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中文简体In modern nonwoven material production, web stretch transition and surface weight fluctuation are two key issues affecting product quality. The high-speed cross lapper machine integrates lightweight carbon fiber rollers, optimized web laying trolley structure, flexible buffer device, five-axis servo control system and contour shaping system and other innovative technologies to form a complete solution.
Reduce the risk of web stretching
The lightweight carbon fiber roller effectively reduces the inertial load of the roller body itself due to its high strength and low density material characteristics. When in contact with the web, its surface is specially treated to ensure sufficient friction to drive the web to run smoothly and minimize the pressure on the web, thereby avoiding the web stretching problem caused by excessive roller weight or speed changes. The fatigue resistance and stability of carbon fiber materials ensure that the roller body maintains consistent performance during long-term high-speed operation, laying the foundation for the stable transmission of the web.
Improvement of web laying trajectory accuracy
The web laying trolley is the core component that determines the uniformity of web lamination. The stability of its running trajectory directly affects the quality of web laying. The optimized web laying trolley structure reduces vibration and shaking during operation through the precise design of the mechanical transmission system. The trolley adopts high-precision guide components and low-friction transmission components to make the speed change of the trolley smoother during reciprocating motion and avoid the deviation of the web laying position caused by mechanical clearance or inertial impact. The transition of the trolley with optimized structure in the acceleration and deceleration stages is smoother, ensuring the continuity and uniformity of the fiber during the laying process, and providing a consistent basic structure for the subsequent superposition of the fiber web.
Resolving the influence of tension fluctuations
In the fiber web production process, slight changes in the raw material supply speed and tension fluctuations at the moment of starting and stopping the high-speed cross lapper machine may cause uneven force on the local fiber web, causing stretching or wrinkles. The flexible buffer device can sense the tension changes of the fiber web in real time and respond quickly through an adaptive adjustment mechanism. When the tension is too large, the buffer device releases part of the tension through the elastic component to prevent the fiber web from being overstretched; when the tension is too small, it keeps the fiber web flat by tightening appropriately. This dynamic adjustment capability is like adding a layer of "protective barrier" to the fiber web, effectively eliminating the impact of various sudden tension fluctuations on the fiber web during the production process, and ensuring that the fiber web is always in a stable stress state.
Achieve precise control of the entire process
The five-axis servo control system controls the movement speed and direction of the web laying trolley, the speed of the carbon fiber roller, the conveying tension of the fiber web, the supply of raw materials, and the overall operation rhythm of the high-speed cross lapper machine through five independent and closely coordinated servo axes. With the help of high-precision sensors to collect the operation data of each link in real time, the system can complete data processing and command issuance within milliseconds to ensure that the movements of each component are highly synchronized. When the web laying trolley changes its direction of movement, the system will immediately adjust the speed of the carbon fiber roller and the state of the buffer device to keep the fiber web in a stable tension and speed during the turning process, fundamentally avoiding the fiber web quality problems caused by the uncoordinated movements of various components.
Optimize the uniformity of the surface weight of the fiber web
After the web laying and transmission links, the fiber web needs to be finalized through the contour shaping system before entering the next process. The system uses a high-precision detection device to scan the surface of the fiber mesh, obtain the grammage distribution data in real time, and fine-tune the fiber mesh locally according to the preset standard profile. For areas with high grammage, the system controls the corresponding shaping components to perform slight combing to make the fiber distribution more uniform; for areas with low grammage, the system guides the surrounding fibers to supplement, thereby reducing the grammage difference on the entire fiber mesh surface. This refined shaping process directly improves the grammage CV value of the fiber mesh, ensuring that the product maintains consistent physical properties in subsequent processing and final applications.
