1. Industry introduction

1.2 Market Share Analysis

The carding machine is a spinning machine that combs the preliminarily processed spinning raw materials into a single fiber state, forms a network fiber thin layer, and then assembles it into a fiber strip. Due to the different types of fibers and process requirements, carding machines also have various structures, such as cotton carder, wool carder, and linen carder.

1.3 Development Trend Analysis

The efficiency of the carding machine continues to increase with the improvement of the carding elements and the carding process. In the 1950s, the high-speed strong carding process was studied, which further improved the production capacity of the carding machine. In order to meet the requirements of extensive use of metal clothing and high speed, the carding machine has been generally equipped with a doffer variable speed (fast/slow speed) device, which is convenient for operation; an autoleveler device (drafting autoleveling) is used to improve the uneven weight of the segments of the fiber strip; automatic can changers and various safety and process self-stop devices are used to reduce the labor intensity of workers, increase the equipment for absorbing noil, fly and dust, improve the labor environment and reduce yarn defects/fault. Modern carding machines continue to develop in the direction of high quality, high output and low consumption. Due to the small distance between the needle faces of the carding machine and the higher and higher running speed, people pay more attention to improving the machining accuracy of the machine parts, improving the quality of the card clothing, and ensuring the stability and reliability of the carding effect. Under the condition of high-speed operation, the devices such as anti-rolling safety of card clothing, cotton suction and dust removal need to be further improved. Measures such as additional carding parts on the carding machine, double-line units, cleaning and carding, and carding and connecting are gradually adopted. In some countries, widening the machine width, enhancing the carding ability of the main comb part, improving the carding machine parts, and improving the ability to remove weeds are listed as topics under exploration.

1.3 Self Analysis

Advantages:

1. The equipment uses analog to control the speed of inverter, which is simple to control and easy to operate.
2. Simple maintenance and clear fault alarm.
3. The equipment is easy to operate, and the manual/automatic operation mode can be switched.

Disadvantage:

• The brand influence is not enough;
• Too many competitors;

Opportunities:

Help users to improve production efficiency, reduce production costs, and make our equipment more competitive in the market.

2. Product Solution

2.1 Wecon Solution

Wecon products used:HMI PI3070ie; PLC: LX5V-2416MR;

• Wecon PI series 7-inch PI3070ie
  • Using Cortex A35 1.2GHz CPU, resolution: 800 x 480;
  • Screen switching and update speed improved;
  • Gallery capacity, software security, communication stability upgrade;
  • Programmed by PIStudio;

• LX5V-2416M
  • Host: AC85-265V (D is DC24V±10%), 24 points 24V input, 16 points transistor output (NPN);
  • Input 24 points, output 16 points;
  • High-speed IO: 8 high-speed outputs, each 200K; 8 single-phase inputs, each 150K;8 AB-phase encoder input, each 100K;
  • Communication port: support RS422, RS485 method. Support 2 expand BD boards;

• LX3V-4DA Module
  • 4 analog outputs;

2.2 Competitive Products Analysis

Product brand: HMI + PLC(MCU) + Inverter;

• PLC: Omron CP1H-XA40DR-A;
• HMI: Omron NB5;

3. System Framework

3.1 Process Flow Description

FB220 semi-worsted carding machine is an innovative design product in the semi-worsted spinning process in China. Its function is to use the combing action of cylinders, rollers and flats to meticulous open, comb, remove the natural fibers, chemical fibers and man-made fibers such as wool, cotton, silk, hemp and other natural fibers that have passed through the knitting machine and the knitting machine. Miscellaneous, aggregated into fixed weight tops for the drawing process. Its structure consists of: automatic wool feeding machine - + double roller feeding comb-type licker-in - + roller opening and carding → cover carding automatic coil changer.

Features:

1. The machine adopts the combined structure of double cylinder, roller carding and flat carding in the process, and is equipped with special metal card clothing, which realizes low damage, high output and fine carding.
2. Adopt high-precision volumetric automatic wool feeding machine to make feeding even and more accurate;
3. Use comb-type licker-in and double-roller feeding to reduce fiber damage (selected for comb-type and common type licker);
4. The stepped pressing roller makes the surface of the strip smooth and clean; the cylinder body has a wind wing structure on both sides to eliminate the accumulated flowers;
5. The multi-station automatic barrel changing device reduces the labor intensity of workers (can be equipped with a single barrel);
6. The whole machine adopts PLC control, frequency conversion, touch screen, and autoleveling to make the whole machine highly mechatronics;
7. The whole machine is equipped with a semi-closed cover, which is beautiful and easy to maintain.
8. In addition to cashmere and wool fibers, the machine is also suitable for carding and slivering of multi-component fibers. Especially the pure cashmere fiber has a damage of 1-2 mm, and the carding of mercerized wool can achieve zero damage.  

3.2 Ladder Programming

3.3. HMI Design

4. Summary

4.1 Advantages of Device

• The output of multiple shifts is counted separately;
• Analog control inverter, safe and fast;
• Fault display, convenient for technicians to troubleshoot;
• Easily check the current speed of cylinder, doffer and transfer roller through calculation;

4.2 Summary

The equipment process was converted from the Omron program, and the customer's request was also converted to be an alternative. They did not give us the opportunity to rewrite the program. Try to enter the carding industry through this opportunity, and strive to take the initiative in the subsequent equipment development.