4 14.0 13.6 13.2 12.8 12.4 12.0

TC 11 + IDF 2

Yarn strength

Light barrier strip for fully automatic synchronisation of the delivery speed with the card by regulating the sliver sagging between the machines

49


50

Card TC 11

Carding

Control / operation

Maintenance

Direct combination for increased efficiency

The combination of the Trützschler Card TC 11 with the Integrated Draw Frame IDF 2 presents an economically attractive and technologically practical solution. Instead of a conventional can changer, the Integrated Draw Frame IDF 2 is connected directly to the card, thus eliminating a draw frame passage. This configuration is also very space saving, since the otherwise required space for a complete draw frame with can magazine for the card cans is eliminated.

540 m2

Advantages of direct card and draw frame combination: • Less material buffer in the process, therefore less tied-up capital • Shorter throughput times • Reduced operating work • Reduced building area

280 m2

48% less space requirement due to Integrated Draw Frame IDF 2

Levelling quality without compromises Immediately before being fed into the drafting system, the card sliver is scanned by the reliable Trützschler sliver sensor; then it is levelled via the drafting system. The close physical proximity of measuring point and drafting system

ensures reliable levelling of the draft. A second sensor is positioned immediately behind the drafting system. Here the sliver is permanently checked to ensure that every metre deposited in the can corresponds to the required quality.

Sensor to determine sliver fineness and quality sensor

Simple and clear operation via the card display


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Card TC 11

Never before was a fully-fledged leveller draw frame more compact The use of a simple drafting system at the card was never a satisfying technological solution since only a fully-fledged levelling draw frame could guarantee a high degree of quality. Trützschler combined the compactness of a simple drafting system with the performance of a leveller draw frame. The characteristics: • Maintenance-free, digitally controlled servo drives • High levelling dynamics through low mass inertia • Draft up to 200% (2-fold) • Delivery speeds up to 700 m/min • Controlled material storage for trouble-free can changing • Trützschler quality sensors in the feed and delivery area • Permanent monitoring of sliver quality The drafting system is integrated in the production flow / sliver run and consists of reliable components of the Trützschler draw frame. This includes also technical highlights, like for instance the pneumatic load of the top rolls. Very good accessibility The casing of the Integrated Draw Frame IDF  2 can be opened quickly without tools. For operation and maintenance purpose, it is simply flipped open in front and back. This ensures quick and uncomplicated performance of service work.

Drafting system and motor are quickly and easily accessible

Top rolls in the open drafting system

The service life of the top roll coating is doubled Savings are also achieved with the top roll coatings in the new IDF 2. On the one hand, the top rolls are now in an asymmetric position in the drafting system, while at the same time the loading cylinders are symmetrically arranged in the proven way. This facilitates easy turning of the top rolls by 180° after the coatings wear off, thus doubling their service life. On the other hand, the drafting system has been modified to a 1 zone drafting system to improve sliver quality. In addition, the optimization effort and thus the service costs are lowered by very easy settings. A strong motor A more powerful maintenance free levelling ­motor makes the IDF 2 more dynamical and a­llows it to react faster.

Closed casing

Top rolls (red) can be turned by 180° after wear of the top roll coatings (wear shown in blue)

51


Card TC 11

Carding

Control / operation

Maintenance

1000

3360

2180

Card TC 11: Technical data

600 3410

2150

52

Floor load:

approx. 22,540 N/m2

Max. surface pressure per base plate:

approx. 57 N/m2

Production:

max. 260 kg/h

Suction (continuous):

4,200 m3/h (-740 Pa)

Net weight:

approx. 6,700 kg incl. can changer

Sound pressure level:

75 dB(A)


Man-Made Fibre Card TC 11-S

Technical data

Integrated Draw Frame IDF 2

Card TC 11

The can coiler or can changer can be freely positioned in front of the card, since it is not mechanically connected to the card.

2150 mm

L3

L3

L6

3576 mm

3576 mm

3576 mm

2150 mm

2150 mm

L1

500 mm

L4

50

0m

L1

m

L5

L2

L2

The can height can be up to max. 1500 mm Can diameter (mm)

L1 1)

L2

L3 2)

L4

L5

L6

600

1715

1930

5455-6345

1200

1200

6000

1000

2350

2750

6090-6980

1400

1400

6200

1) without can delivery ramps 2) depending on width of service aisle between card and can changer (under floor)

Apart from production output, the values for current consumption depend also on the various settings and the material

P [kW] 20 (Card + tuft feeder + automatic can changer)

Maximum continuous power consumption

18 16 14 12 10 8 6 4 2 0

0

20

40

60

80

100

120

140

160

180

200

Production [kg/h]

220

240

260

53


54

Card TC 11

Carding

Control / operation

Equipment, standard

The extensive standard equipment of the TC 11:

Large cylinder with 5.3 m² clothing surface Function-oriented overall design for excellent accessibility Setting Optimiser T-Con MAGNOTOP System TC-MT Integrated Tuft Feeder DIRECTFEED with moveable feed tray Integral tray, SENSOFEED+ Thick place monitoring and metal detection in the feed area WEBFEED Unit with 1 or 3 opening rolls Precision Knife Setting System PMS Tooth belt guided aluminium flat bars Precision Flat Setting System PFS Premium clothings made by Trßtzschler Card Clothing TCC Computer control with large colour touch screen Quality data entry and display Spectrogram analysis Quality and maintenance management TC-CB electronic main cylinder brake Digitally controlled, maintenance-free servo motors Coordinated levelling systems in short and long-wave area SERVOSPEED drive for high delivery speeds Infinitely variable flats speed Data exchange via CF card Network connection for communication with LINECOMMANDER Can coiler for cans with 600, 900 or 1000 mm diameter Monitored continuous central suction above floor Central safety locking system

Maintenance


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Options

Options and additional equipment for the individual, tailor-made Tr端tzschler Card TC 11: Application-oriented optimisation: Recycling Fibre Set TC-MWC 3 Man-Made Fibre Card TC 11-S Man-Made Fibre Set TC-MMF for processing fibre blends on TC 11 Infinitely variable speed control of cylinder and WEBFEED TC-VSD Motorised adjustment for Precision Knife Setting System PMS Motorised adjustment for the Precision Flat Setting System PFS

Individual project planning: Monitored continuous central suction under floor Separate strips suction above or under floor

Tools and accessories: Nep Sensor NEPCONTROL TC-NCT Flat Measuring System FLATCONTROL TC-FCT Flat Grinding Device TC-FG Grinding Device TC-GD for grinding cylinder and doffer clothing Wire Mounting Equipment TC-ME

Options for delivery or slivery coiling system: Automatic Can Changer TC-C above or under floor Integrated Draw Frame IDF 2 for round cans

Card TC 11

55


Card TC 11

Carding

Control / operation

Maintenance

Integrated Draw Frame IDF 2: Specifications

The drafting system is positioned on the can changer. For this reason, the Integrated Draw Frame IDF 2 requires no additional space.

The can delivery is made onto a can delivery ramp. Alternatively, it is also possible to transfer four full cans each to a can carriage.

2110 mm

4067 mm

Integrated Draw Frame with can changer for cans with 450 mm (18) diameter

 450 mm

2750 mm

Integrated Draw Frame with can changer for cans with 1000 mm (40) diameter 2250 mm

56

 1000 mm


Man-Made Fibre Card TC 11-S

Integrated Draw Frame IDF 2

Technical data

Equipment characteristics

Version:

– Draw frame + can changer for fitting to a Card TC 11 – With short-term levelling and sliver count monitoring

Production:

max. 260 kg/h

Delivery speed:

max. 700 m/min

Material:

Fibers up to 60 mm (cotton, man-made fibers, cotton and manmade fiber blends, recycling spinning materials)

Draft:

2-fold

Drafting system:

2 over 2 with pneumatic loading of top rolls and integrated suction

Can sizes:

– Round can diameter: 400 –1000 mm (18 – 40) – Height of round cans: 900 – 1525 mm

Installed power:

4,0 kW

Max. continuous power consumption:

2,5 kW

Suction (continuous):

350 m3/h (– 450 Pa)

Sound pressure level:

79 dB(A)

www.machines-for-textiles.com/blue-competence Trützschler GmbH & Co. KG Textilmaschinenfabrik P.O. Box 410164 · 41241 Mönchengladbach, Germany Duvenstr. 82-92 · 41199 Mönchengladbach, Germany Phone: +49 (0)2166 607-0 · Fax: +49 (0)2166 607-405 E-mail: info@truetzschler.de · www.truetzschler.com

Disclaimer: This brochure has been created by us to the best of our knowledge and with great care. We are however not liable for any spelling mistakes or technical changes. Photographs and illustrations are of informative value only and some show special optional equipment that is not included in standard delivery. We provide no guarantee for the current relevance, correctness, completeness or quality of the information provided. All liability claims against us or the respective author pertaining to material or immaterial damages caused by the use or circulation of the ­provided information, even if found to be incorrect or incomplete, are excluded. Our information is non-binding. Print No.: 13030-12/13-e · Agentur Brinkmann GmbH, Krefeld

Card TC 11

57


S P I N N I N G

N O N W O V E N S

MAN-MADE FIBERS

CARD CLOTHING

Fiber preparation

Opening/Blending

Staple fiber lines

Metallic wires

- Bale opening

Card feeding

Filament lines

- Spinning

- Blending

Cards/Crosslapping

- BCF

- Nonwovens/

- Cleaning

Wet laying lines

- Industrial yarn

- Opening

Web needling

Precursor lines

- Open End

- Foreign matter

Hydro entanglement

Carbon fiber lines

Flat tops

Longstaple

Chemical bonding

Fillets

- Dedusting

Thermobonding

Carding segments

- Tuft blending

Finishing

Service machines

- Waste recycling

Drying

Service 24/7

Cards

Heatsetting

Draw frames

Winding

Combing machinery

Slitting

separation

www.truetzschler.com


TRUTZSCHLER TC 11 CARD